The Wireless Plant of the Future

:
From Roadmap to Reality
White Paper A-10
Copyright © 2006 by Apprion, Inc.
The Wireless Plant of the Future:
From Roadmap to Reality
lNTRODUCTlON
Wireless technology is poised to make significant improvements to efficiency, productiv-
ity and automation within the manufacturing industry. Frequently, the cost benefits of
using ‘wireless’ are clearly understood, however there is no one type of wireless technology
that solves all problems. In order to maximize the value of industrial wireless networking
investment, companies must be able to select the best technology for a given application.
In order to achieve the necessary scalability, security and interoperability of a ‘best of
breed’ wireless infrastructure, users must develop a common framework and architecture
for all types of RF communications to work within. When designed properly this archi-
tecture creates a common wireless infrastructure that crosses functional departments and
conditionally supports multiple applications of differing criticality. In order to do so this
framework must:
• Align technology with business objectives and priorities
• Enable a vendor neutral operating environment
• Leverage and extend legacy systems
• Support open standards
• Provide effective technology lifecycle management capabilities to assimilate emerging
technology
• Distribute intelligence, policy and management into the network
The goals of this strategy are to give management powerful tools to concentrate on the
most critical issues, to more easily identify new ways to improve operations and bottom
line performance, and to concentrate on their core business in an environment in which
a new, intelligent wireless grid supports and enhances operations instead of becoming a
management burden
1
To be successful,
the WPoF must be
grounded in existing
realities and must
start from the
premise that on
going operations are
absolutely essential.
Too many new
technologies have
been offered up
without taking into
account the real
world of existing
systems, practices,
and investments.
DEFlNlNG THE WlRELESS PLANT OF THE FUTURE
The Wireless Plant of the Future is the realization of sensor-to-system connectivity. It
requires that a plant has the technical building blocks in place, overcomes the obstacles
that impede the adoption of wireless solutions, and is able to coordinate all asset data
streams so that they provide useful, clear, actionable information for daily management
and for analysis leading to cost and efficiency improvements.
The infrastructure and the ideas behind the WPoF are not completely new. Sensors, net-
works, and process management systems have all been present in plant environments for
decades. But the concurrent developments of extreme miniaturization now possible in sen-
sor technology coupled with low power consumption and robust wireless protocols now
make possible a qualitative leap forward. Instead of the old piecemeal systems of moni-
tors and gauges, The WPoF is built on a cohesive environment in which data is constantly
streaming and being automatically monitored, with intelligent alerting systems, smart over-
sight…an automated network of intelligence in which tens of thousands of sensors become
the eyes and ears of plant management, relieving management of the burden of doing what
the sensors and intelligent network can do 24/7 without blinking.

The I llusTraTI ve PlanT
The Wireless Plant of the Future, regardless of industry, will have several characteristics
that will allow management to better monitor and control the plant environment.
real-time data acquisition
Thanks to RFID and a comprehensive sensor network, managers will have a rich stream of
outputs from all plant assets and a procedure for immediate alerts based on mission criticality
and cost of downtime. That is, the intelligence part of the system is custom tailored for the spe-
cific concerns of management to define what is most critical, which issues need the most imme-
diate attention and which will have the potentially greatest financial impact. Furthermore, each
asset will have a customized diagnostics record for the purpose of benchmarking its perfor-
mance against that of other assets in its class. As a result, management will continually analyze
asset behavior in the context of known processing states, and an asset’s unique characteristics,
to ensure maximal availability, reliability, and efficiency. Additionally, the multiple wired and
wireless networks within a plant environment will be interwoven into an intelligent operations
network. While many technology vendors have a built-in rigidity and exclusiveness, the opti-
mal system is flexible and expandable--extending the legacy wired systems which have already
proven their usefulness, with newer deployments of wireless encompassing a wide range of
protocols as needed. This flexibility and extensibility allows users to leverage a common wire-
less infrastructure for applications of differing criticality. This new, unitary network is reliable,
easily managed and secure.
