Emerson_Smart_Wireless_Solutions.pdf

Emerson Smart Wireless Solutions

3
Appliance & Tools
Emerson. Creating Technology and
Solutions for a World in Action
Solutions for a
Solutions for a World in Action
World in Action

6
• Rosemount
• Micro Motion
• Rosemount
Analytical
• Daniel
• Mobrey
• Fisher
• Baumann
• Bettis
• El-O-Matic
• Shafer
Measurement Valves &
Regulators
• DeltaV
• Ovation
• Industry
Solutions
• Chemical
• Oil & Gas
• Refining
• Power & Water
• Life Sciences
• Metals & Mining
• Pulp & Paper
• Food & Beverage
• Remote Automation
• Marine
Systems &
Solutions
Asset
Optimization
• AMS Suite
• Services and
Technologies
• Mechanical
Equipment
• Electrical
Systems
• Process
Equipment
• Instruments
& Valves

12
Process Manufacturers Constantly Strive to
Improve Their Business Performance
The industry faces dynamic business conditions
z Keep plants in mature markets competitive
z Effectively and safely operate new facilities in emerging markets with a
less experienced workforce
z Manage wide variations in raw material cost and quality
z Retain knowledge
z Meet changing regulations

Plant Knowledge Is the Key
to Improving Business Performance
Imbedding predictive intelligence throughout the plant, allows our
customers to improve output, lower cost and make the plant
easier and safer to operate
Software detects
vibration & provides lube
oil analysis to detect
premature wear—helping
prevent
mechanical failure.
Lets you make decisions
to optimize
production and
availability.
Digital Control
Tell you of wear,
installation issues or
process variations that
may cause service
interruption…and
tell you how to correct.
Measurement
Devices
Warn you of a
plugged
impulse line…
with time to
correct and
avoid a
shutdown.
Asset Management
Digital Valves
Software detects
vibration and provides
lube oil analysis to detect
premature wear – helping
prevent
mechanical failure.

14
Why Predictive Intelligence?
Catch Problems Before They Occur
Equipment
Health
0%
100%
Time
advanced warning = time
to respond

15
SMART
ASSET OPTIMIZATION
SMART
FINAL CONTROL
SMART
MACHINERY HEALTH
PlantWeb Digital Plant Architecture
Revolutionized Automation
PlantWeb
PlantWeb Digital Plant Architecture
Digital Plant Architecture
SMART
MEASUREMENT
SMART
REMOTE AUTOMATION
SMART
DIGITAL CONTROL
SMART
SAFETY
PlantWeb uses the predictive
power of field intelligence to
improve plant performance

16
z Reduced maintenance cost by 10%
z Reduced unplanned shutdowns by 10%
z Reduced waste production to almost zero
Customer Results Are Measurable
z Start-up time reduced 90%, 4+ months faster
z 6 month return on investment
z Increased power output by 6.4% for the same amount
of fuel
z Reduced maintenance & operations staff 33%
Power, North America:
Chemical, Europe:
Pharmaceutical, North America:
Oil & Gas, Latin America:
z Capacity utilization increased 33%
z Batch cycle time reduced 20%
z Q/A review time reduced 56%
z Construction of new production line averted

17
Over the last 12 years, Emerson has invested in
building a strong global solutions capability
Customers Need Help Applying the Right
Technology to Achieve Results
Project Planning &
Management
Project
Engineering
Plant Start-up &
Commissioning
Process & Asset
Optimization

With All Today’s Technologies …
Customers Would Like to Know More
With All Today
With All Today’
’s Technologies
s Technologies …
…
z Real-time power usage throughout the facility
z Leaks and releases that will cost environmental
quality and millions in fines
z Corrosion inside the miles of piping
z Vibration or temperature
excursions that are
attacking equipment life
z Safety of all our personnel

The ‘Age of Wireless’ Provides the Eyes and
Ears to Move Facilities to the Next Level
The ‘Age of Wireless’ Provides the Eyes and
Ears to Move Facilities to the Next Level
Smart Control
Systems
Smart
Analytical
Smart Final
Control
Smart Asset
Optimization Smart
Measurement
Smart Machinery
Health
Smart Safety

