Using Wireless Hart Technology
Using Wireless Hart Technology
in Process Industries
U i WirelessHART
Using Wi l HART T Technology
h l
in Process Industries
30,000,000
Installed
Wireless
• Introduction
• What Can Wireless Do For You
• Understanding HART
• Wireless Building Blocks
• Using WirelessHART
• Host Integration
• Planning a WirelessHART Project
• Summaryy
Today we will discuss ….
WirelessHART Attributes
Battery life (power options)
Range
Control
Mesh & Star topologies
p g
Radio / Antenna characteristics
Co-existence
Security IEC Approved Standard
Update rates
WHAT WIRELESSHART CAN DO FOR
YOU
Contents
• Process Monitoring T
Type Cl
Class D
Description
i ti
Hard to reach / expensive to
install locations Safety 0 Critical
Full access to multivariable
devices 1 Closed Loop regulatory
control
• Asset Management 2 Closed loop supervisory
Control control
Condition monitoring
Configuration database 3 Open loop control
• Control 4 Al ti
Alerting
Open loop Monitoring
5 Data logging and
Closed loop Up/Download
Designed
g for Process
NAMUR WirelessHART Field Test Report
• Conclusions:
WirelessHART allows
successful deployment of
wireless sensor networks
WirelessHART in principle is
applicable for monitoring
applications (NE124 Class C)
Suppliers have improvement
potential related to
implementation supporting
applications
pp
WirelessHART offers opportunities despite
p legacy
g y burdens
Designed
g for Process
NAMUR WirelessHART Field Test Report
• Recommendations
A single standard
Gateway
Standardize Battery
design and connection
Configuration
standardization and
interface
Devices
Designed
g for Process
Process Monitoring Applications
• Equipment Monitoring
Bearing temperatures
Vibration
Corrosion
Oil pressure
Air flow
Designed
g for Process
Applications
• Asset Management
Maintenance
• Calibration
• Record
R d valve
l signatures
i t
• Radar echo
Diagnostics
• Valve position feedback
• Device health (status)
Works With Existingg Systems
y
Traditional Wired System
Works With Existing
g Systems
y
Remote I/O System
Works With Existing g Systems
y
Wireless – Similar to Remote I/O
Reduce Installation Cost
Material, Time and Labor
Analog I/O
Device termination
System terminations
Multicore terminations
Multicore terminations
WirelessHART Network
Serial I/O
1 system connection
Gateway
Reduce Project
j Execution Time
It’s More Than Just The Wire Savings
It’s
It s just that easy!
Summary
Universal
• PV – TAG – Diagnostic
Common Practice
• Calibration – PV range
Device Specific
• Linearization tables –
Technology specific
Understandingg HART
Device Description (DD)
• Handheld host
Simple instruments
IS version for hazardous areas
• PC-based host
Asset management
Condition monitoring
Understanding
g HART
Communication Modes
• Master
Master-Slave
Slave Mode:
Communication is initiated by a
master device
• Point-to-point
p or multi-drop
p
• Primary Master:
Control room (system)
• Secondary Master:
Handheld
• Burst Mode:
Master instructs the slave device
to continuously broadcast a
standard HART reply message
(e g PV) until instructed to stop
(e.g. stop.
Understandingg HART
Multiplexer/Pass through Operation
Control or
• HART multiplexers Asset Management System
Monitor PVs
Typically a PC (SCADA) Analog +
HART Data
acts as the host
Can be added as retrofit
• Remote I/O can p
pass Analog
HART
Data
HART commands to
the host
Connect to I/O as
though it were a modem
Read/write all data
Understanding
g HART
Summary
• Radio
Frequency
• Unlicensed band ISM
(Industrial, Scientific and
Medical)
2.4 to 2.5GHz
• Need to co-exist with other
users -15 channels available
• Available worldwide
Readily available
• Standard IEEE802.15.4 Radio
Low Power
• Low power = longer battery life
Working
g With ISM Bands
Coexisting with Other Networks
• Star
St configuration
fi ti • Mesh configuration
Best for control Best for reliability
Low data latency Multiple paths
Plant unlikely to change Adapts to changing plant
Star Mesh
Main User Concerns
• Make it Reliable
Manage power
Process
P plants
l t change
h
Need to coexist
• Make it Secure
Secure the data
Authenticate data and
devices IEC Approved Standard (IEC 62591Ed. 1.0)
• Make it Simple
As simple as 4-20mA
Make it Reliable
Power is Everything!