2
visualizing the Whole Plant in real Time
Plants today operate as a collection of separate fiefdoms, competing for resources and IT
support time. The divisions are treated as distinct and act as such. The WPoF will run as a
single organism but includes logical partitions designed specifically for each plant, in order
to support differing functions, criticalities, and security needs. Another key feature of the
WPoF is the way it interlinks process management, IT, and other functional departments
in ways that let them better understand and visualize the efficiency, interdependencies, pro-
ductivity and profitability of the overall operation.
Organic growth and flexible deployment
Traditionally, technology adoption has followed a strict roll-out schedule not often
designed by the end-user organization nor scheduled to match the needs of the organiza-
tion. The constraints have been imposed by the IT department which only has the staffing
and capacity to undertake a fixed number of projects, by the technology itself, or by the
lack of adequate backbone infrastructure. The platform in the WPoF allows for a more
organic and flexible experience. For example, an operator will be able to quickly add sen-
sors, create new applications, or institute new procedures fluidly without disturbing IT
or waiting for a drawn out deployment project. As such, the WPoF platform supports the
way managers in a plant think rather than how a development timeline would like them to
think.
Point-applications
The ultimate purpose of the technology within the WPoF is to extend existing applications
and to enable valuable new applications not previously feasible. Some examples of how
technology in the WPoF allows for application innovation include:
security CCTV cameras, access badges enabled with RFID, and high-security access
parameters within the WPoF environment provide not just security, but precision,
intelligent control and monitoring: restricting access based on levels of security,
tracking attempts to violate security protocols, and providing “smart control” to
sensitive areas thus reducing the likelihood of security breaches and providing a
data-driven feedback loop that helps security managers identify potential vulner-
abilities and improve systems.
Workforce Mobility Wireless connectivity allows mobile workers to access their
application and perform their job where they work. Whether it is logging data or
managing operations, worker mobility impacts productivity and efficiency.
Wireless I/O Temperature/Pressure/Flow/level sensing Asset information is
available from applied and embedded sensory points enabling sophisticated diagnos-
tics, remote monitoring and control, and plant optimization.
Mobile asset and Material Tracking Tracking asset location allows for better use of
assets as well as regulatory compliance for the use, storage, and transport of hazardous
B
Technology adoption
should match the
needs of the com-
pany and the plant,
not the other way
around.
chemicals. Tracking is also used for developing the most efficient routes in asset transport.
safety Environment alarms and personnel management allows for greater safety
and compliance with OSHA regulations, especially in dangerous environments and
in locations where the plant is in close proximity to residential areas.
Thanks to a robust network, the application classes discussed may also be handled remotely by
personnel within the organization or via partners at off-site asset management operations centers.
COMPLlCATlONS lN GETTlNG FROM HERE TO THERE
Plants today have many technologies and systems already in place to handle operations,
monitor assets, and ensure compliance, safety and security. Currently $100 billion is being
spent globally on industrial sensors every year and expenditures are growing. By 2010,
research firm ARC predicts that $1 billion will be spent on wireless sensor networking
within plant environments in addition to the $26 billion is currently spent on process con-
trols. Hardly any operation occurs in a modern industrial plant without the aid of some
computer system. Thanks to the considerable investment in industrial automation technol-
ogies, the basic building blocks of the WPoF exist in most facilities around the world. To
date, these systems have remained internally fragmented as a result of several impediments
to upgrade and integration. These impediments are preventing companies from deriving
and leveraging the real value of the WPoF. Examples are as follows:
OrganI zaTI Onal resTraI nTs
A common hurdle to plant upgrades is organizational. Because of the cross-divisional
nature of deployment and real-time data management inherent in the WPoF, there is often
a lack of a single stakeholder driven to secure the necessary funding and resources for such
an effort. Second, coordination issues with existing IT and processes create difficulties in
adding new systems to the closely guarded IT infrastructure. Third, most organizations
face a lack of resources in-house with the knowledge to design, test, deploy, and manage
such heterogeneous systems.