28
Wireless Removes Limits to Move Facilities the
Next Level of Performance
Wireless Removes Limits to Move Facilities the
Next Level of Performance
Smart Control
Systems
Smart
Analytical
Smart Final
Control
Smart Asset
Optimization
Smart Safety
Smart
Measurement
Smart Machinery
Health
Smart Wireless
28

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PlantWeb uses the predictive
power of field intelligence to
improve plant performance
Emerson Is Unplugging PlantWeb to Extend the
Benefits to Assets Previously Out of Reach
Emerson Is Unplugging
Emerson Is Unplugging PlantWeb
PlantWeb to Extend the
to Extend the
SMART
MEASUREMENT
SMART
REMOTE AUTOMATION
SMART
FINAL CONTROL
SMART
MACHINERY HEALTH
SMART
MEASUREMENT
SMART
MEASUREMENT
SMART
ASSET OPTIMIZATION
SMART
DIGITAL CONTROL
SMART
MOBILE WORKER
SMART
SAFETY

30
Emerson Has a Long History of Successful
Wireless Solutions to Build On
z We are a wireless leader today
– Emerson leads the industry with a 19.9% market share in wireless
Source: ARC 2006 Wireless Market Analysis
z Our wireless portfolio is broad
– Open Plant Network supporting remote wireless applications
– Mobile Operator and Maintenance Worker
– PlantWeb Alerts designed for individual notification
– Remote Automation in harsh Oil & Gas applications
z Started investing in next generation, wireless program in 1998
We have successfully completed
3 years of customer trials for wireless
in industrial environments

Emerson Developed an Architecture to
Extend Plant Visibility … Wirelessly
Extend Plant Visibility
Extend Plant Visibility …
… Wirelessly
Wirelessly
Operations Asset Management
Plant Network
Control Network
Plant Network
Field Network
SP100*
SP100*
Wireless Standards:
802.11
802.16
802.11
802.16
802.15.4
Wireless HART
Field
Devices
Control Network
Asset Tracking
Security
Mobile Worker
Self-Organizing Networks *SP100 Standards in
Development

z Process Applications:
– Sensing,
condition monitoring,
control and diagnostics
z Bandwidth:
Short, high priority
communications
z Security/Reliability:
We cannot ‘drop a call’
– Must coexist and perform
in dynamic, harsh plant environment
z Power: LOW, lots of devices, widely distributed in harsh
environments, batteries must last 5-10 years
z Standards (802.15.4)
– Essential for market adoption
– Driven by Process community
Wireless “Field” Networks
Have Specific Requirements
Wireless “Field” Networks
Have Specific Requirements
KEY!!!
KEY!!!

33
Announcing Wireless Results, New Products, and a
Collaboration to Extend Solutions
Announcing Wireless Results, New Products, and a
Collaboration to Extend Solutions
Extending PlantWeb with Smart Wireless Solutions for
Process, Plant and Business Applications
z Wireless field networks are easy and
deliver fast and significant benefits
– Emerson has a pipeline of new
wireless products
z Emerson is working with Cisco to deliver
open standard solutions for wireless plant
networks
– Emerson and Cisco deliver best-in-
class plant and business applications
to our customers

34
Enabling Plant Applications Has Some Very Specific
Requirements
Requirements
Requirements
z Plant/Business
Applications:
– Video, voice, mobile
tools, tracking
z Bandwidth:
High; multiple
applications must
share the service
z Security/Reliability:
Industrial security and
robust coexistence essential
– Must pass IT muster
z Power: Devices can be line powered or recharged daily
z Standards:
– Essential to capture innovation
– Driven by IT community

35
Emerson and Cisco Are Uniting to Deliver Wireless
Plant Network and Applications
Emerson and Cisco Offer Open-Standard Wireless
Solutions for the Process Industries
Emerson is the global leader
in process automation
Cisco is the global leader
in industrial networking

36
Together We Deliver Complete, Best-in-Class
Wireless Solutions for the Process Industries
Together We Deliver Complete, Best
Together We Deliver Complete, Best-
-in
in-
-Class
Class

