Wireless Instrumentation
in the Pharmaceutical
Industry
Andy Wallace
Smart Wireless® Solutions Product Manager
UK & Ireland
Agenda

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 2.4Ghz

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 Haves


Reliability
–
Path Stability
–
Better than 99.9999%
Security
–


Authentication

Verification

Anti-Jamming

Key Management

Only operate when needed – preserve battery life
Scalable
–

Encryption
Low Power
–

Avoid fake and random attacks
Emerson
Smart Wireless
Capable of expansion without architecture changes
Flexible
–
Bandwidth Control - speed
–
Power Control – limit number of jumps
–
Channel Control – blacklisting if necessary
–
Latency Control
Com
Pra
Challenges 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 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 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 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
Networks
WirelessHART Networks
In-Plant Smart Wireless® Solutions are
Easy to Install, Use and Are Reliable!
Self Organising!
To
Host
Modbus,
Ethernet,
WiFi,
OPC,
Self Healing!
Gateway ‘grooms’ network for speed and loading
Together 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…
The 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 neighbours
3. Connect to a neighbour using JOIN key to authenticate
4. Neighbour uses NETWORK key to pass message up to gateway
5. Gateway determines optimised schedule
6. Schedule is flooded to the devices
Developing Neighbours

Typically 2 Parents

3 Children – Load Balanced

Many Neighbours (identified redundant paths)
N
N
C
P
C
P
C
N
N
Mesh Networks offers scalability…..
Animation courtesy of Dust Networks
Customer Site: Devices Scattered Throughout
the Process Facility With No Direct Line of Sight

High Data Reliability

Data Latency Varies
–
99.75 to 100.00%
–
0.66 to 6.22 seconds
–
Readings every 10 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 Reliability

High Data Reliability

Data Latency Varies
–
100.00%
–
0.82 to 5.20 seconds
–
Readings every 10 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
Self-organizing Wireless
Network in a Process Building
Major Pharmaceuticals Mfr
Four-story pilot lab
Customers 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 without
operator assistance
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 construction
Built 1993. Main building dimensions: 246’ 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
Trial site from column #5-12: 153’ x 70’
East Wing (column 7-11):
92’ x 70’
Device Placement:
T7 in Mech/Util room on floor
Suite C-1
Bay D-1
7
M/U
Bay H-1
First Floor
Bay J-1
Suite K-1
M/U
Device Placement:
No devices on Second Floor
Suite C-2
M/U
Bay H-2
M/U
Second Floor
Bay J-2
M/U
M/U
Bay D-2
Suite K-2
M/U
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
4
Suite C-3
M/U
Bay D-3
M/U
8
5
6
12
WG
PT
TT
1
M/U
2
Bay H-3
M/U
Control
Room
3
Third Floor
Bay J-3
M/U
Suite K-3
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
Bay
C-M
M/U
Bay
D-M
M/U
11
10
9
M/U
Bay
H-M
M/U
Bay
J-M
Fourth Floor
M/U
Suite
K-M
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 network
The 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.”
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
2A
4
B
Suite C-3
M/U
Bay D-3
M/U
8
5
6
12
WG
A
PT
TT
1
M/U
2
Bay H-3
M/U
Control
Room
3
775
PT
Cart
TT
Third Floor
Bay J-3
M/U
Suite K-3
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)
2B
4
B
8
Suite C-3
M/U
Bay D-3
M/U
5
6
11
12
WG
1
M/U
2
Bay H-3
M/U
Bay J-3
9
Control
Room
3
775
Third Floor
PT
Cart
C
TT
10
M/U
Suite K-3
775 Diagnostics! 1st application was to a 3144P
with no RTD installed.
Unleash the hidden
Plant
Why Predictive Intelligence?
Catch Problems Before They Occur
Equipment Health
100%
0%
Advanced Warning =
time to respond before
it causes a shutdown
Time
A digital plant architecture that uses the power of
wireless field intelligence to improve plant
performance
Equipment and Plant Availability Increased
with Vibration Monitoring
 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


Measurements delivered wirelessly
through 1420 gateway
Available early 2008 - Trials in
progress
In-plant equipment or
remote, hazardous, or
unmanned area
Operating Costs Reduced with High
Resolution Online Corrosion Monitoring
8
0.14
7
0.12
6
0.1
5
0.08
4
0.06
3
0.04
2
0.02
1
0
0
Metal Loss



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
Corrosion Rate
Corrosion Rate (mpy)
RCS Microcor Wireless Transmitter
(MWT) enables cost effective, near
real-time corrosion rate
0.16
7/14/07 12:00 AM

Hard-wiring to install online systems
is often difficult in mature assets
7/28/07 12:00 AM
–
System detects an increase
in the corrosion rate of
pipelines, heat exchangers,
distillation columns….
7/21/07 12:00 AM
Corrosion related leaks, spills, and
accidents are a serious concern in
aging infrastructure
Metal Loss (mils)

775 Diagnostics! 1st application was to a 3144P
with no RTD installed.
Upgrade 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 approval
775 HART Upgrade
Module
Self Organizing Networks Will Unlock Stranded
Diagnostics in Legacy Plants
upgrade
modules
will
20 million installed Wireless
HART devices
have
underutilized
unlockbecause
these diagnostics
and extend ROI
diagnostics
the plant doesn’t
support a digital architecture
Legacy
Host
Thank You
Questions