COMMI TMenT TO legaCy sysTeMs
A very sticky issue is the commitment plants have made to the wide range of legacy sys-
tems already installed. The decision to stick with legacy systems is often not so much an
actual management decision as it is an organizational default flowing from the “if it isn’t
broke…” way of thinking. But legacy systems lock plant management into a very limited
range of vendors to ensure compatibility. This is restrictive and counterproductive for an
organization. It may be in the interest of technology vendor X to build systems that only
work with other systems that carry the X brand, but it is not in the long-term interest of a
plant operator to have their future options closed off by today’s technology purchase.
4
The WPoF will run
as a single organism,
including logical
partitions, to link
together IT, process
management and
other divisions to
provide a precise,
real-time view of
efficiency, productivity,
security, and potential
problem areas.
COsT & COMPlexI Ty OF DePlOyMenT/ManageMenT
There is an increased cost and complexity associated with real-time data systems and
wireless technology. This is compounded by the cost of ownership associated with main-
taining legacy systems and paying for the capabilities needed to service and manage the
growing tapestry of new systems many of which operate with different bandwidths, dif-
ferent communications protocols, and different technologies. The simplicity promised by
wireless seems to come at the cost of having to coordinate an ever more complicated set of
networks. This total cost of ownership issue is particularly troublesome because handling
non-autonomous networks has not been part of the management discipline.
TeChnOlOgI Cal resTraI nTs
In addition to the technical issues of interoperability and scalability, another widely shared
concern is the issue of data security over wireless protocols. Collecting sensitive plant data
is valuable but the risk of having it shared with unwanted parties is sometimes enough to
deter management from pursuing a wireless strategy. Some wireless transmission protocols
have at times lacked robust encryption which is an even greater problem when the range
of the transmission bleeds off beyond plant walls. Moreover, security must be addressed at
each layer of the system, not just within the network.
Finally, deploying a wireless network is complicated by the very physics of wireless. The
more that wireless proliferates in any environment, the greater the problem of simple radio
wave interference--something no mere technical standard can prevent. Hence, scaling up
a plant’s existing networks, or introducing new ones can decrease the value of all existing
networks.
APPRlON: CREATlNG THE PLANT OF THE FUTURE TODAY
Apprion acts as a value-added partner bringing knowledge and expertise of cutting-edge
technologies to bear in order to offer industrial plants the most informed view of wireless
and other WPoF technologies. In this role, Apprion insulates a plant from the turbulence
of the developing technology arena by assuming responsibility for site assessments and
technology deployment. Apprion avoids the hidden “lock-ins” that trap industrial com-
panies in systems pushed by vendors whose products don’t work well with other systems.
Simply put, Apprion facilitates adoption by getting rid of the headaches.
I On: The I nTellI genT OPeraTI Ons neTWOrk
A key tool in integrating the often large existing array of often uneonnected wired networks
with new and eventually much larger nets of secure wireless and creating an intelligent net-
work above that requires what software engineers call an “abstraction layer” — a kind of
universal translation system that turns all protocols into a kind of common language and
which acts as a single network— interacting with all plant systems.
B
.
One of Apprion’s most powerful tools is called ION, the Intelligent Operations Network.
Apprion created ION to provide a cohesive wireless communications platform across both
the physical as well as the functional areas of plant operations. The effective result is the
Intelligent Wireless Grid, which apportions the shared network to support diverse applica-
tions with the necessary security, policy and performance management.
This allows plant managers to focus on what matters, while a third party provides a cost effec-
tive method for capitalizing on the vast array of wireless-enabled products and devices com-
ing to market. Thanks to Apprion’s state-of-the-art ION technology platform, the Intelligent
Wireless Grid makes the Wireless Plant of the Future a reality. Apprion’s ION platform unifies
the security, policy, and network performance management in a single overarching system.
I nTellI genT WI reless grI D
Thanks to standards and innovation, wireless technologies offer a compelling mix of cost
and performance that will drive adoption in various areas of the enterprise. In order to
move beyond experimentation, toward a future where wireless is used in control applica-
tions, there must be an overarching framework to accommodate and apply multiple wireless
technologies. Since there is great heterogeneity to the applications and no “one size fits all”
solutions with regard to the technology, it is important the necessary monitoring, manage-
ment and security capabilities span the entire wireless enterprise to insure the most efficient
use of the limited resources, while at the same time allowing the disparate applications to
6
The IOn platform
pulls together per-
formance monitor-
ing, security, safety,
and compliance in
a single unified sys-
tem. as part of an
Intelligent grid, the
system is precision
designed for each
plant to let man-
agement focus on
critical issues, focus
on improving opera-
tions.
share the spectrum within the context of their importance, time sensitivity and mission criti-
cality.
