Wireless Instrumentation Wireless Instrumentation in the Pharmaceutical in the Pharmaceutical IndustryIndustry

Andy WallaceSmart Wireless® Solutions Product Manager

UK & Ireland

AgendaAgenda

Intro to wireless networks

– Star, Star Mesh and Mesh Network topologies

Simplified overview of Mesh Networks & TSMP

– Case study for reliability and redundancy

Application of wireless in a 4 storey pharma building

Unlocking the ‘Hidden Plant’

Wireless Sensor Networks

Operating Frequency 2.4GhzOperating Frequency 2.4Ghz License-free but regulated frequency band

Shares ‘space’ with many other wireless devices in that spectrum for example

• Bluetooth

• Radios

• Cordless Phones

• WiFi

IEEE 802.15.4 – 16 channels– (Home wifi is 802.11)

The key is

– Ensuring ‘your’ message gets through

Wireless Network - Must HavesWireless Network - Must Haves

Key Management

Anti-Jamming

Verification

Authentication

Encryption

Common Industry Practice Today

EmersonSmart Wireless

Key Management

Anti-Jamming

Verification

Authentication

Encryption

Common Industry Practice Today

EmersonSmart Wireless

Reliability

– Path Stability

– Better than 99.9999%

Security

– Avoid fake and random attacks

Low Power

– Only operate when needed – preserve battery life

Scalable

– Capable of expansion without architecture changes

Flexible

– Bandwidth Control - speed

– Power Control – limit number of jumps

– Channel Control – blacklisting if necessary

– Latency Control

Challenges for Wireless NetworksChallenges for Wireless Networks RF environments are dynamic – they change

– RF mirroring from infrastructure

• Doors opening/closing

• Portable plant

– Change over time; people, weather, temp structures

A link that is strong today may be weak tomorrow or even the same day!

Three major failure modes:

– Interference from other ‘wireless’ devices

– Changes in the physical environment that block communication links

– Loss of individual network nodes in some topologies

Star NetworksStar Networks

Central base-station communicates directly to sensor nodes - Generally mains powered.

All routes are ‘linear’ where each node only has one possible communication path – good distances

The failure of an individual link means that information is lost. 

Generally requires site surveys and link-level configuration. 

Each node must be positioned correctly and each point-to-point link tuned for maximum reliability.

Star Mesh (Cluster Tree)Star Mesh (Cluster Tree)

Star-mesh networks have redundant routing at the core (blue) and star routing at the edge – typically with mains powered routing nodes and optionally battery-powered end nodes. 

Does not allow for true end-to-end redundancy nor do they eliminate the installation challenges of star networks.

Mesh NetworksMesh Networks

Full-mesh networks provide fully redundant routing to the edge of the network. 

Increased reliability, easy network installation and long-term predictability

Every device has the same routing capabilities. 

Lower power consumption

True self-organising and self-healing without constraints imposed by device type and architecture

Easy network expansion

Self Organising Mesh NetworksWirelessHART Networks

In-Plant Smart Wireless® Solutions are Easy to Install, Use and Are Reliable!In-Plant Smart Wireless® Solutions are Easy to Install, Use and Are Reliable!

ToHost

Modbus,

Ethernet,

WiFi,

OPC,

Self Organising!

Self Healing!

Gateway ‘grooms’ network for speed and loading

Together We Deliver Complete, Best-in-Class Wireless Solutions for the Process IndustriesTogether We Deliver Complete, Best-in-Class Wireless Solutions for the Process Industries

Cisco Unified Wireless Architecture

– Industrial-class Mesh IEEE 802.11 Access Points

– Wireless Control System for centralized network and security management

Plant applications include video, voice, mobility, tracking

– Leverage Cisco’s extensive partner network

– Customer chooses preferred partner

Your Smart Wireless Opportunities Are without Limits…Your Smart Wireless Opportunities Are without Limits…

The Device Join Process Has Almost Zero User Interaction ------ SimpleThe Device Join Process Has Almost Zero User Interaction ------ Simple

1. Put JOIN key into the WirelessHART Field Device (WFD) using standard tools (375, AMS, etc.)

2. Listen to neighbours3. Connect to a neighbour using JOIN key to authenticate4. Neighbour uses NETWORK key to pass message up to gateway5. Gateway determines optimised schedule6. Schedule is flooded to the devices

Developing NeighboursDeveloping Neighbours Typically 2 Parents

3 Children – Load Balanced

Many Neighbours (identified redundant paths)

C P

C

CP

N

N

N

N

Mesh Networks offers scalability…..Mesh Networks offers scalability…..

