Wireless in Process Automation

Trends and Outlook

ETSI Board #67
13 June 2008

David Humphrey Harry Forbes

Senior Analyst, Europe Senior Analyst, North America
ARC Advisory Group ARC Advisory Group
DHumphrey@ARCweb.com HForbes@ARCweb.com

© 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

© ARC Advisory Group

Manufacturing Process Type

Continuous Process Discrete

Process Attribute
Manufacturing Unit 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 PAC/PLC

Profibus-DP,
HART,
DeviceNet,
Commonly Used Device Foundation Fieldbus,
Interbus,
Networks Profibus-PA,
AS-i,
Ethernet
Ethernet

© ARC Advisory Group

 Wireless Network Level
Domain
Controller APC History Server
ENG ENG

Management
Level 3

HMI HMI HMI HMI HMI HMI

Server Server Server Server

Operation
Level 2

Control
Level 1

Field Devices
Level 0

© ARC Advisory Group

Process Manufacturing
Wireless Market Forecast

 Size and Growth

 Wireless penetration into Process Field Device
Market

© ARC Advisory Group

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

© ARC Advisory Group

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

© ARC Advisory Group

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

© ARC Advisory Group

Advanced Metering:
Integrates Devices at the Edge of the Grid

Advanced Metering +
Demand Response

Power Generation Transmission Distribution End

Generation Switchyard Substation Substation 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

© ARC Advisory Group

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

© ARC Advisory Group

WLAN Infrastructure Trend:
Process Manufacturing

Bridge
or Router

Layer 2
WLAN Mesh
Segment Portal

Layer 2
WLAN
Segment

.11s Mesh #1 .11s Mesh #2

© ARC Advisory Group

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

© ARC Advisory Group

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)

© ARC Advisory Group

Location System Architecture

Enterprise
Applications

Location Engine Appliance

Exciters
Wi-Fi UWB Passive
Network Readers Readers

Wi-Fi Tags, clients, Dual-mode

Passive RFID Tags
integrated sensors Wi-Fi /UWB Tags

© ARC Advisory Group

Wireless Standards Organizations
and Initiatives

© ARC Advisory Group

WSN Standards and Technologies

 IEEE 802
 ZigBee Alliance
 HART Communication Foundation
 IETF
 ISA
 TinyOS Alliance
 Bluetooth SIG
 Proprietary technologies (ANT, Z-Wave, others)

© ARC Advisory Group

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

© ARC Advisory Group

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
© ARC Advisory Group
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

Timeslot
 Time-division multiple access (TDMA)
Frame n-1 Frame n Frame n+1

... ... ...

Time
© ARC Advisory Group
HART Communication Foundation

 Network Manager
• Critical
• Makes all decisions
• Devices can be “dumb”
 Presently a sole-
sourced 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
© ARC Advisory Group
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

© ARC Advisory Group

IETF

 RFC 4944 (6LowPAN)

• IPV6 over 802.15.4 IP V4 IPV6
Network Network
 ROLL Working Group
• Began May 2007 Sensor Network Gateway

• Routing over low- IPV4-IPV6 Routing

power lossy nets
IPV6 Services Layer
• Application areas:
Sensor Network Data Link Layer
• Industrial
• Home
• Buildings
Sensor Network
(Mesh, Star, or Tree)

© ARC Advisory Group

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
application sensing application

routing Routing Layer

messaging Messaging Layer

packet Radio Packet UART Packet

byte Radio byte Sensor Sensor SW

bit RFM UART clocks ADC ADC

HW

© ARC Advisory Group

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

© ARC Advisory Group

 Thank You.
For more information, contact the authors at
DHumphrey@ARCweb.com
HForbes@ARCweb.com

or visit www.arcweb.com
© ARC Advisory Group