38
What Does This Mean for Customers?
z Lower infrastructure costs
– Doesn’t require a full infrastructure deployment to
get FAST, EASY benefits
z Best technical solution
– Proven field network reliability >99%
– Best-in-class applications and solutions from
industry leaders
z Low risk
– Emerson, working with Cisco, will take responsibility
for the total wireless solution
z Easy, Flexible, Scalable solutions….
and

39
Start Anywhere! Customers Can Cost-Effectively
Start and Grow Their Smart Wireless
Start Anywhere! Customers Can Cost
Start Anywhere! Customers Can Cost-
-Effectively
Effectively
z Need process
information?
– Easily install and
add devices as
needed
z Need plant
applications?
– Install open Cisco Unified
Wireless coverage
– Add applications as
needed

40
Your Smart Wireless Opportunities Are
without Limits…
without Limits
without Limits…
…

41
Emerson Provides a Complete Solution to
… Wirelessly
Wirelessly
z Business and plant management
Security, video surveillance, and RFID asset
tracking
z Workforce productivity
Remote and mobile operations and
maintenance, automated work flow
management, and mobile worker
communications
z Plant and process information
Extended plant and asset information,
stranded diagnostics, and extending the ‘walls’
of the plant
z Services to tailor the solution to your
needs
Network design and installation services,
industry hardened network solutions

42
… Wirelessly
Wirelessly
tracking
communications
of the plant
needs

43
Mobile operators
can view and
acknowledge
alarms
Wireless Plant Networks Empower
Workers in the Field
Field workers
can interface
directly with
maintenance
management
systems
Maintenance
workers can
automate
manual work
processes
Use VoIP to
broadcast
messages to
specific groups in
the field

44
Smart Wireless Offers Many Wireless
Opportunities Today
Opportunities Today
Opportunities Today
z DeltaV offers wireless applications as a standard
– First digital automation system to embrace standard platforms and open
protocols inherently in the architecture
– Allowed Emerson to support our customers in a wide variety of wireless
solutions for years
– Customers who have been using wireless technologies to extend the
reach of the control network
– Deployed 802.11 mobile and remote solutions with DeltaV since the first
ratification of the standard in 1998

45
DeltaV Wireless Applications
DeltaV
DeltaV Wireless Applications
Wireless Applications
Control & I/O
z Use 802.11 to connect
access control information
remotely
– Connecting a remote controller
– Connecting remote DeltaV
locations
– Connecting a remote
workstation
– Connecting remote 3420s to
DeltaV
Mobile Worker
z Wireless access DeltaV
applications through any
device that supports
Windows XP/Mobile 5.0 or
Microsoft Terminal Server
– PDAs, cell phones for alarms
and alerts
– Rugged tablet for batch
management
– Plant Messenger

47
Emerson Provides a Complete Solution to Extend
Plant Visibility … Wirelessly
Plant Visibility
Plant Visibility …
… Wirelessly
Wirelessly
tracking
communications
of the plant
needs

48
Wireless Field Networks Improve and Extend Insight
into Plant and Process Information
Wireless Field Networks Improve and Extend Insight
into Plant and Process Information
Access stranded
diagnostic in
valves
Use online
wireless
monitoring of
motor bearing
temperature and
vibration to
augment walk-
around data
collection
Monitor redundant tank
level systems with
wireless level
measurements
Automate operator
rounds with
incremental low
cost monitoring
Improve
environmental
compliance with
wireless
monitoring of
safety relief valves

Route
What Is Required to Provide a Complete Wireless
Solution?
Enter-
prise
DCS
Route the Data
to the User
Seamlessly Integrate Data into
Hosts & Validate
Quality Information
High
Data Reliability
Standard Interfaces with
No Special Software
Collect
Rich Data
Collect Integrate & Validate
Easy Installation
Global Support & Expertise to Ensure Success
PLC Asset

9 Available!
9 Available!
Route
Smart Wireless Solutions
Available From Emerson
Collect
SmartStart™ Wireless Installation / Configuration Services
9 Available!
Integrate & Validate
Measurement
9Pressure
9Flow
9Level
9Temperature
Wireless
Rosemount
648 &
702
Wireless
Rosemount
3051S
Control System, Historian
9Seamless integration via OPC,
Ethernet, Modbus
Asset Management
9AMS Device Manager Wireless
Interface
9Available!
In Plant
91420 Wireless
Gateway
Remote
9 ROC Wireless
Gateway for Oil &
Gas