Animation courtesy of Dust Networks

Customer Site: Devices Scattered Throughout the Process Facility With No Direct Line of SightCustomer Site: Devices Scattered Throughout the Process Facility With No Direct Line of Sight

High Data Reliability

– 99.75 to 100.00%

– Readings every 10 seconds

Data Latency Varies

– 0.66 to 6.22 seconds

– 3.22 seconds Average

“Device Hop Depth”

– Demonstrated capability of up to 9 hops for at least 256 unique paths back to the gateway

Expansion is Simple: Added Online Devices to the Network also Increases Network ReliabilityExpansion is Simple: Added Online Devices to the Network also Increases Network Reliability

High Data Reliability

– 100.00%

– Readings every 10 seconds

Data Latency Varies

– 0.82 to 5.20 seconds

– 2.44 seconds average

“Device Hop Depth”

– Demonstrated capability of up to 12 hops for at least 4096 unique paths back to the gateway

Major Pharmaceuticals MfrFour-story pilot lab

Self-organizing WirelessSelf-organizing WirelessNetwork in a Process BuildingNetwork in a Process Building

Customers Are Solving Real Plant Problems:Major Life Sciences CompanyCustomers Are Solving Real Plant Problems:Major Life Sciences Company

Application: Moving platform/skid measurements

Eliminate need to continually re-configure process systems for instruments that move with portable process skids

– Pumps, filtration, milling, CIP/SIP packages

Startup and installation of all devices was completed in < 8 hrs

Initial trials achieved 100% reliability throughout 12” reinforced concrete building with five floors

– Moving platforms never had a measurement drop off the system

– Platform brought in from another storage building joined network withoutoperator assistance

Trial #1: How Many Floors from a Single 1420 Wireless Gateway?Trial #1: How Many Floors from a Single 1420 Wireless Gateway?

Rosemount Model 1420 Wireless Gateway mounted on wall

outside Third Floor Control Room.

12 Rosemount Model 648 Wireless Temperature transmitters

used to form network.

Devices T1 – 11 placed from First Floor to Roof.

Device T12 held in reserve.

Trial Building: Reinforced concrete constructionBuilt 1993. Main building dimensions: 246’ x 70’

Trial site from column #5-12: 153’ x 70’East Wing (column 7-11): 92’ x 70’

East Wing

Process bays/suites: Wide: 24’ w x 27’ d Narrow: 17’ w x 27’ d

Other areas: Aisle: 92’ l x 16’ w Mech/Util: 7’ w x 27’ d

First Floor

Suite C-1 Bay D-1 M/U

Suite K-1Bay J-1Bay H-1M/U

7

Device Placement: T7 in Mech/Util room on floor

Second Floor

Suite C-2 Bay D-2 M/UM/U

M/UM/U Suite K-2Bay H-2M/U Bay J-2

Device Placement: No devices on Second Floor

Third Floor

Suite C-3 M/U Bay D-3 M/U

M/U Bay H-3 M/U M/U Suite K-3Bay J-3

1

2

3

4

5

6

12

8

WG

Device placement (all dimensions are height from floor): 1420 Wireless Gateway (WG) to right of Control Room door on wall - 76” T1 in Mech/Util room on panel - 60” T5 on vessel in Bay D-3 - 30” T2 between vessel and wall in Bay H-3 - 18” T6 on shelf in stairwell - 54” T3 on vessel in Bay H-3 - 18” T8 in Mech/Util room on panel - 60” T4 on mezzanine (“Floor 3-1/2”) in Bay D-3 - 96” T12 on shelf in Aisle - 60” PT and TT (PT-1160 & TT-1160) in Control Room awaiting trial #2: Moving Cart

PTTT

Control Room

Fourth Floor

M/U

M/U M/U M/U

M/UBay C-M

Bay D-M

Bay H-M

Bay J-M

Suite K-M

11

10

9

Device Placement: T11 in Mech/Util room on panel - 60” T10 inside roof access door (“Fifth Floor”) on floor T9 on roof; steel roof access door closed

11May07 Test #1: TT-1160 & PT-1160 in Control Room; balance of devices per dwg

Trial #2 – “Moving Cart:” Moving an instrumented platform through a formed networkTrial #2 – “Moving Cart:” Moving an instrumented platform through a formed networkThe set-up, 11May07: “Cart” was a 4’ x 3’ x 9” high castered utility cart with 55-gal drum for

mass. PT-1160 (3051S) and TT-1160 (648) on cart at opposite corners.

Model 775 Wireless Upgrade Module (‘thumb”) added to spare 3144P (tag # TT80H280). Device kept in Control Room [process bay/suite area classification is Cl. 1/Div. 1].

Testing done in stages:

2A – No devices moved; Trial #1 set-up used; Cart starts @ position “A” on Third Floor moves to position “B.”

2B – All instruments re-positioned to Third Floor. Cart moves from “B” to “C.”