As a practical matter there are numerous wireless technologies and protocols that have
relevance to plant operations, including both standards-based and proprietary technolo-
gies operating at a number of different frequencies. Furthermore, unique ‘mesh’ routing
schemes that relay messages across neighboring nodes can be applied to various RF tech-
nologies to provide greater flexibility in overcoming the distance and performance chal-
lenges that have hampered some wireless deployment. This broad spectrum of options
provides hope for wireless to be effectively applied to any number of connectivity needs
by matching the most appropriate technology with the specific needs and requirements in
every area of plant operations.
aPPrI On as TrusTeD, I nDePenDenT ParTner
Apprion also provides plant managers an independent partner, free to objectively assess,
consult, and manage the array of technologies without the allegiance to a single bus, pro-
tocol, or system. In that way, Apprion is able to offer the abstraction layer between ven-
dors and plant managers. Aprrion’s goal is not making more technology. Our goal is mak-
ing the technology which a plant needs work and bringing data to all stakeholders within
the plant in ways that help them improve performance, productivity, security and safety.
In order successfully migrate to a WPoF platform, plant management will need to rely on
partners who can be depended upon for unbiased, solution-oriented advice about systems
that will work in the real world of industry. Apprion, is equipped with the technology,
expertise, and operations center capabilities to guide the transition. Thanks to Apprion’s
unique ION system and patented Intelligent Wireless Grid plants are able to fully upgrade,
and do so at a fraction of the cost of a traditional IT deployment.
THE BENEFlTS OF ADOPTlON
Apprion looks at the benefits in a three-tier hierarchy:

TI er One BeneFI Ts: The I MMeDI aTe
Installation Cost savings installation of wirelessly connected assets is up to 10x cheaper
than the alternative wired implementation and/or having personnel take constant readings
of asset status.
Point economic savings beyond installation costs, wireless allows for a negligible incre-
mental cost for each additional sensor or point added to a network. Adding more wire is
extremely costly. Adding another wireless sensor can cost as little as the sensor itself.
7
apprion's goal is not
to make more tech-
nology, but to opti-
mize wireless technol-
ogy integrating it
into systems a plant
can use to improve
performance, prod-
cuctivity, plant secu-
rity, safety, and com-
pliance.
TI er TWO BeneFI Ts: OPeraTI ng eFFI CI enCI es
Thousands of Positive rOI's Application including security, monitoring and safety, etc.
would not be possible if not for a mesh of sensors, networking, and systems able to han-
dle such applications. Some examples of applications include:
• Energy savings from building lighting management
• Greater regulatory compliance from instant reporting
• Reduced insurance costs from more comprehensive plant safety measures
• Stemmed shrinkage from increased security measures
Plant-wide scalability an ease of deployment and scalability is now possible thanks to
an adaptive platform that is able to grow, expand and incorporate new sensor systems,
new monitors, and include additional legacy systems with no limits.
Dynamic Deployments the ability to accommodate unplanned deployments onto the net-
work is technically valuable and saves both money and time traditionally spent designing,
negotiating, and conducting point-solution installations.
TI er Three BeneFI Ts: The I nTellI genT WI reless grI D aDDs ManageMenT
value anD leTs ManageMenT FOCus On WhaT MaTTers
Finally, Tier Three captures the highest level of value creation — where the Intelligent
Wireless Grid literally alters the way plant management and IT interacts with the plant
environment to add value.
Focus on the Critical The freedom of deploying applications on the plants Intelligent
Wireless Grid allows management the ability to rapidly reshuffle priorities and deploy
applications that focus on what is pressing rather than what is in the inflexible IT
deployment schedule.
Focus on Optimization With less time spent making sure network and application
deployments are going smoothly, management has more time to focus on the original
purpose of the deployments, plant optimization. Furthermore, the rich cache of asset and
performance data now possible is critical to streamlining costs of operation.
