What Process Control Professionals Think About Wireless Analysis of an ISA100 and Control Magazine S

1
What Process Control Professionals Think About
WirelessAnalysis of an ISA100 and Control
Magazine Survey

• October 07
• ISA Expo Houston, Texas
• Paul Sereiko, Dick Caro

2
Speaker Background

• Paul Sereiko
• President and CEO, AirSprite Technologies
• Co-chair, ISA-SP100 Marketing Working Group HART
  Communication Foundation, Marketing Group
• Contact
• psereiko_at_airsprite.com
• 508.281.2720

3
Agenda

• Background
• Use Case Interviews
• Control Magazine Survey
• Summary and Conclusions

4
Background

• Understand user needs for wireless automation in
  the plant
• Guide ISA100 standard development
• Educate users
• Guide wireless suppliers
• Use case interviews plus Control readership
  survey
• Information collected
• Application types
• Network characteristics
• Plant and enterprise integration
• Reliability and security

5
Background

• Almost 500 use case and survey responses as of
  May 2007
• Credits
• Written by Walt Boyes (Control) Paul Sereiko
  (AirSprite)
• Special thanks to Jose Gutierrez (Emerson), Dave
  Kaufman (Honeywell), ISA, Cullen Langford,
  Robert Shear (Dust Networks), Dick Caro (CMS),
  Mike Dow (Freescale), and Andy Bent (AirSprite)

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Agenda

• Background
• Use Case Interviews
• Structure
• Sources
• Sizing
• Node spacing
• Data timing
• Control Magazine Survey
• Summary and Conclusions

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Use Case Structure

• Site Description Where wireless is to be
  deployed
• Oil refinery
• Food processing plant
• Paper mill
• Train car
• Etc
• Application What a wireless solution
  accomplishes
• Tank level monitoring
• Perimeter security monitoring
• Etc
• Tasks How individual tasks are accomplished and
  required type and quality of service
• Periodic reporting of monitored values
• Alerting and alarming
• Device installation and commissioning
• Device diagnostics and maintenance
• Etc

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Use Case Template
9
Use Case Sources - 1
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Use Case Sources - 2
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What Have We Learned from the Use Cases?

• There are three kinds of lies lies, damned lies,
  and statistics.
• Benjamin Disraeli (1804 - 1881)
• Statistician A man who believes figures don't
  lie, but admits that under analysis some of them
  won't stand up either.
• Evan Esar (1899 - 1995), Esar's Comic Dictionary
• Statistics The only science that enables
  different experts using the same figures to draw
  different conclusions.
• Evan Esar (1899 - 1995), Esar's Comic Dictionary

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A Few Sample Statistics

• Current Database
• Included Use Cases 26 completed use case in
  proper format

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Site Sizes (log)
Many sites are in the 10-20 acre range
100,000 m2 24 acres
14
Node Spacing
Commentary Spacing varied widely Small spacing
needs typify high-volume manufacturing
(discrete). Large spacing is for massive outdoor
areas like wind farms, and drilling fields.
Sweet Spot
Implications ISA100 should specify to assure 30
meter range in obstructed environments. For
longer ranges the standard should consider
requirements for an SP100.11a High Power radio.
15
Timing of Wireless Data
Commentary Rate at which data changes cluster
nicely around three time intervals-milliseconds,
seconds, and multiple minutes.
16
Control Cases vs. Monitoring Cases

• Commentary
• As expected monitoring cases require a much
  slower network than control cases. On average
• 4 times slower expected change of data intervals
• 6 times slower desired reporting intervals
• 27 times slower latency !

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Agenda

• Background
• Use Case Interviews
• Control Magazine Survey
• Participants
• Coverage needed
• Wireless vs. wired usage
• Wireless application candidates
• Reliability Security
• Node spacing
• Battery life
• Summary and Conclusions

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Control Magazine Survey Summary

• Questions mirrored use-case interview questions
• Distributed to LARGE databases
• ISA 100,000
• Control Magazine 45,000
• Posted on large company web sites
• Emerson
• Honeywell
• Yokogawa
• Posted on industry pundit blogs
• Walt Boyes
• Gary Hintchell

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Who Participated in the Online Survey?
If other category were included Field Device
manufacturers and Petroleum industries would
dominate .
20
Other Respondents
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Wireless Coverage Needed to be Effective
Commentary Hotspot coverage with growth via
tiling seems most practical.
22
Multi-Vendor Environment Dominates
23
Wireless Sensing Almost Non-Existent Today
24
Multiple Integration Paths
Implications Support of MULTIPLE protocols and
MULTIPLE connection methods is critical. 2-wire
still dominant physical interface within
installed base.
25
Alerting and Monitoring are Overwhelming
Candidates for Wireless Systems
26
Reliability Security are Critical Factors
Reliability Security Important Topics 66.4
Data Reliability will affect use of
wireless 54.4 Security will most influence
decision
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Node Spacing Online Survey
200 400 800m
Sweet Spot
Greater than 0, but lt 5 Meters
Commentary A broader base of long range
applications was found in this sample than in the
use case interviews
Implications Supports lower power and long range
radio ISA100 option from prior slide
28
Expected Battery Life
Control Magazine
Commentary Significantly different results from
the two surveys. Possible bias from integrators
and field device manufacturers in Control
Magazine.
Implications May be flexibility in battery life
requirements. Opportunity for vendor
differentiation.
Use Case Interviews
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Agenda

• Background
• Use Case Interviews
• Control Magazine Survey
• Summary and Conclusions

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Summary Using The Data

• 84.8 Wireless will be used for monitoring
• 48.6 Used for alerting
• 24.6 / 23.2 Used for low-speed control gt2 sec
  cycle time
• 13 Used for high-speed control
• 90.7 Expect devices powered by batteries
• 72 Line Power, 56.8 4-20mA current loops
• 37 Exact time measurement is taken w/in 1 sec
• 18 Notified between 10 secs and 1 minute
• 42.6 Encryption should be required
• 64.8 Message authentication should be required
• 64.3 Device authentication should be required
• 71.1 Send data to digital controls
• 54.7 Send data to PLCs
• Must cooperate with Fieldbus protocols
• 76.2 Must cooperate with Ethernet
• 50 Modbus
• 38.9 Foundation Fieldbus
• 18.3 Profibus PA

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Top Conclusions

• Opportunity Non-existent wireless sensing is
  opportunity for end users, vendors, and emerging
  standards
• Getting started Hotspots and tiling looks
  practical
• Interoperable Multi-vendor instrument
  facilities dominate wireless standards should
  be of high value
• Integration Multi-paths needed especially to
  DCS
• Applications Monitoring/alerting of greatest
  interest
• Reliability and security Critical factor for
  emerging standards and vendors
• Power Battery life expectations vary vendors
  can differentiate

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• Thank you
• Paul Sereiko
• AirSprite
• psereiko_at_airsprite.com
• 508.281.2720