High Speed Host Connection
• Time
Ti Slot
Sl t STX
Transaction
1 Slot = 1 Transaction on
ACK
• Time Synchronization
Cycle n-1 Cycle n Cycle n+1
Time synchronization
y and time slots are handled automatically!
y
Make it Reliable
Slot Timing
Session
S i
Key A
Modify
Make it Secure
Data Protection – Check Message Integrity
The WirelessHART sensor
network provides:
Message integrity checking
• Message Integrity Code (MIC) is
unique and is part of each
message
• Receiving device checks data
has not been altered.
Security
Counter MIC Data
Control
Message
Make it Secure
Network Protection – Unauthorized Devices
• An unauthorized
device tries to join
the network
• Join Key
management
g
The join key can be
changed
Use an access
control list
Make it Secure
Network Protection – Replay Attack
• Keep the network busy
handling data
Read data and repeat it
onto the network
• The message is ignored
The Counter at the
network layer is time slot
dependant
• The replay has to
happen in the same time
Security slot (10msec)
Counter MIC Data
Control
Message
g
Make it Secure
Network Protection – Denial of Service
• Keep the network busy
handling data
Saturate the network with
authentic looking data –
Join Requests
• Join request ignored
The Network Manager g has
list of authorized
instruments
Needs to be an authorized
d i
device
A counter logs each failed
join request – alert site
security
Make it Secure
Network Protection - Monitoring
• WirelessHART does
NOT use TCP/IP,
making it safe from
many internet
i t t attacks
tt k
Make it Simple
Make it
B ilt in
Built i Security
S it as Simple Self-Building Mesh Network
as 4-20mA
Reduce
Engineering
HART Commands
Universal Common Practice Use existing tools
I t
Instrumentt Specific
S ifi and knowledge
Make it Simple
Device Commissioning
Work Flow is Similar
Summary
• Mapping PV to registers –
Function blocks or modules
Wireless Cooperation Team - WCT
Specifications in 2010
Accessing Data “On Demand”
Gateways
y may yp
provide separate
p
connections for cyclic and acyclic data
• Host integration
Uses standard high speed
networks
Map process data at the
gateway
C li and
Cyclic d acyclic
li iinformation
f ti
available
PLANNING A SUCCESSFUL
WIRELESS PROJECT WITH
WIRELESSHART
Project
j Scope
p
Network Planning
76
Project
j Scope
p
Plant Infrastructure Assessment
• Walk through of the
area
• Assume worst case
for planning
85 meters
• Traditional “site
survey”” is
i nott
required
77
Network Planning
g – 3 Dimensional
Environment
Line of Sight or
Low Obstructions
High Obstructions
Where many instruments are locate
78
Device Placement
Design a Network – Minimum 5 Devices
Place devices like wired
• Self-Organizing will adapt
wireless to process environment
• Plan to install like wired
Network Minimum of 5
devices
• Based on experience
• Less will work
• Network becomes stronger with
more devices
• Initial network is an investment
in future network
79
Device Placement
Field Device Connectivity – Best Practice
• Each field device has at
least 3 neighbors
The 3rd neighbor will act as
a backup if one of the two
primary paths is obstructed
or unavailable
• D
Devices
i mounted
t d >0.5m
05
from any vertical surface
• Devices mounted >1.5m
1.5m
off the ground
Only 2 neighbors is okay
but not best practice
80
Device Placement
Vertical Placement of Devices
• Omni
Omni-directional
directional antenna
Radiates the same power on any
horizontal angle
◦
• Less
L th
than 45
Same distances as horizontal
plane
• Rule of thumb
<15m high – don’t worry about it!