Focus on Core Finally, an Intelligent Wireless Grid centralizes all data collection, asset
monitoring, and network maintenance. This is particularly useful for experienced industrial
plant management. By engaging third-party operations expertise, managers are able to
fully focus on their core business.
For More Information Contact:
apprioninfo@apprion.com
650-964-4321
B
The ultimate goal
of the Intelligent
Wireless grid is to
allow management
to focus on the criti-
cal, focus on perfor-
mance optimization,
and focus on the core
business without the
distractions new tech-
nology can create.

the cost benefits of using ‘wireless’ are clearly understood. Wireless technology is poised to make significant improvements to efficiency. When designed properly this architecture creates a common wireless infrastructure that crosses functional departments and conditionally supports multiple applications of differing criticality. users must develop a common framework and architecture for all types of RF communications to work within. In order to do so this framework must: • • • • • • Align technology with business objectives and priorities Enable a vendor neutral operating environment Leverage and extend legacy systems Support open standards Provide effective technology lifecycle management capabilities to assimilate emerging technology Distribute intelligence. to more easily identify new ways to improve operations and bottom line performance. Too many new technologies have been offered up without taking into account the real world of existing systems.The Wireless Plant of the Future: From Roadmap to Reality Introduct Ion To be successful. Frequently. security and interoperability of a ‘best of breed’ wireless infrastructure. however there is no one type of wireless technology that solves all problems. policy and management into the network The goals of this strategy are to give management powerful tools to concentrate on the most critical issues. In order to maximize the value of industrial wireless networking investment. and to concentrate on their core business in an environment in which a new. the WPoF must be grounded in existing realities and must start from the premise that on going operations are absolutely essential. and investments. intelligent wireless grid supports and enhances operations instead of becoming a management burden  . In order to achieve the necessary scalability. productivity and automation within the manufacturing industry. practices. companies must be able to select the best technology for a given application.

clear. each asset will have a customized diagnostics record for the purpose of benchmarking its performance against that of other assets in its class. The infrastructure and the ideas behind the WPoF are not completely new. actionable information for daily management and for analysis leading to cost and efficiency improvements. the multiple wired and wireless networks within a plant environment will be interwoven into an intelligent operations network. The WPoF is built on a cohesive environment in which data is constantly streaming and being automatically monitored. Instead of the old piecemeal systems of monitors and gauges. and is able to coordinate all asset data streams so that they provide useful. As a result. managers will have a rich stream of outputs from all plant assets and a procedure for immediate alerts based on mission criticality and cost of downtime. Additionally. regardless of industry. networks. management will continually analyze asset behavior in the context of known processing states. Sensors. real-time data acquisition Thanks to RFID and a comprehensive sensor network. with intelligent alerting systems. and efficiency. relieving management of the burden of doing what the sensors and intelligent network can do 24/7 without blinking. and an asset’s unique characteristics. overcomes the obstacles that impede the adoption of wireless solutions. Furthermore. which issues need the most immediate attention and which will have the potentially greatest financial impact. the intelligence part of the system is custom tailored for the specific concerns of management to define what is most critical. It requires that a plant has the technical building blocks in place. reliability. will have several characteristics that will allow management to better monitor and control the plant environment. While many technology vendors have a built-in rigidity and exclusiveness.def I nI ng the wIreless plant of the future The Wireless Plant of the Future is the realization of sensor-to-system connectivity. This new. That is. and process management systems have all been present in plant environments for decades. The Illus TraTI ve Pla nT The Wireless Plant of the Future. unitary network is reliable. But the concurrent developments of extreme miniaturization now possible in sensor technology coupled with low power consumption and robust wireless protocols now make possible a qualitative leap forward. smart oversight…an automated network of intelligence in which tens of thousands of sensors become the eyes and ears of plant management. to ensure maximal availability. This flexibility and extensibility allows users to leverage a common wireless infrastructure for applications of differing criticality. with newer deployments of wireless encompassing a wide range of protocols as needed. easily managed and secure. the optimal system is flexible and expandable--extending the legacy wired systems which have already proven their usefulness.  .

