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Transcript of Wire Less Project
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Application of Industrial Wireless Technology in ZhenhaiRefinery Ethylene Pipeline Project
Hu Boqi, Chief Designer, Sinopec Zhenhai Refining & Chemical Engineering Co., Ltd
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Table of Contents
Introduction ............. ............. ............... ............. ................ ............. ............... ............. ............. ............... .............. ............... ......... 3Background ............. ............. ............... ............. ................ ............. ............... ............. ............. ............... .............. ............... ......... 3Wireless Configuration............................................................................................................................................................... 4Technical Considerations ............. ............. ................ ............. ............... ............. ............... ............. .............. ............... ............. . 5
Multi-function wireless network vs. single-function wireless network ............ ............. ............... ............. ................ ............. ..... 6ISA100 vs. WirelessHART ....................................................................................................................................................... 6
Reliability and Safety Issues................ ............. ............... .............. ............... ............. ............... ............. ............... .............. ....... 8OneWireless Advantages........................................................................................................................................................... 8Conclusion................................................................................................................................................................................. 10References................................................................................................................................................................................. 10
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This paper describes the application of industrial wireless technology as part of the Sinopec Zhenhai Refinery ethylene
pipeline project. In order to ensure reliable and safe operation, wireless temperature transmitters were applied to monitor
temperature measurement points every 1 kilometer.
Industrial wireless technology provided key advantages to the Zhenhai Refinery, including lower installation and maintenance
costs, as well as reduced commissioning time.
This paper compares two international industrial wireless standards, WirelessHART and ISA100, used for process plant
monitoring and control. It also describes Honeywells OneWireless solution, which provides a single, multifunctional wireless
network structure supporting diverse plant applications and employing multiprotocol wireless instruments.
Introduction
In the petroleum refining and chemical industries, the use of industrial wireless technology in process monitoring and control
allows for flexible information acquisition, independent of cables, from a variety of sources. This includes measurement points
in remote areas of the plant, as well as places where wiring installation is difficult or where cables are liable to be damaged or
burnt. Other challenging applications include rotary or moving equipment, measurement points exposed to the risks of poor
signal transmission or disturbance, retrofit projects in which all cable bridges and holders are occupied, projects with tight
installation schedules, and sites without an autonomous power supply. Wireless technology also supports on-site
commissioning and safety applications by providing mobile station and wireless video monitoring.
Todays advanced industrial wireless solutions have helped Sinopec Zhenhai Refining & Chemical Engineering Co., Ltd.
achieve real-time temperature monitoring on low-temperature ethylene transport pipelines connecting its discharge port and
low-temperature tank areas, as well as data integration with its Distributed Control System (DCS) in the low-temperature tank
area.
Unlike traditional point-to-point wireless communication technology, industrial wireless solutions adopt techniques such as
mesh multi-path, FHSS/DSSS frequency hopping and end-to-end wireless communication control. These solutions ensure
reliable and safe wireless communication applications, and deliver advantages such as rapid communication, management ofdelayed communication configuration and an extended power supply to on-site instrument (transmitter) by batteries.
The reliability of wireless technology in industrial control applications is guaranteed by the digital nature of wireless
transmission, together with mesh multi-path space communication, time synchronization and collision detection, and high
immunity frequency hopping.
Background
The low-temperature ethylene transport line planned by Zhenhai Refining & Chemical Engineering Co., Ltd. has a total length
of about 7,650 meters, connecting the facilitys discharge port and low-temperature tank area. The transport pipeline has an
OD of 325 mm and a wall thickness of 4.5 mm. Constructed from 304 carbon steel, it is protected by a 230 mm thick
insulation. The required temperature range for transport of ethylene is between -150 and -100 C.
To ensure normal operation of the transport line and avoid accidents, real-time temperature monitoring is necessary.
Measurement points are distributed at an interval of 500 m at both ends of the line and at 1 km in other segments. Pipeline
temperature data is transmitted to the DCS located in the control room in the low-temperature tank area for centralized and
real-time monitoring.
A traditional measurement and control solution employing regular cables and measurement points distributed 1 km away from
each other along the entire length of the 7.6 km line would face extreme difficulty. This is primarily because temperature
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signals experience significant attenuation when they travel along cables for a few kilometers, and are consequently hard to
measure at the DCS control room.
Taking the communication system of Foundation Fieldbus as an example, the total length of its main fieldbus and branches
does not exceed 1.9 km (at a communication rate of 31.25 k/bps). The longest communication distances of Modbus RS485
and Profibus DP/PA are about 1.2 km (9.6 k/bps) and 1.9 km, respectively, making it difficult to adopt cable communication
solutions. If fiber optic cables are used for communication, each measurement point has to be equipped with accessories such
as optical-electrical converters, resulting in high equipment costs, difficult project implementation, interruption of
communication due to fault points or fiber breaks, and high maintenance cost and workload.