81
Device Placement
Identify Line Of Sight (LOS) Height
• Identify obstruction
height
Most devices installed
below this height
• Identify LOS height
LOS Height = Obstruction
Height + 2m
Gateways and Repeaters
get maximum range when
mounted at LOS Height
82
Device Placement
Repeaters
Repeaters LT
S-27
Line of Sight
S-31
LT
100
S-35
CY
100
S-33 S-30
S-28
LT
I-5
S-26
LT 100
LT S 29
S-29
100 LT
101
100
E-16
Building 1 E-15
WirelessHART Network E-18
Gateway
E-11
High Obstacles
S-36
CY
200
83
Device Placement
Gateway Location
• Three Options
Easiest for Integration
Center of Initial Network
Center of Process Unit
• Rule of Thumb
Plan for connection to 25% of
devices communicate directly to
gateway
Ensures ample connectivity and
eliminates pinch points
84
Device Placement
Network Expansion
• Existing Network is
Foundation for Scalability
Add new devices to perimeter
of existing network
Add new devices to interior of
existing network
Self-organizing incorporates
and expands without disruption
85
Device Placement
This is a MESH network
• Don’t
Don t forget this is a mesh
network
Instruments do not need to
be within the range of the
gateway
They just need to be close
to another wireless
instrument
86
Instrument Specification
p Sheet
Wired HART & WirelessHART
Optional Information:
Keys can be pre-
programmed or
entered in the field.
Keys can be changed
after commissioning.
Device Specification
p
Adapter
88
Device Specification
p
Gateway Specification
Sheet
REQ. P.O.
FIELD
BY CHK’D APPR.
TAG:
Host Protocols Modbus RTU □ Modbus TCPIP □ Modbus data format: ______________
OPC □ Profibus DP □ FF HSE □
Other □ ________________
Data Connections: RS485 □ RS232C □ Ethernet 10baseT □ Ethernet 100base-TX □
89
Commissioning
Co ss o g
Commissioning the Network
• HART handheld or PC
tool will allow you to join
instruments to the network
Overlapping networks will
have different network IDs
• Steps
p
Install and power Gateway
Install devices one by one
• Begin with closest to the
gateway
STAR or Point-to-Point
P i t t P i t Communica
C i
90
Commissioning
Commissioning a WirelessHART Device
• Steps
Install or activate the
device’s power source
Enter the Network ID
Enter the Network Join Key
Set the refresh (update) rate
Verify the device has joined
the network
• At the device using a
handheld or other tool
• At the gateway
91
Commissioning g
Verify Device & Network Configuration
• Verify Device Operation
Check device TAG
Check device engineering units TT-105
Deg C
Check PV Update rate
4 sec
Check battery voltage 8.75 vdc
• Verify Gateway
Check for minimum of 5 direct
connections
Check for 25% of devices with
direct connections in large
g
networks
• <10% add repeaters if
necessary
92
Commissioning g
Verify Network Operation
• After all devices have
been commissioned
Allow time for the network to
optimize (>4 hours)
Check each device for at
least 3 neighbors
Check path stability
• 60% minimum
• Increasing the elevation of
th antenna
the t can correctt
many situations
• Add repeater if necessary
93
Documentation
Wireless Symbols
Adapter
p with loop
p powered
p device
Wi l
Wireless Field
Fi ld Device
D i
TT YO
TE TT 105 105
105 105
Gateway Repeater
YG YA
5202 Network ID 5202-2
94
Documentation
Loop Diagram
• Gateway
• Field Device with External
Sensingg Element ((RTD))
• Self-contained Field Device
• Analog
g Field Device with
Adapter
Planning
g a WirelessHART Project
j
Summary
• Segment
Seg e youryou network
e o like e you
would remote I/O
• Assess the potential
communication rangesg
• Determine gateway and device
locations
• Place repeaters if needed
• Documentation
• Commission and let network IEC Approved Standard (IEC 62591Ed. 1.0)
stabilize
• Establish security procedures
96
USING WIRELESSHART TECHNOLOGY IN
PROCESS INDUSTRIES
SUMMARY
Today you discovered….
discovered
• What WirelessHART
can do for you
• Where
Wh wireless
i l solutions
l ti can bbe
applied
• How WirelessHART co-exists
co exists with
other networks
• How Security and Reliability is
addressed
dd d
• How to plan a wireless project
Now You Know ….
Attributes WirelessHART
Backward Compatibility – with 30 M 9
installed devices
Designed by and for the Process Industry 9
Can be used in Hazardous Areas 9
Star & mesh wiring topologies 9
Monitoring AND Control Applications 9
Security - Built –in
in, Always On 9
Attributes of WirelessHART - Summary
Attributes WirelessHART