Traditionally. not the other way around. an operator will be able to quickly add sensors. Organic growth and flexible deployment Technology adoption should match the needs of the company and the plant. productivity and profitability of the overall operation. Wireless I/O Temperature/Pressure/Flow/level sensing Asset information is available from applied and embedded sensory points enabling sophisticated diagnostics. The platform in the WPoF allows for a more organic and flexible experience. competing for resources and IT support time. As such. technology adoption has followed a strict roll-out schedule not often designed by the end-user organization nor scheduled to match the needs of the organization. and transport of hazardous  . Another key feature of the WPoF is the way it interlinks process management. The WPoF will run as a single organism but includes logical partitions designed specifically for each plant. and providing “smart control” to sensitive areas thus reducing the likelihood of security breaches and providing a data-driven feedback loop that helps security managers identify potential vulnerabilities and improve systems. and security needs. The constraints have been imposed by the IT department which only has the staffing and capacity to undertake a fixed number of projects. Point-applications The ultimate purpose of the technology within the WPoF is to extend existing applications and to enable valuable new applications not previously feasible. Whether it is logging data or managing operations. the WPoF platform supports the way managers in a plant think rather than how a development timeline would like them to think. IT. criticalities.visualizing the Whole Plant in real Time Plants today operate as a collection of separate fiefdoms. in order to support differing functions. and high-security access parameters within the WPoF environment provide not just security. tracking attempts to violate security protocols. Mobile asset and Material Tracking Tracking asset location allows for better use of assets as well as regulatory compliance for the use. interdependencies. or institute new procedures fluidly without disturbing IT or waiting for a drawn out deployment project. by the technology itself. storage. access badges enabled with RFID. but precision. intelligent control and monitoring: restricting access based on levels of security. The divisions are treated as distinct and act as such. Some examples of how technology in the WPoF allows for application innovation include: security CCTV cameras. Workforce Mobility Wireless connectivity allows mobile workers to access their application and perform their job where they work. and plant optimization. For example. and other functional departments in ways that let them better understand and visualize the efficiency. create new applications. or by the lack of adequate backbone infrastructure. worker mobility impacts productivity and efficiency. remote monitoring and control.

To date. COMMITM enT TO legaC y sy s TeM s A very sticky issue is the commitment plants have made to the wide range of legacy systems already installed. monitor assets. most organizations face a lack of resources in-house with the knowledge to design. process management and other divisions to provide a precise. research firm ARC predicts that $1 billion will be spent on wireless sensor networking within plant environments in addition to the $26 billion is currently spent on process controls. By 2010. and potential problem areas. deploy. there is often a lack of a single stakeholder driven to secure the necessary funding and resources for such an effort.  . the basic building blocks of the WPoF exist in most facilities around the world. and ensure compliance. Plants today have many technologies and systems already in place to handle operations. safety Environment alarms and personnel management allows for greater safety and compliance with OSHA regulations. productivity. but it is not in the long-term interest of a plant operator to have their future options closed off by today’s technology purchase. including logical partitions. Thanks to a robust network. security. to link together IT. these systems have remained internally fragmented as a result of several impediments to upgrade and integration. Third. Currently $100 billion is being spent globally on industrial sensors every year and expenditures are growing. Thanks to the considerable investment in industrial automation technologies. Tracking is also used for developing the most efficient routes in asset transport. especially in dangerous environments and in locations where the plant is in close proximity to residential areas. Hardly any operation occurs in a modern industrial plant without the aid of some computer system.chemicals. coordination issues with existing IT and processes create difficulties in adding new systems to the closely guarded IT infrastructure. the application classes discussed may also be handled remotely by personnel within the organization or via partners at off-site asset management operations centers. Examples are as follows: Organ I zaTIO nal resT r aIn T s A common hurdle to plant upgrades is organizational. These impediments are preventing companies from deriving and leveraging the real value of the WPoF. Because of the cross-divisional nature of deployment and real-time data management inherent in the WPoF. real-time view of efficiency. It may be in the interest of technology vendor X to build systems that only work with other systems that carry the X brand. compl I catI ons In gett Ing from here to there The WPoF will run as a single organism. safety and security. Second. This is restrictive and counterproductive for an organization. and manage such heterogeneous systems. test. But legacy systems lock plant management into a very limited range of vendors to ensure compatibility. The decision to stick with legacy systems is often not so much an actual management decision as it is an organizational default flowing from the “if it isn’t broke…” way of thinking.