In Plant
91420 Wireless
Gateway
Remote
9 ROC Wireless
Gateway for Oil &
Gas
Control System, Historian
9Seamless integration via OPC,
Ethernet, Modbus
+ DeltaV and Ovation Easy Wireless
Interface
Asset Management
9AMS Device Manager Wireless
Interface
+ Advanced Applications
Smart Wireless Solutions
Coming Soon From Emerson
Collect
Measurement
& Valves
9Pressure
9Temperature
9 +Level
9 +Flow
+Stranded diagnostics
+Valves or any
HART device
+pH & Conductivity
+Vibration
+Corrosion
9Discretes
+On/off valves
+ Coming Soon!
Route
+ Coming Soon!
SmartStart™ Wireless Installation / Configuration Services
Integrate & Validate
9 Available!
9 Available!

52
Research, trials and reviews confirmed unique
requirements for wireless:
Reliability
Low installed cost
Industrial grade security
Standards
Stress-free solution
Control capable wireless architecture
Low power
Process Industries Have Unique
Requirements For Wireless

53
Early Wireless Testing with Customers
Helped Develop Our Approach
2003 2005
2004 2006
3 Yrs Testing At Customer Sites
Competitive
Evaluation
Architecture, Usability and Security
Reviews with Customers and Experts
Smart
Wireless
solutions
use self-
organizing
mesh
networks
Customer Testing
Customer Research

The Emerson Smart Wireless Self-Organizing Field
Network
The Emerson Smart Wireless Self-Organizing Field
Network
z Self-organizing Mesh Networks have demonstrated high
reliability in the field
– Use IEEE 802.15.4 with added channel hopping and
Time Synchronized Mesh Protocol (TSMP), Direct Sequence Spread
Spectrum (DSSS) on 2.4Ghz ISM band
– Robust/tolerant to almost all interference and coexists with other
wireless networks
– Demonstrated 99%+ field reliability

Self-Organizing Networks Just Work!
No Site Survey, >99% Data Reliability, Robust
Self-Organizing Networks Just Work!
No Site Survey, >99% Data Reliability, Robust
To
Host

56
Proven In-Plant Smart Wireless
Solutions Address Customer Concerns
Proven In
Proven In-
-Plant Smart Wireless
Plant Smart Wireless
Reliability
Low installed cost
Standards
Stress-free solutions
Low power

57
Smart Wireless Field Offers > 99% Reliability
z High network reliability –
the percentage of messages
that actually reach their
destination – is essential
z Point-to-point solutions have
actual installed reliabilities as low as
40% because of dynamic and harsh process environments
z Real world results for Smart wireless field solutions in trials in a
wide variety of industrial areas have confirmed >99% reliability
– If communication path is disrupted or fails for any reason, the network
automatically finds another path to carry the message

58
Proven In-Plant Smart Wireless Solutions
Address Customer Concerns
Proven In
Proven In-
-Plant Smart Wireless Solutions
Plant Smart Wireless Solutions
Reliability
Low installed cost
Standards
Low power

59
Control Room
What’s the Cost of Information?
What
What’
’s the Cost of Information?
s the Cost of Information?
Marshalling Panel
Junction Box(s)
$$$$$$$
Bundled Sensor Cable
Up to 90%
Installation Cost
Reduction
Up to 90%
Up to 90%
Installation Cost
Installation Cost
Reduction
Reduction
Legacy
Host &
Applications

60
Smart Wireless Reduces Installation Costs up to
90%
90%
90%
z Lower material costs
– No wire
– No bundled cable
– No conduit
– No junction boxes
– No marshalling panels
z Lower engineering costs
– No engineering and drawings of
power and communication wiring
z Eliminate labor costs for
– Pulling wire
– Installing conduit
– Installing terminations, junction
boxes and marshalling panels
z Online calculator at
http://rosemount.d1asia.ph/Smart_Wirele
ss/CONTENTS/WirelessCalculator_EN.a
spx

