Wireless in Process Automation
Trends and Outlook
ETSI Board #67
13 June 2008
David Humphrey
Senior Analyst, Europe
ARC Advisory Group
DHumphrey@ARCweb.com
Harry Forbes
Senior Analyst, North America
ARC Advisory Group
HForbes@ARCweb.com
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© ARC Advisory Group
Who Is ARC Advisory Group?
Strategic Advisory and Management Consulting Firm:
 The leader in manufacturing and logistics
• Supply Chain: Sourcing to Fulfillment
• Plant Systems: Production Management to Controls
• Product Lifecycle Management: Design to Service
 First-hand industry and application experience
 Technology trends and business forecasts
 Formed in 1986 – 22 years of growing knowledge
Enterprise to Plant Floor
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Agenda
 Industrial Wireless Segmentation
• Which are the critical parameters?
 Process Industries Wireless Market Forecast
 Wireless Applications in Manufacturing
 Wireless Standards organizations and efforts
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Industrial Wireless Segmentation
 Device Power Model
• Replaceable battery (low-power)
• Rechargeable battery
• Mains power
 Manufacturing Process Type
• Continuous Process Manufacturing
• Discrete Manufacturing
 Wireless Network level
• Sensor level network
• WLAN level network
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Manufacturing Process Type
Process Attribute
Continuous Process
Manufacturing Unit
Discrete
Manufacturing Unit
Sensor types
Predominately Analog
Predominantly Discrete
Sensor count per unit
1000
100
Unit Physical Size
1000 Meter
10 Meter
Units per Plant
10s
100s
Production Cycle Length
100 Days
1 Day
Unit Startup Time
Hours
Minutes
Control Loop Time
.1-1000 Sec
.001-.5 Sec
Field Device Cost
$1000
$100
Installation Cost/device cost
10 X
4X
Automation Technology
DCS
Commonly Used Device
Networks
HART,
Foundation Fieldbus,
Profibus-PA,
Ethernet
PAC/PLC
Profibus-DP,
DeviceNet,
Interbus,
AS-i,
Ethernet
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Wireless Network Level
Domain
Controller
APC
ENG
History
Server
ENG
Management
Level 3
HMI
Server
HMI
HMI
HMI
Server
Server
HMI
HMI
Server
Operation
Level 2
Control
Level 1
Field Devices
Level 0
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Process Manufacturing
Wireless Market Forecast
 Size and Growth
 Wireless penetration into Process Field Device
Market
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Wireless Market Growth in Process Industries
1,200
1,000
800
600
400
200
0
2007
2008
2009
2010
2011
2012
Worldwide Market for Wireless Devices in Process Manufacturing
($Millions) ©2008 ARC Advisory Group
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Wireless Impact on Field Device Markets?
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Wireless Field Device Penetration
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Current and Emerging
Process Wireless Applications
 Bridging
 Field Process Sensing
 Equipment Condition Monitoring
 Advanced Metering Infrastructure (AMI)
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Wireless Cable Replacement (Bridging)
 Many commercial products
• E.g. Cooper (MTL/Elpro),
Phoenix Contact, ProSoft, others
 Proprietary and Wi-Fi radio
 Optimized for longer range
 Not glamorous, but very
useful and economical
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Wireless Process Sensing
 Commercial products




since 2003
Longer life now possible
More reliable
communication
Better security
Becoming standards-based
• IEEE 802.15.4
• HART V.7 (WirelessHART)
• ISA 100
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Equipment Condition Monitoring - Present
 These address assets that are NOT being
monitored now, which
is most plant assets
 ECM Application Components
• Specialized Mobile Computers
• Vibration Sensors
• Analytical Software
• Historical Data Repository
 Current suppliers include:
• ABB
• Emerson
• GE/Bentley
• Honeywell
• SKF
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Advanced Metering:
Integrates Devices at the Edge of the Grid
Advanced Metering +
Demand Response
Power
Generation
Generation Switchyard
Transmission
Substation
Distribution
Substation
End
User
Common Information Infrastructure
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WLAN Applications
 Mobile Operator Support
• Process Operations
• Maintenance, Safety, Environmental operations
 Visibility During Planned Shutdowns
(“turnarounds”)
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Mobile Operator Support
 Initially networked via cradles
 Applications
• Rounds and readings
• Data Capture
• Work Order Generation
• Condition Monitoring
• Process Operations
• Turnaround visibility
 Combines with AutoID,
and sensing
 Converged with voice
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WLAN Infrastructure Trend:
Discrete Manufacturing
 Wi-Fi coverage becomes dense
 Multiple Wireless Applications
• Automation
• Data
• Voice
• Location services
 Manufacturers are moving to a
unified WLAN network model
• Common services
• Wider coverage
 RF Spectrum management will
become a part of network
management practices
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WLAN Infrastructure Trend:
Process Manufacturing
Bridge
or Router
Layer 2
WLAN
Segment
Mesh
Portal
Layer 2
WLAN
Segment
.11s Mesh #1
.11s Mesh #2
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Discrete Manufacturing Sensor Applications:
ABB WISA
 Commercial Product
 Uses Bluetooth radio
• Radio only, not stack
 Unique sensor power solution
• No batteries
• Rotating magnetic field induced around machine
 Well thought-out requirements for discrete manufacturing
sensor use-cases
• Number of sensors, range, latency, reliability, etc.
