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Industrial Wireless Solutions

Industrial Wireless Solutions. Agenda. Introduction Products & Specs Applications. Introduction to wireless. Imagine. Introduction to wireless. Imagine. Introduction to Wireless. Conventional Monitoring Conditions Long conduit runs between sensors and control room

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Industrial Wireless Solutions

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  1. Industrial Wireless Solutions

  2. Agenda • Introduction • Products & Specs • Applications

  3. Introduction to wireless • Imagine

  4. Introduction to wireless • Imagine

  5. 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

  6. 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

  7. Introduction to Wireless • Wireless adaptation Radios simply eliminate the need to run wires for any sensor application

  8. “What, no fittings?”

  9. Introduction to Wireless • What is industrial wireless? • Transmitting information via radio • Transmitters • Receivers • Gateways • Monitoring solution • 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

  10. Introduction to Wireless • Applications considerations • Monitoring (90+%) • Requirements • Pipelines • Pressure monitoring, heat tracing monitoring • Motor operated valves • Feedback needed to confirm valve position

  11. 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

  12. 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

  13. Introduction to Wireless Wireless technology advantage I/O Monitoring I/O I/O Mass I/O …

  14. 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

  15. 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

  16. 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

  17. Introduction to Wireless • Application: Utilities & Municipal • Water management  • 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

  18. 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 Wireless driven by business need Application Examples

  19. 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.

  20. 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 cost-prohibitive. • 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.

  21. 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.

  22. Frequency Hopping SS - Security Power Watt 928MHz 869.65 MHz Frequency 902MHz Time/mSec 869.4 MHz

  23. The Products

  24. Digital Analog Pulse Digital Analog Pulse Digital Analog Thermocouple Digital Analog The Products • One–way communication • Transmitters • 2 digital outputs & 1 analog signal • Transmitters & Receivers • 2 digital outputs, 1 thermocouple & 1 analog signal

  25. Airport Management SCADA Radar Station Fuel Tanks Standby Generator The Products • Two-way communication devices • Transceivers • Gateways Digital Analog Pulse Digital Analog Pulse

  26. The Products • I/O Expansion Products • Serial units Up to 32 units

  27. The Products • Enclosures • Explosionproof Enclosures • NEMA 4, 7, 9 • Non-metallic Enclosures • NEMA 3, 4, 4X, and 12 applications

  28. The Products • Class I Div 1 Installations • Wireless components require: • Explosion proof enclosure kit • EJB • GUB • Division 1 Antenna

  29. The Products • Industrial and Class I Div 2 • Wireless components require: • “Enclosure suitable for the environment” • Non-metallic Enclosure • NEMA 4X • Fiberglass Reinforced Polyester

  30. The Products • Antennas Dipole, collinear, Yagi, and whip antennas in various lengths and ratings are available to meet all power, range, and direction variables.

  31. The Applications

  32. The Applications

  33. The Applications

  34. The Applications • Tank Farm • Remote tank monitoring • Power plant • Stack gas monitoring

  35. The Applications Remote Tank Monitoring

  36. The Applications Power Plant - Stack Gas Monitoring

  37. 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

  38. 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

  39. Industrial Wireless Process Manufacturers (902- 928MHz Range)* % Market Share GE MDS 15% Cooper Crouse-Hinds 12% Ferguson Beaurogard 6% Fedd Systems 6% Phoenix 6% Accutech 5% Adalet Wireless 4% Bentek Systems 4% American Innovations 3% Cameron Measurement Systems 2% Emerson Process Management 2% Honeywell 2% Others 32% Total (Market Size $66.4 MM) 100% * Source: Arc Advisory Group, 2008 Manufacturer Breakdown

  40. 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.  

  41. Questions?

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