61
Smart Wireless Reduces Installation Costs in
Remote Oil and Gas Applications
z Smart Wireless communication capability allows the ROC to communicate with
wireless devices
– Significant cost benefits when used for monitoring process variables that may be located
more than 5-10 feet away from the RTU
– Wiring has significant costs in remote locations since land is often leased and surfaces
may be rocky and difficult for wiring
– Remoteness of such locations also makes manual monitoring very expensive

62
Proven In
Proven In-
Reliability
Low installed cost
Standards
Low power

Best In Class Security Solution
Addresses Customers’ Biggest Concern
Best In Class Security Solution
Addresses Customers’ Biggest Concern
9
9
Key Management
9
9
Anti-jamming
9
9
9
Verification
9
9
9
Authentication
9
9
9
Encryption
Information
System
Gateway
Network
Devices
Threat to:
Protection
• Ethernet: VPN, HTTPS - All other ports
are closed
• Serial (RS485/232): Modbus
• No TCP/IP messaging
• AES 128 bit encryption
• User definable key rotation
• Direct Sequence Spread Spectrum
Self-Organizing Network Gateway Information Systems
Legacy Host
Wired or
Wireless
Validated with
Validated with
customers and
customers and
wireless experts
wireless experts

64
Proven In
Proven In-
Reliability – we can’t “drop a call”
Low installed cost
Standards
Low power

65
HART Foundation Released the Wireless HART
Specification
Specification
Specification
Approved
September 2007
Approved
September 2007

Global Support for
WirelessHART Standard
Global Support for
WirelessHART Standard
“Three leading organizations dedicated to control network
technology, the Fieldbus Foundation (FF), HART
Communication Foundation (HCF) and Profibus
Nutzerorganisation e.V. (PNO), have formed a Wireless
Cooperation Team… ”

Wireless Spectrum Approvals
Wireless Spectrum Approvals
India
China
Philippines
Malaysia
Indonesia
Australia
Japan
Plus Many Additional Countries in
AP and Around the World

69
Proven In-Plant Smart Wireless
Proven In
Proven In-
-Plant Smart Wireless
Plant Smart Wireless
Reliability
Low installed cost
Standards
Low power

70
z No specialty tools
z Familiar instrument practices
In-Plant Smart Wireless Solutions
Are Easy to Install
In
In-
Are Easy to Install
Are Easy to Install
z No site surveys
z Seamless integration between wired
and wireless worlds
z Wireless Gateways seamlessly
integrate data with no special software
Installed our first
wireless –
nothing special –
it just works!
Looks wired
to me . . .

Smart Wireless Upgrade Module
Unlocks “Stranded Diagnostics”
Unlocks
Unlocks “
“Stranded Diagnostics
Stranded Diagnostics”
”
20 million installed HART devices have underutilized
diagnostics because the plant doesn’t
support a digital architecture
To Host
Asset
Software
775 THUM – The HART Upgrade Module
unlocks these diagnostics
To Host

72
Proven In
Proven In-
Reliability
Low installed cost
Standards
Low power

73
Safety
•Smart Wireless
Solutions Address
SP100 Use Classes
1-5
¾Classes 3-5
proven in use by
customers
Control
Monitoring
Class 0: Emergency action
(always critical)
Class 1: Closed loop reg. control
(often critical)
Class 2: Closed loop supv. Control
(usually non-critical)
Class 3: Open loop control
(human in the loop)
Class 4: Alerting
(Short-term operational consequence)
Class 5: Logging & downloading/
uploading
(No immediate operational consequence)
In-Plant Smart Wireless Solutions
Address SP100 Use Classes
In
In-

74
Proven In
Proven In-
Reliability
Low installed cost
Standards are a requirement
Low power

75
Power Is Gold in Smart Wireless
Field Devices
Field Devices
Field Devices
z Energy efficiency is a key consideration in the development
of every Emerson wireless device and network component
z Goal is to maximize the period before maintenance is
required
z Products have SmartPower™ capabilities
– Advanced power management techniques
– Fast device wakeup times
– Low-power electronics
– Energy scavenging technologies such as solar power, vibration and
thermal power
z Battery life of 5-15 years depending on application
z The gateway is constantly optimizing the entire network for
power and doesn’t overload any one device