 FESTO has done related work using IEEE 802.15.4
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Location Tracking
 Technology Decision Variables
• Technology
• Radio type
• RSSI vs. TDOA
• Required Precision of Location
• Cost ( installed cost, Total Cost of Ownership)
 Possible Radios for Location Technologies
• Wi-Fi (Aeroscout, Ekahau, Cisco, others)
• 802.15.4 (Innerwireless, others)
• UWB (Zebra/Multispectral Solutions, Nanotron)
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Location System Architecture
Enterprise
Applications
Location Engine
Wi-Fi
Network
Wi-Fi Tags, clients,
integrated sensors
Appliance
Exciters
UWB
Readers
Dual-mode
Wi-Fi /UWB Tags
Passive
Readers
Passive RFID Tags
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Wireless Standards Organizations
and Initiatives
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WSN Standards and Technologies
 IEEE 802
 ZigBee Alliance
 HART Communication Foundation
 IETF
 ISA
 TinyOS Alliance
 Bluetooth SIG
 Proprietary technologies (ANT, Z-Wave, others)
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IEEE 802
 802.15.4e
• MAC amendment to the existing standard 802.15.4-2006
to
• better support the industrial markets
• permit compatibility with Chinese WPAN
• Suppliers do not use standard 15.4 MACs
• 15.4 TDMA (called GTS) network operation
• not completely specified
 802.11n
• Next enhancement to Wi-Fi
 802.11s
• Multi-vendor Wi-Fi mesh networking
• Ballots have failed so far
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ZigBee Alliance




Built over IEEE 802.15.4 standard
ZigBee Scope
• Network layer, Security, Mgmt, Profiles
• Network formation
• RF Channel choice
• Scope equivalent to TCP/IP Suite
• Too broad
• Largely unsuccessful
Solved the low-power
problem with:
• Reduced function devices, RFDs
• Mains-powered routers
• Not a good fit
for manufacturing
applications
ZigBee Application focus
• Began with building lighting (2003)
• Challenging performance requirements
• Few commercial products
• Now has shifted to Advanced Metering/Home Automation Networks
• AMI needs wireless access to home energy controls
• Utilities will want secure end-end IP connections
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HART Communication Foundation
 WirelessHART
 Part of HART Field Communication Specification, Revision
7.0
• Ratified September 2007
• Allows for wireless transmission of HART protocol
 Based on IEEE 802.15.4 PHY with modified MAC Layer
 Full mesh network topology
 Adaptive frequency hopping
 Time-division multiple access (TDMA)
Timeslot
Frame n-1
Frame n
Frame n+1
...
...
...
Time
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HART Communication Foundation
 Network Manager
• Critical
• Makes all decisions
• Devices can be “dumb”
 Presently a solesourced technology
• Dust Networks SoC and module products
 2nd source of WirelessHART technology is possible
• Client Device portion only, not network manager
• Talk but no investment yet
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ISA 100
 Instrumentation, Systems, and Automation
Society (ISA)
 ISA develops standards for ANSI
 ISA 100 scope includes all types of manufacturing
 ISA 100.11a is first standard. Due 2009
 ISA Compliance Institute
• ISA began compliance function only in 2007
• Compliance work for 3 important ISA standards
• Wireless (ISA 100)
• Cyber-security (ISA 99)
• Enterprise Interoperability (ISA 95)
• ISA ability to execute is unproven
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IETF
 RFC 4944 (6LowPAN)
• IPV6 over 802.15.4
 ROLL Working Group
• Began May 2007
• Routing over lowpower lossy nets
• Application areas:
• Industrial
• Home
• Buildings
IP V4
Network
IPV6
Network
Sensor Network Gateway
IPV4-IPV6 Routing
IPV6 Services Layer
Sensor Network Data Link Layer
Sensor Network
(Mesh, Star, or Tree)
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TinyOS Alliance
 TinyOS is an open-source OS for WSNs
• Used for most academic WSN research
• Global collaboration among academics
• Not used in commercial WSN applications
sensing application
application
routing
messaging
packet
byte
bit
Routing Layer
Messaging Layer
Radio Packet
UART Packet
Radio byte
RFM
Sensor
UART
clocks
ADC
Sensor
ADC
SW
HW
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Bluetooth SIG
 Low Power Bluetooth (formerly Wibree)
• Compatible with Bluetooth 7-device PANs
 ANT (Garmin) for non-Bluetooth applications
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Summary: Things To Remember
 Critical Industrial Wireless Segmentations
• Power use model (replaceable, rechargeable, mains)
• Process vs. discrete applications
• Wireless Sensor Networks vs. WLAN
 Industrial Wireless Market Will Grow Rapidly
• But adoption cycles and service lives are long
 Current wireless applications in process manufacturing:
• Cable replacement
• Process Sensing
• Equipment condition monitoring
• Mobile operator support
• Location tracking – attractive, but far less mature
 Industrial Wireless Standards
• Many, many organizations are participating now
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Thank You.
For more information, contact the authors at
DHumphrey@ARCweb.com
HForbes@ARCweb.com
or visit www.arcweb.com
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