Finally. Apprion insulates a plant from the turbulence of the developing technology arena by assuming responsibility for site assessments and technology deployment. Simply put. This is compounded by the cost of ownership associated with maintaining legacy systems and paying for the capabilities needed to service and manage the growing tapestry of new systems many of which operate with different bandwidths. In this role.  . different communications protocols. The more that wireless proliferates in any environment. and different technologies. or introducing new ones can decrease the value of all existing networks. TeChn OlOgICal res T r aIn Ts In addition to the technical issues of interoperability and scalability. Moreover. scaling up a plant’s existing networks. Apprion facilitates adoption by getting rid of the headaches. security must be addressed at each layer of the system. Apprion avoids the hidden “lock-ins” that trap industrial companies in systems pushed by vendors whose products don’t work well with other systems. Hence. The simplicity promised by wireless seems to come at the cost of having to coordinate an ever more complicated set of networks. deploying a wireless network is complicated by the very physics of wireless. Some wireless transmission protocols have at times lacked robust encryption which is an even greater problem when the range of the transmission bleeds off beyond plant walls. Collecting sensitive plant data is valuable but the risk of having it shared with unwanted parties is sometimes enough to deter management from pursuing a wireless strategy. IO n: The In TellIgenT OP e r aT I On s n e T W Or k A key tool in integrating the often large existing array of often uneonnected wired networks with new and eventually much larger nets of secure wireless and creating an intelligent network above that requires what software engineers call an “abstraction layer” — a kind of universal translation system that turns all protocols into a kind of common language and which acts as a single network— interacting with all plant systems. appr I on: creat I ng the p lant of the future today Apprion acts as a value-added partner bringing knowledge and expertise of cutting-edge technologies to bear in order to offer industrial plants the most informed view of wireless and other WPoF technologies. not just within the network. This total cost of ownership issue is particularly troublesome because handling non-autonomous networks has not been part of the management discipline. another widely shared concern is the issue of data security over wireless protocols.COsT & C OMPlexIT y O F D ePl O yM e nT/ M a n a g eMe nT There is an increased cost and complexity associated with real-time data systems and wireless technology. the greater the problem of simple radio wave interference--something no mere technical standard can prevent.

The effective result is the Intelligent Wireless Grid. focus on improving operations. which apportions the shared network to support diverse applications with the necessary security.. toward a future where wireless is used in control applications. the Intelligent Operations Network. and network performance management in a single overarching system. while at the same time allowing the disparate applications to  . security. policy. the system is precision designed for each plant to let management focus on critical issues. there must be an overarching framework to accommodate and apply multiple wireless technologies. wireless technologies offer a compelling mix of cost and performance that will drive adoption in various areas of the enterprise. policy and performance management. as part of an Intelligent grid. This allows plant managers to focus on what matters. management and security capabilities span the entire wireless enterprise to insure the most efficient use of the limited resources. it is important the necessary monitoring. In order to move beyond experimentation. Since there is great heterogeneity to the applications and no “one size fits all” solutions with regard to the technology. The IOn platform pulls together performance monitoring. safety. the Intelligent Wireless Grid makes the Wireless Plant of the Future a reality. while a third party provides a cost effective method for capitalizing on the vast array of wireless-enabled products and devices coming to market. One of Apprion’s most powerful tools is called ION. Apprion’s ION platform unifies the security. Thanks to Apprion’s state-of-the-art ION technology platform. and compliance in a single unified system. Apprion created ION to provide a cohesive wireless communications platform across both the physical as well as the functional areas of plant operations. In T ellI genT WIreles s g r I D Thanks to standards and innovation.