Third Floor

Suite C-3 M/U Bay D-3 M/U

M/U Bay H-3 M/U M/U Suite K-3Bay J-3

1

2

3

4

5

6

12

8

WG

Device placement (dimensions shown are height from floor): WG to right of Control Room door on wall - 76” T1 in Mech/Util room on panel - 60” T5 on vessel in Bay D-3 - 30” T2 between vessel and wall in Bay H-3 - 18” T6 on shelf in stairwell - 54” T3 on vessel in Bay H-3 - 18” T8 in Mech/Util room on panel - 60” T4 on mezzanine (“Floor 3-1/2”) - 96” T12 on shelf in Aisle - 60” PT and TT (PT-1160 & TT-1160) in Control Room awaiting trial #2: Moving Cart

PTTT

Control Room

A

B

2A

CartPT

TT

775

Third Floor

Suite C-3 M/U Bay D-3 M/U

M/U Bay H-3 M/U M/U Suite K-3Bay J-3

1

2

3

4

5

12

WG

Device placement (dimensions shown are height from floor) : WG to right of Control Room door on wall - 76” T1 in Mech/Util room on panel - 60” T7 on shelf in Aisle - 60” T2 on vessel in Bay H-3 - 18” T8 on panel in Bay J-3 - 48” T3 on vessel in Bay H-3 - 18” T9 in Mech/Util room on panel - 60” T4 on mezzanine (“Floor 3-1/2”) in Bay D-3 – 108” T10 on vessel in Bay J-3 - 30” T5 on vessel in Bay D-3 - 30” T11 on shelf in Aisle - 60” T6 on mezzanine (“Floor 3-1/2”) in Suite K-3 – 96” T12 on shelf in Aisle - 60” PT and TT (PT-1160 & TT-1160) on Moving Cart 775 is TT80H280 (spare 3144P, no RTDs)

Control Room

B

C

CartPT

TT

11

9

10

8

6

2B

775

775 Diagnostics! 1st application was to a 3144Pwith no RTD installed.

Unleash the hidden Plant

Why Predictive Intelligence? Catch Problems Before They OccurWhy Predictive Intelligence? Catch Problems Before They Occur

Equ

ipm

ent

Hea

lth

0%

100%

Time

Advanced Warning = time to respond before it causes a shutdown

A digital plant architecture that uses the power of wireless field intelligence to improve plant

performance

Detect Subtle Changes in Plant

Operation to Improve

Performance

SPM actively monitors process mean values and standard deviation

Detect Subtle Changes in Plant

Operation to Improve

Performance

SPM actively monitors process mean values and standard deviation

Equipment and Plant Availability Increased with Vibration MonitoringEquipment and Plant Availability Increased with Vibration Monitoring

Measurements delivered wirelessly through 1420 gateway

Available early 2008 - Trials in progress

Predictive and timely indication of failure trends

Delivers accurate and actionable data more effectively than monthly snapshots

Gives Peakvue and overall vibration readings

Send Maintenance ONCE to repair …

… Not 20 TIMES to CHECK

In-plant equipment or remote, hazardous, or unmanned area

Operating Costs Reduced with High Resolution Online Corrosion MonitoringOperating Costs Reduced with High Resolution Online Corrosion Monitoring Corrosion related leaks, spills, and

accidents are a serious concern in aging infrastructure

– Hard-wiring to install online systems is often difficult in mature assets

RCS Microcor Wireless Transmitter (MWT) enables cost effective, near real-time corrosion rate

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16

7/14

/07

12:0

0 A

M

7/21

/07

12:0

0 A

M

7/28

/07

12:0

0 A

M

Met

al L

oss

(mils

)

0

1

2

3

4

5

6

7

8

Cor

rosi

on R

ate

(mpy

)

Metal Loss Corrosion Rate

Emerson partnering with Rohrback Cosasco Systems (RCS) to bring technology to the market

Measurements delivered wirelessly through 1420 gateway or ROC 800 gateway

Available early 2008

System detects an increase in the corrosion rate of pipelines, heat exchangers, distillation columns….

775 Diagnostics! 1st application was to a 3144Pwith no RTD installed.

Upgrade Installed HART Devices to Redundant Wireless CommunicationsUpgrade Installed HART Devices to Redundant Wireless Communications

Connect to already installed transmitters

2 versions

– One for valves

– One for other devices

Self contained power

– Uses energy from loop wiring

– Or encapsulated battery

HART comms pass through

– AMS connectivity

IS approval775 HART Upgrade

Module

Self Organizing Networks Will Unlock Stranded Diagnostics in Legacy PlantsSelf Organizing Networks Will Unlock Stranded Diagnostics in Legacy Plants

LegacyHost

20 million installed HART devices have underutilized diagnostics because the plant doesn’t

support a digital architecture

Wireless upgrade modules will unlock these diagnostics and extend ROI

Thank YouQuestions