SmartPower™: Long Life Power Module
SmartPower™: Long Life Power Module
Keyed Plug –
Easy replacement
Fail-safe connection
Intrinsically Safe –
Can be changed in hazardous locations
No need to remove device from process
Standardization –
All devices use same
Reduced inventory
Easy Maintenance –
Alert when low
Innovative –
Patents pending
Safe –
Short circuit protection
No special training required
Advanced Components – Lithium-
Thionyl Chloride chemistry
Valox® PBT enclosure

77
Proven In
Proven In-
Reliability
Low installed cost
Low power

78
Reliability – we can’t “drop a call”
Low installed cost
Low power
Proven Smart Wireless Solutions Address
Customer Concerns
Customer Concerns
Customer Concerns
Wireless is ready for the “mainstream” market.

79
Customers are already realizing the benefits –
Installed in over 150 sites!
Customers are already realizing the benefits
Customers are already realizing the benefits –
–
Some Asia Sites:
z SRC – Singapore
z Bao Steel – China
z SECCO – China
z Worsley – Australia
z MEC – Japan
z Vishnu Chemical –
India
z Labuan Gas
Terminal - Malaysia

80
Customers Are Solving Real Plant Problems:
Milford Power
Milford Power
Milford Power
z Application: Monitor remote pumping and
equipment facilities
z Wired solution cost prohibitive due to
distance and logistics
– Wireless saved $75,000 in installation and capital costs
z Smart Wireless solution communicates easily in dense
environment with many obstructions
– All 12 devices were communicating within 2 hours
– Wireless communication was not interrupted when new building was
erected in the middle of the network
z Smart Wireless helps prevent freeze damage to water
pumping and circulation equipment, which would cost the plant
$20,000 per incident
“We looked at various technologies and selected the Emerson… Especially
important was the easy, flexible self-organizing network that could be installed and
operational in a very short time…this is an excellent solution that works well, is
easy to install and very easy to expand…”
— Cliff Esmiol, Maintenance Supervisor

81
Performance Improved on Boiler Feed
Pumps at Power Plant
z Self-organizing network installed on
boiler feed pumps
– Improved performance through monitoring
pressure and temperature
– Preventative maintenance schedules
determined
z Provided solution for measuring points
without hassle of wiring
z Smart Wireless exceeded
performance expectations in dense
plant environment

82
PPG Lake Charles
PPG Lake Charles
PPG Lake Charles
z Applications:
– Temperature profiling of plant steam headers
– Redundant level measurement on caustic tanks
– Vibration monitoring of brine centrifuges
z Multi-discipline team guiding adoption of
wireless
z Smart Wireless network coexists with
other wireless systems
“When Emerson first approached me with their industrial wireless solution, they
said ‘We’re plug and play.’ I have to admit I laughed; nothing I’d seen so far was
that easy. But I’m a believer now. Five minutes after installing it, the wireless
network came to life. It’s been there ever since.”
—Tim Gerami, Senior Design Engineer
It WORKS and it is EASY!
“Five minutes after installing it, the
wireless network came to life. It’s been
there ever since” –
Tim Gerami, Senior Design Engineer

83
Wheeling Pittsburg Steel
z Applications:
– Coiling water flow and grease system
health in Hot Strip Mill
– Cooling water flow to work rolls in Roughing Mill
z Secondary systems needed diagnostics
to minimize unscheduled downtime,
improve production and quality
– Wired devices too difficult to install and
maintain in this congested, hot environment
z Since installation, unscheduled downtime is
nearly eliminated and productivity improved by
as much as 10%
“We are building an infrastructure that opens up opportunities for more applications.
The result is better information from difficult-to-reach areas of the mill, and this is
helping our personnel prevent unscheduled downtime, meet customers’ quality
requirements, and optimize productivity.”
—Gary Borham, Operations Manager
Coiling Water
Spray on Hot Steel

84
Pulp and Paper Mill
Pulp and Paper Mill
Pulp and Paper Mill
z Application: Rotating Lime Kiln mid-zone
temperature monitoring
z Solution to this challenging temperature
application needed to solve throughput
problem
–Wired technology could not handle rotating
equipment
z Wireless temperature transmitters placed
180o apart at mid-zone of kiln gave insight
needed to solve mill bottleneck
“Four days after the order was placed we could see minute-by-minute
mid-zone temperatures trending on the control system … Since the wireless
system has been installed, we can tell if there’s build-up of lime in the mid-zone
area. Overall, we have improved operation of the lime kiln, and increased
throughput by 5%.” —Pulp Mill Leader
Rotating Lime Kiln
Rotating Equipment!
“Increased throughput by 5%” –
Pulp Mill Leader

