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Wireless presentation
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- 3. 3 Introduction to wireless Imagine
- 4. 4 Introduction to wireless Imagine
- 5. 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. 6 The realitywith 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 Introduction to Wireless
- 7. 7 Wireless adaptation Radios simplyeliminate the need to run wires for any sensor application Radios simply eliminate the need to run wires for any sensor application Introduction to Wireless
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- 9. 9 What isindustrial 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 Introduction to Wireless
- 10. 10 Applications considerations –Monitoring (90+%) • Requirements Pipelines – Pressure monitoring, heat tracing monitoring Motor operated valves – Feedback needed to confirm valve position Introduction to Wireless
- 11. 11 Applications considerations –Control • Requirements Process control – Automated and manual process control for various industries Alarms – Monitor conditions and automate alarms when needed Introduction to Wireless
- 12. 12 Why gowireless? – 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 Introduction to Wireless
- 13. 13 Wireless technology advantage Mass I/O I/O Monitoring I/OI/O Introduction to Wireless …
- 14. 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. 15 Application: ProcessIndustries 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 Introduction to Wireless
- 16. 16 Application: FactoryAutomation 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 Introduction to Wireless
- 17. 17 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 Introduction to Wireless
- 18. 18 Wireless driven bybusiness need 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 Application Examples
- 19. 19 Wireless best fitwhen… 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. 20 Wireless best fitwhen… 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. 21 Standard terms anddefinitions 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. 22 Time/mSec Power Watt Frequency 928M H z 902M H z Frequency Hopping SS- Security 869.4 M H z 869.65 M H z
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- 24. 24 The Products One–waycommunication – Transmitters • 2 digital outputs & 1 analog signal – Transmitters & Receivers • 2 digital outputs, 1 thermocouple & 1 analog signal Digital Analog Pulse Digital Analog Pulse Digital Analog Thermocouple Digital Analog
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- 26. 26 The Products Two-waycommunication devices – Transceivers – Gateways Digital Analog Pulse Digital Analog Pulse Radar Station Fuel Tanks Standby Generator Airport Management SCADA
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- 28. 28 The Products I/OExpansion Products – Serial units Up to 32 units
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- 34. 34 The Products Enclosures –Explosionproof Enclosures • NEMA 4, 7, 9 – Non-metallic Enclosures • NEMA 3, 4, 4X, and 12 applications
- 35. 35 Class IDiv 1 Installations – Wireless components require: • Explosion proof enclosure kit EJB GUB • Division 1 Antenna The Products
- 36. 36 Industrial andClass I Div 2 – Wireless components require: • “Enclosure suitable for the environment” • Non-metallic Enclosure NEMA 4X Fiberglass Reinforced Polyester The Products
- 37. 37 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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- 41. 41 The Applications TankFarm – Remote tank monitoring Power plant – Stack gas monitoring
- 42. 42 The Applications Remote TankMonitoring
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- 44. 44 Power Plant -Stack Gas Monitoring Control Room Stack Blower Stack Monitoring System The Applications
- 45. 45 Key Features Keyfeatures 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
- 46. 46 Benefits Benefits – Costsavings 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
- 47. 47 Manufacturer Breakdown Industrial WirelessProcess 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
- 48. 48 Things to takeaway 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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Editor's Notes
- #4 Say you are operating MOV’s (motor operated valves) in a tank farm in a remote area of your facility. And you’d like confirmation in the control room that a given valve did indeed open or close, so you can handle a failure before it creates a potentially dangerous situation. OLD WAY: Send someone on a 20- minute trip to visually inspect, or wire a sensor back to the control room (if you had unlimited manpower and budget). NEW WAY: Install one Cooper Crouse-Hinds transmitter and one gateway to receive confirmation wirelessly, without ever leaving your chair. BENEFIT: No worries, no wire.
- #5 Imagine that you need to monitor pressure fluctuations at quarter- mile intervals along a few hundred miles of pipeline, with the ability to shut down any segment of the line should a sudden spike or drop in pressure indicate a potentially hazardous situation. OLD WAY: Devote several people to doing nothing but monitoring segments of the line, or spend an arm and a leg hardwiring sensors across a few hundred miles. NEW WAY: Install Cooper Crouse- Hinds transmitters and gateways to wirelessly monitor the entire line. With a single glance in the control room and without the expense of hard- wired solutions. BENEFIT: Peace of mind without breaking the bank.
- #6 For instance, if a conduit raceway were needed over a long distance, customers would need to put together quotes, get approval, and schedule with a contractor. Cost of running a new wired conduit- $100-200, $2000 nuclear
- #7 The reality with wired solutions So besides the constraints of running long distances and the possibilities of obstacles----- Processes or equipment needing to be monitored are often in motion making wired connections unmanageable Remote applications don't have powered AC lines requiring further investments
- #8 Wireless radios simply eliminate the wires needed to relay sensor signals, this includes the pipe, fittings, wire and the structure to support it. Wireless radios can also be used to send back a signal to close a valve or sound an alarm.
- #9 At first response, I wonder what our founders would have to say? No fittings- but there is enclosure business yet to be discussed…
- #10 What we are introducing, is a game changing addition to our product line, game changing in the applications where it is used and benefits that it delivers, game changing in the way that it is sold. Our wireless solutions is not a choice of customers over conduit, fittings and wire , or cable tray, but a solution where those methods are not practical due to distance, obstacles, or expense
- #11 Monitoring applications far exceed control, because of the hesitance of users to trust wireless to date for controlling processes, but this is changing rapidly. Examples of where these are used…for you to relate to customers and distributors
- #12 Control applications are growing as customers recognize the benefits and the possibilities of its performance.
