Industrial Wireless
Solutions
Agenda
Introduction
Products & Specs
Applications
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Introduction to wireless
 Imagine
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Introduction to wireless
 Imagine
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Introduction to Wireless
 Conventional Monitoring Conditions
– Long conduit runs between sensors and control room
– Cost of materials- estimated $100/ft to run conduit or
cable
– Lack of resources to do maintenance
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Introduction to Wireless
 The reality with wired solutions
– Long distances from critical monitoring
– Large obstructions can make wiring impractical or
impossible
– Processes or equipment need monitoring in use
– No power available in remote applications
– Expense
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Introduction to Wireless
Wireless adaptation
Radios simply eliminate the need to run wires for any sensor
application
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“What, no fittings?”
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Introduction to Wireless
 What is industrial wireless?
– Transmitting information via radio
• Transmitters
• Receivers
• Gateways
– Monitoring solution
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Tank levels monitors
Motor operated valves
Pumps
Heat trace
– No need for wires or cable
– Radios are programmable
• Multiple radios on a reliable path
• To send data upon
 Request
 Periodically
 Pre-determined signal values
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Introduction to Wireless
 Applications considerations
– Monitoring (90+%)
• Requirements
 Pipelines
– Pressure monitoring, heat
tracing monitoring
 Motor operated valves
– Feedback needed to confirm
valve position
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Introduction to Wireless
 Applications considerations
– Control
• Requirements
 Process control
– Automated and manual
process control for various
industries
 Alarms
– Monitor conditions and
automate alarms when
needed
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Introduction to Wireless
 Why go wireless?
– Cost effective solution
• Avoiding long wire or conduit runs
• Eliminating trenching and cable trays
• Facilitating solutions for applications hindered by physical
obstruction
– Added value
• Increased operational safety by continuous monitoring
• Mobile and flexible monitoring
• Easy to upgrade as you grow
• Low cost per access point
• Easy to install
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Introduction to Wireless
Wireless technology advantage
I/O
Monitoring
I/O
I/O
Mass
I/O
…
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Introduction to Wireless
 Application: Oil & Gas
– Well-head and pump monitoring system
– Pipeline pressure, flow and valve
monitoring
– Protection system monitoring
– Leak detection monitoring
– Underground gas storage monitoring
– Pump/compressor station control
systems
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Introduction to Wireless
 Application: Process Industries
Eg Chemical plants, Pulp & paper, steel
mills, power gen, glass manufacturing
– Flow monitoring
– Tank level monitoring
– Condition monitoring of equipment
– Utility plant alarms
– Effluent treatment plants
– Security and access-control
– Remote water pumps
– Monitoring of fire-fighting and safety
systems
– Gas detection systems
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Introduction to Wireless
 Application: Factory Automation
Eg. Assembly plants, component manufacturers,
Pharmaceutical, food & beverage, packaging
• Detection of moving machinery
• Power network monitoring
• PLC interconnection
• Alarm monitoring of portable machinery
• Utility plant alarms
• Effluent treatment plants
• Security and access-control
• Rotating and moving machinery
• Alert and Evacuation alarm systems
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Introduction to Wireless
 Application: Utilities & Municipal
– Water management
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Pump station control
Tank monitoring, level and security
Flow metering systems
Irrigation monitoring and control
Water quality monitoring
Large network SCADA systems
Treatment plant monitoring
Early flood-warning systems
– Electricity distribution
• Monitoring of power poles
• HV Feeder alarm fault monitoring
– Gas reticulation
• Valve stations
• Pressure monitoring
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Wireless driven by business need
Application Examples
 Process monitoring
 Rotating equipment – e.g.
Kilns
 Safety systems – showers,
etc.
 Operator safety status
 Mobile asset
tracking
 On/Off valve
position/control
 Remote process
set-up
 Temporary
installations
 Wired alternative
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Wireless best fit when…
 Manually collected data: Wireless can eliminate the need to
send technicians into the field to read gauges
 "Must have" measurements: Environmental or safety
regulations may require additional measurements. Wireless
allows the easy placement of instruments where needed.
 Need for diagnostics: Many plants have hundreds of field
devices. Wireless allows access to diagnostic information in
certain of these areas
 Temporary Monitoring: process may only need a short ( 1-3
months ) monitoring. Wireless allows easy, fast, and
inexpensive install for these requirements
 “Want to have" measurements: Wireless permits adding
instruments in locations that could not previously be justified.
 Long distances involved: Wireless can eliminate the need for
long cable runs and trenching to connect tank farms and similar
assets spread over a wide area.
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Wireless best fit when…
 Many pumps and motors: Plants often have hundreds of
pumps and motors. And while continuous condition monitoring is
noble in concept, wiring vibration sensors to all of them would
be prohibitive. Wireless allows an easy connection.
 Extreme environments: Hot, dangerous and/or hazardous
environments make it difficult to install instruments and run wire.
Wireless minimizes the problem.
 Crowded environments: Wireless eliminates the need to snake
new wires through crowded enclosures and conduit.
 New wiring is too expensive: Installed costs of $50 to $100
per foot can make adding new wired measurement points costprohibitive.