85
Croda
Croda
Croda
z Application: Temperature monitoring of
chemical in moving railcars
z Rate-of-rise temperature monitoring critical for safety and plant
performance
– Railcars continuously move, making hard wired
measurement impractical
– Employees had to climb on top of railcars for measurement;
dangerous in winter
z Smart Wireless solutions give early detection of temperature rise of
chemical and eliminate manual readings
– Railcar position had no effect on self-organizing network performance; line of
site not required
– Safety improvement by eliminating operator trips to the top of the railcars
– Early detection means early neutralization procedures, improved plant safety
“There are savings of $14,600 per year in reduced operations and
maintenance costs, but, the incalculable savings were in safety”
—Denny Fetters, I&E Designer
Sensors on RAIL CARS / Safety Issue!
“Savings of $14,600 per year…but the
incalculable savings were in safety” –
Denny Fetters, I&E Designer

86
Major Refining Company
z Application: Plugged filter detection on
coker unit pumps
– Critical to prevent damage to pump on
loss of suction
z Existing pneumatic transmitters
required manual gauge readings to
detect loss of suction, were prone to
error and required extensive maintenance
z Smart Wireless provided a cost effective solution that would
improve measurement reliability and maintenance productivity
– Conventional instruments were prohibitive due to the cost of running
new instrument wire and power lines
z Improved availability of Coking operation
“[Insight] from predictive wireless filter plugging alerts prevented a shutdown. Operators
were able to shut down the pump, clean the filter and get it back on line in a matter of
hours. If the alert were not present, the filter pump would have been damaged, and
would have needed to be completely replaced”
— Project Manager, Major Refining Company

87
Customers Are Solving Real Plant
Problems: Major Life Sciences Corp
z Application: Moving platform/skid measurements
z Eliminate need to continually re-configure process systems for
instruments that move with portable process skids
– Pumps, filtration, milling, CIP/SIP packages
z Startup and installation of all devices was completed in
< 8 hrs
z Initial trials achieved 100% reliability
throughout 12” reinforced concrete
building with five floors
– Moving platforms never had a
measurement drop off the system
– Platform brought in from another
storage building joined network without
operator assistance

88
Heat Trace Monitoring – Profile
Heat Trace Monitoring
Heat Trace Monitoring –
– Profile
Profile
z Issue: reliably monitor
temperature of a major product
line, with heat-tracing
z Solution: Wireless devices
provide temperature profile.
z Results
– Reduced downtime due to clogged
pipes
– Wireless provided significant cost
savings
– Seamless integration into legacy host
Wireless devices change economics
• Improves Capex costs (less scaffolding)
• Improves Opex – less downtime!

89
Automating Operator Rounds
z Issue
– Inconsistency in operator gathered
information
z Solution
– Wireless monitoring points
z Key applications
– Motor bearing temperature
– Pump casing temperature
– dP filter monitoring
– Boiler profiling
– Compressor head temperature
z Results
– Customer has reliable, accurate data
to make better business decisions
– Customer has implemented enhanced
cooling systems that have solved
historical maintenance issues with
assets
Fan 1
Fans 2 & 3
140
150
160
170
180
190
200
0:00 12:00 0:00 12:00 0:00 12:00 0:00 12:00 0:00 12:00 0:00
Date and Time
Temperature
(Deg.
F)
1/21/2005 1/22/2005 1/23/2005 1/24/2005 1/25/2005
Fan 1
Fans 2 & 3
140
150
160
170
180
190
200
0:00 12:00 0:00 12:00 0:00 12:00 0:00 12:00 0:00 12:00 0:00
Date and Time
Temperature
(Deg.
F)
1/21/2005 1/22/2005 1/23/2005 1/24/2005 1/25/2005