- #13 So the applications for wireless solutions is really wherever conduit and cable do not make a viable or cost effective solution. If raceways are difficult, expensive or just plain impossible, wireless is the answer
- #14 Transmitters, transceivers, gateways--- what are they, they can all be configured to talk to each other, or to just one… Start small then build reliable wireless connectivity as needed Up to five transceivers can be used as repeaters Gateway units monitor and control I/O signals via protocol interface
- #15 Materials that we are providing are loaded with examples and stories to learn how these are applied, industries we currently cover.
- #16 Process industries-
- #17 Factory automation- study these for leads to discuss with customers
- #18 And utilities and municipal works
- #23 Here it is in action verses time!
- #24 Lets take a closer look at what these products are and what they can do
- #25 These are the basic building blocks of our new line, and the simplest to apply Transmitters These ultra-low power consumption units are economical solutions for monitoring remote process signals. They can transmit 2 digital inputs and 1 analog signal to other wire l e s s devices, and thousands can be configured into a network. The rugged aluminum enclosure (with IP66, NEMA 4X rating), makes these transmitters ideally suited for harsh applications. They revert to a ‘sleep mode’ between transmissions to conserve power, and an optional battery pack makes them particularly suitable where power is not available. Transmitters and Receivers This transmitter/receiver pair is used to transmit up to 2 digital inputs, 1 thermocouple, and 1 analog signal. Flexible by design, you can easily incorporate these products into a wider transceiver or gateway network. Pre- configured for ease of installation, these transmitters and receivers are DIN rail mounted and mains powered, but each can also be purchased individually.
- #27 Two way simply means the units operate as transmitters and receivers. Why important? Carry signal, act as repeaters and to send back acknowledgements or a desired action Transceiver vs gateway Transceivers (D2 W MIO) A D2 W MIO transceiver is a wireless device made up of a transmitter and receiver. Since each module can receive input and send output signals, it can be used to monitor transducers and other sensors and to control industrial processes. Four different versions of the D2 W MIO are available with a varying number of inputs and outputs (analog, digital, pulse, thermocouple) required for the application, as shown below. Gateways (D2 W GMD) Wireless gateways interface between other Cooper Crouse- Hinds wireless devices and control systems (to PLC’s, SCADA, and DCS). In addition, they can act as an eight input/output transceiver and feed this information into PLC terminal units when available. Additional I/O can be added to these units using a D2 NW SER.
- #29 Serial Units (D2 NW SER) These units enable you to expand the I/O capability of your Cooper Crouse- Hinds transceivers and gateways by serial connection, using a (RS485) cable. The I/O channel combinations you can create by connecting up to 31 x D2 NW SER to a single radio are virtually limitless.
- #35 Wireless solutions from CCH as described are components-- do not generally come ready for installation, need enclosures Explosionproof Enclosures (NEMA 4, 7, 9) Use these enclosures to protect your Cooper Crouse-Hinds wireless components in applications where frequent/heavy rain, spray, and humidity are common – like offshore drilling facilities, cooling towers, handling facilities or waste water treatment plants. And use them to enhance safety in applications where hazardous gases and vapors are present – like pro c e s s industries, missile bases or gas manufacturing plants. Non-metallic Enclosures Use these enclosures for NEMA 3, 4, 4X, and 12 applications – typically harsh, wet, dusty and industrial environments requiring a robust design.
- #36 Business that we know so well, providing the enclosures! Enclosure kits complete with drilled, tapped, and plugged openings, and radio DIN rail mounting provisions are listed in the catalog.
- #37 For these areas, we are providing CCH nonmetallic enclosures with the mounting provisions, customers may determine where they want to have their conduit and antenna openings—if needed. For Division 2 applications, customer needs to select an enclosure suitable for the environment (the components are already suitable for the hazard). For this we recommend the CCH nonmetallic enclosure. Other enclosures may be used in any size desired, which system integrators will like.
- #38 A radio is only as effective as the antenna that is required for the application—materials and the demonstration kits provided will help in the selection.
- #42 Thought it would be wise to review two applications to help you understand how these are applied, before moving on.
- #43 3 ways: Remote Tank Monitoring Raceway, phone lines, wireless solutions to the SCADA system in the control room - imagine distance or obstacles between the transceivers Reliable two-way communications Low radio loading – exception reporting Secure data encryption Expandable I/O with peer-to-peer connectivity Easy-to-configure software – powerful diagnostics
- #45 Sensor at top of the stack detects excessive acid content monitored in the control room, control room can send instruction back via the transceivers to shut down or adjust the process
- #46 Flexible Vast selection of digital, analog, and pulse inputs per transceiver – offers customers the ability to use fewer radios per system reducing overall costs. Repeaters are not necessary – Transceivers can also act as a repeater, further decreasing system costs Expandable – Up to 31 serial expansion units can be added to any transceiver to expand the overall system’s I/O capability Each radio is cable of sending / transmitting over 20 miles when using an antenna. Reliable - Redundant paths can be formed between any given transceiver to ensure information is passed along to its end destination. The system routinely pings other wireless devices to ensure wireless connections are intact. The system changes frequencies as it communicates (known as frequency hopping spread spectrum) to minimize interference with other sources of radio transmissions at any one given frequency Secure Radios use a highly secure data encryption technique
- #47 Now consider the opportunity for you to sell these products- Wireless devices offer customers monitoring information or control over devices which have traditionally not been easily accessible by wired means. The wireless line of products minimizes the customer's need to inspect, maintain and operate industrial processes and equipment. Consider the labor required where these solutions are not used…
- #48 Fragmented, only Adalet sells through our channel in haz locations. Cooper holds 12% now, market is growing at 35% per year, plenty of opportunity!!