 Need for feedback: Manual valves that have no position
feedback can cause safety problems. Wirelessly monitoring can
cost as little as 10%of a wired solution.
 No other way: Wireless works for mobile assets, remote sites
and rotating equipment where using wired instruments is
impossible or impractical.
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Standard terms and definitions
 WIBnet™ - wireless-information-backbone. Network technology
allowing flexible, secure and scalable peer-to-peer connectivity
of wireless data.
 Industrial-grade –This means temperature , vibration, humidly
specs, certification to at least Class I Div 2 , and superior power
options and packaging.
 Event data management –exception reporting technique to
transfer wireless data that ensures the most reliable, secure and
fastest transfer physically possible. This technique also provides
easy scalability and increased bandwidth.
 Frequency Hopping Spread Spectrum (FHSS) –random use
of a defined band of frequencies. Invented during the WWII as a
way to send wireless data more securely with less interference.
 AES (Advance Encryption Standard ), WEP (Wired
Equivalency Privacy ) –these are encryption techniques used
in today’s wireless world.
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Frequency Hopping SS - Security
Power
Watt
Time/mSec
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The Products
The Products
 One–way communication
– Transmitters
• 2 digital outputs &
1 analog signal
Digital
Analog
Pulse
Digital
Analog
Pulse
– Transmitters & Receivers
• 2 digital outputs, 1 thermocouple
& 1 analog signal
Digital Analog
Thermocouple
Digital Analog
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The Products
 Two-way communication devices
– Transceivers
Digital
Analog
Pulse
Digital
Analog
Pulse
– Gateways
Airport
Management
SCADA
Radar
Station
Fuel
Tanks
Standby
Generator
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The Products
 I/O Expansion Products
– Serial units
Up to 32 units
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The Products
 Enclosures
– Explosionproof Enclosures
• NEMA 4, 7, 9
– Non-metallic Enclosures
• NEMA 3, 4, 4X, and 12 applications
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The Products
 Class I Div 1 Installations
– Wireless components require:
• Explosion proof enclosure kit
 EJB
 GUB
• Division 1 Antenna
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The Products
 Industrial and Class I Div 2
– Wireless components require:
• “Enclosure suitable for the
environment”
• Non-metallic Enclosure
 NEMA 4X
 Fiberglass Reinforced Polyester
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The Products
 Antennas
Dipole, collinear, Yagi, and whip antennas in various lengths
and ratings are available to meet all power, range, and
direction variables.
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The Applications
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The Applications
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The Applications
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The Applications
 Tank Farm
– Remote tank monitoring
 Power plant
– Stack gas monitoring
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The Applications
Remote Tank Monitoring
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The Applications
Power Plant - Stack Gas Monitoring
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Key Features
 Key features of Wireless Solutions:
– Flexible
• Vast selection of digital, analog, and pulse inputs per
transceiver
• Repeaters are not necessary
– Expandable
• Up to 31 serial expansion units
• Each radio is capable of sending / transmitting 20 miles
when using an antenna
– Reliable
• Redundant paths can be formed
• Routine connection verification
• Frequency hopping spread spectrum
– Secure
• Radios use a highly secure data encryption technique
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Benefits
 Benefits
– Cost savings stem from:
• Reduced repair costs, and machinery
downtime/damage (leaks, corrosion, etc)
• Improved operational efficiency and process control
• Safety costs (avoided injuries)
• Reduced manual/personal monitoring
• Eliminated conduit/cable systems/cable trays
installations
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Manufacturer Breakdown
Industrial Wireless Process Manufacturers (902928MHz Range)*
% Market Share
GE MDS
Cooper Crouse-Hinds
Ferguson Beaurogard
Fedd Systems
Phoenix
Accutech
Adalet Wireless
Bentek Systems
American Innovations
Cameron Measurement Systems
Emerson Process Management
Honeywell
Others
Total (Market Size $66.4 MM)
15%
12%
6%
6%
6%
5%
4%
4%
3%
2%
2%
2%
32%
100%
* Source: Arc Advisory Group, 2008
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Things to take away
 Cost-effectiveness -
When directly compared to wired installations, wireless is a
very cost effective alternative. Wireless modules allow seamless integration into all
applications enabling installation costs to be kept to a minimum.
 Reliability - Radio protocols include multiple addressing levels, error checking,
handshaking and automatic re-try mechanisms that guard against transmission failure.
Should a communications failure occur, wireless solutions can provide multiple levels of
alarm.
 Security -
Most technology employed is state-of-art. As a result, each product has
four levels of protection.
– Data is embedded in wireless transmissions using a unique modulation technique.
– The data format has a unique structure with added security features, including
network and address validation.
– Data is encrypted using a high-security encryption algorithm.
– Wireless protocol operates on an exception-reporting basis, transmitting when there
is a change. This greatly increases the difficulty in collecting wireless samples for
decoding.
 Ease of installation -
Our modules have built-in diagnostics and remote
configuration abilities that are designed to save time and hassles. Our free 24 hour
technical support provides further assistance should you require it.
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Questions?