90
Environmental Monitoring –
Emissions
Environmental Monitoring
–
Emissions
Emissions
z Issue
– Relief valves only checked manually
every 8 hours to verify releases and
non-releases
– Low resolution results in larger fines
fines.
z Solution
– Wireless monitoring of pressure safety
valves with 15 second updates
z Key applications
– Pressure measurement at safety valve
z Results
– Reduction in fines for emissions
– Integration into asset management
systems providing data reporting and
historical device data
Input to Environmental Data Historian
• Analysis / Calculations
• Trends / Reports
• Alert notification

91
Tank Level
Environmental Monitoring
–
Tank Level
Tank Level
z Issue
– Environmental regulations require
secondary measurement systems on
tanks containing hazardous material
– Must use redundant communication
system and measurement technology
z Solution
– Wireless communication of level
measurements
z Key applications
– dP tank levels
z Results
– Redundant system allows easy, lower cost
compliance with local regulations
– More accurate primary system
– Seamless integration into legacy host

92
Wireless Innovators
Application Contest
Wireless Innovators
Wireless Innovators
Application Contest
Application Contest
z Rewarding the pioneering
spirit of our customers
z Global contest with regional
awards
z Categories include:
– Most Innovative Use of Wireless
Technologies
– Best Business Justification
z Peer customer judges

93
… Wirelessly
Wirelessly
tracking
communications
of the plant
needs

94
We’ve Expanded Our Capabilities
to Support Customers
We
We’
’ve Expanded Our Capabilities
ve Expanded Our Capabilities
z We are building a global network of
service and technical support resources
z Emerson wireless services are focused
on:
– Reliability: Providing the high uptime
required by the process industries
– Performance: Meeting all of your
application needs
– Security: Ensuring complete control
and protection
– Standards: Using industry standards
extensively

95
Wireless Plant Network - Services
Wireless Plant Network
Wireless Plant Network -
- Services
Services
z Equipment selection
z Network design
z Physical network installation management
z Application implementation
z Network configuration and tuning to optimize
performance for implemented applications
z Ongoing administration
– Security monitoring
– Network metrics and benchmarking
– Continuation Engineering to adopt new wireless
technologies as appropriate

96
Wireless Field Networks – Services
Wireless Field Networks
Wireless Field Networks –
– Services
Services
z On-site wireless technician comes
with the “SmartPackTM Starter Kit”
z On-site technician will:
– Manage installation of wireless devices
– Install AMS Device Manager
– Do full network health assessment
– Verify device functionality
– Verify gateway connection via users choice (Modbus, OPC, Ethernet)
z Integration of wireless data from 1420 Gateway to DeltaV
– Bring all of the wireless measurements into control system
– Integrate data into user interface for operations, historian, etc.

97
Pondering Your Next Step?
z “How do I learn more?”
z “Is it risky?”
z “How do I get started?”

98
Learn More At
Learn More At
Learn More At
z Free online resource for fast
and easy learning on
industrial wireless
z 20+ courses cover:
– Understanding wireless technology
– Using wireless in the process industry
– Implementing a wireless solution
www.PlantWebUniversity.com

99
We’ve Made It Easy to Get Started
with SmartPack™ Starter Kit
We
We’
’ve Made It Easy to Get Started
ve Made It Easy to Get Started
with
with SmartPack
SmartPack™
™ Starter Kit
Starter Kit

100
SmartPack Starter Kit Available TODAY
SmartPack
SmartPack Starter Kit Available
Starter Kit Available TODAY
TODAY
z The SmartPack™ starter kit
Includes:
– Factory configured wireless
devices and 1420 Smart Wireless
Gateway
• Network will work right of the box
– AMS Intelligent Device Manager
predictive maintenance software
– SmartStart™ services

101
The Future of Wireless Is Here Today!
z We want everyone to put a SmartPack™ in their plant
to begin experiencing the true potential of wireless
z Test drive wireless
z We have made it
– Secure
– Reliable!
– Stress-Free
– Easy

102
Emerson Smart Wireless
Integrate to any Host
z Emerson PlantWeb z Legacy/Existing Host
– Seamless extension – Easily integrated
– OPC / Modbus

www.EmersonProcess.com/SmartWireless

Emerson_Smart_Wireless_Solutions.pdf

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Emerson_Smart_Wireless_Solutions.pdf