unique ‘mesh’ routing schemes that relay messages across neighboring nodes can be applied to various RF technologies to provide greater flexibility in overcoming the distance and performance challenges that have hampered some wireless deployment. In that way. or system. Thanks to Apprion’s unique ION system and patented Intelligent Wireless Grid plants are able to fully upgrade. Point economic savings beyond installation costs. consult.  . Adding more wire is extremely costly. aPPrIO n as Trus T eD.share the spectrum within the context of their importance. protocol. and do so at a fraction of the cost of a traditional IT deployment. Furthermore. This broad spectrum of options provides hope for wireless to be effectively applied to any number of connectivity needs by matching the most appropriate technology with the specific needs and requirements in every area of plant operations. the Benef Its of adopt Ion Apprion looks at the benefits in a three-tier hierarchy: T Ier One BeneFIT s: Th e I M M eD IaTe Installation Cost savings installation of wirelessly connected assets is up to 10x cheaper than the alternative wired implementation and/or having personnel take constant readings of asset status. and manage the array of technologies without the allegiance to a single bus. Apprion is able to offer the abstraction layer between vendors and plant managers. Adding another wireless sensor can cost as little as the sensor itself. Aprrion’s goal is not making more technology. safety. is equipped with the technology. productivity. and operations center capabilities to guide the transition. expertise. time sensitivity and mission criticality. Our goal is making the technology which a plant needs work and bringing data to all stakeholders within the plant in ways that help them improve performance. free to objectively assess. prodcuctivity. wireless allows for a negligible incre- mental cost for each additional sensor or point added to a network. and compliance. I nDe Pe nD e nT Pa rTn e r apprion's goal is not to make more technology. Apprion also provides plant managers an independent partner. security and safety. Apprion. As a practical matter there are numerous wireless technologies and protocols that have relevance to plant operations. solution-oriented advice about systems that will work in the real world of industry. including both standards-based and proprietary technologies operating at a number of different frequencies. plant management will need to rely on partners who can be depended upon for unbiased. In order successfully migrate to a WPoF platform. plant security. but to optimize wireless technology integrating it into systems a plant can use to improve performance.

and network maintenance. the rich cache of asset and performance data now possible is critical to streamlining costs of operation. Focus on Optimization With less time spent making sure network and application deployments are going smoothly.T Ier TWO BeneFIT s: O P e r aT In g eF F I C Ie nC Ie s Thousands of Positive rOI's Application including security. an Intelligent Wireless Grid centralizes all data collection. management has more time to focus on the original purpose of the deployments. Focus on the Critical The freedom of deploying applications on the plants Intelligent Wireless Grid allows management the ability to rapidly reshuffle priorities and deploy applications that focus on what is pressing rather than what is in the inflexible IT deployment schedule. focus on performance optimization. expand and incorporate new sensor systems. asset monitoring. For More Information Contact: apprioninfo@apprion. Tier Three captures the highest level of value creation — where the Intelligent Wireless Grid literally alters the way plant management and IT interacts with the plant environment to add value. new monitors. Dynamic Deployments the ability to accommodate unplanned deployments onto the netThe ultimate goal of the Intelligent Wireless grid is to allow management to focus on the critical. would not be possible if not for a mesh of sensors. By engaging third-party operations expertise. T Ier Three Bene FIT s: T h e I n Te l lIg e n T WI r e l e s s g r I D a D Ds M a n a g eM e n T value a nD leTs Man a g eMe nT F O Cu s O n Wh aT M aT Te r s Finally. Some examples of applications include: • Energy savings from building lighting management • Greater regulatory compliance from instant reporting • Reduced insurance costs from more comprehensive plant safety measures • Stemmed shrinkage from increased security measures Plant-wide scalability an ease of deployment and scalability is now possible thanks to an adaptive platform that is able to grow. This is particularly useful for experienced industrial plant management. managers are able to fully focus on their core business. negotiating. and conducting point-solution installations. etc. networking. plant optimization. Focus on Core Finally. work is technically valuable and saves both money and time traditionally spent designing. and focus on the core business without the distractions new technology can create. and systems able to handle such applications.com 650-964-4321  . monitoring and safety. Furthermore. and include additional legacy systems with no limits.

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