Wireless Configuration
With Honeywells OneWireless industrial wireless solution, it is easy to monitor the ethylene pipeline without using any cable,
bridge or connection. Seven temperature measurement points are defined along the low-temperature ethylene transport
pipeline, including T1 (located 1,000 m from the tank area DCS control room), T2 (1,850 m, elevated), T3 (2,850 m), T4 (3,850
m), T5 (4,850 m, elevated), T6 (5,950 m), and T7 (6,950 m), among which T2 and T5 are critical measurement points. T1 and
T7 use wired temperature transmitters, and other measurements points use wireless temperature transmitters.
Wireless communication is performed between transmitters installed at pipeline temperature measurement points and
multinodes. As a gateway, multinode M1 located in the low-temperature tank area transmits all data simultaneously to the
DCS. Three multinodes (with external power supplies) form the wireless mesh backbone for rapid communications. Nodes M1,
M2 and M3, installed on top of the low-temperature tank area control room, are located 1,000 m away from the tank area
control room and 700 m away from dock control room, respectively. These nodes are all equipped with 20 dbi, high-gain,
board-type directional antennas and lightning protection terminals (see Figure 1).
Figure 1
The self-organizing and self-sealing wireless mesh backbone provides a communication speed up to 54 Mbps. Additionalmultinodes can be added to create redundant multi-path communication. The backbone supports a number of wireless
applications, including communication with wireless transmitters and wireless mobile workstations. Plant personnel can view
DCS pages and information via mobile workstations at any measurement point for on-site operation. This multi-functional
wireless mesh network also incorporates wireless video communication, real-time location applications, pipe and tank
corrosion solutions, and other Wi-Fi wireless communication. In addition, it supports a variety of field instrumentation and
communication protocols in compliance with international standards such as HART, Foundation Fieldbus, 4-20 mA and
Profibus.
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The wireless network integrates data to the control system in the tank area via the multinode M1 using Modbus TCP, Modbus
RS485/232, OPC or HART communication. Modbus RS485 was adopted in this project for control of system data integration.
Five wireless temperature transmitters (T2 to T6) with 20 dbi high-gain directional antennae (long distance transmission and
concealed installation) and lightning protection terminals are installed on the 1 m column over the pipe support and used for
remote communication. Among the transmitters, T2 uses two antennae for the redundant communication path. The
temperature measurement component of the temperature transmitters has PT100 outside-attached thermal resistance with
leads directly connected to the wireless temperature transmitters. Each of the devices includes thermal resistance consisting
of 316 stainless steel with a temperature range between -150 and -100 and a length of 350 mm.
The Honeywell wireless solution also provides a management software platform (server) for the project. Installed in the tank
area control room, it performs the following functions: visualized monitoring of communication status of the wireless network,
support for online remote configuration of wireless transmitters, and management of diagnosis and security functions on the
wireless network.
The wireless communication network performs frequency hopping at 2.4 GHz public wave band (ISM). Self-organization and
self-healing functions, short communication time delays, rapid self-recovery, flexible scaling and easy installation characterize
the network. All wireless instruments are approved by SRRC. The data refresh interval of the Honeywell transmitters, which
are designed for explosion isolation and intrinsic safety, can be set to 1 s, 5 s, 10 s or 30 s. The battery life of these devices
(4.5 years at 1 s refresh interval or 10 years at 5 s refresh interval) is very predictable.
No. Name Model Qty.
1
Multi-function wireless node (with
power supply conversion module)
WNMS-M00000-W00000-F00000-PM-
XXXX 3
2 Wireless temperature transmitter
STTW400-000-0000-V0000-XD,MB,1C-
XXXX 5
3
Surface type thermal resistance
PT100 PT100 7
4
Wireless network management
platform: software 25 points SP 1
5 Workstation
DELL D630 workstation, 2G memory,
160G solid-state hard drive 1
6
Wireless network authentication
device XSK00 1
Technical Considerations
Honeywells OneWireless technology, adopted for real-time temperature monitoring on the Zhenhai Refinery pipeline project,eliminated traditional restrictions imposed by wiring connections and allowed remote acquisition of transport pipeline process
parameters in a more flexible and convenient way. Moreover, the wireless solution was seamlessly integrated with the
existing, cable-based DCS to further extend the control network architecture.
The benefits of Honeywells wireless solution include a higher level of pipeline transport safety monitoring, greater construction
efficiency, and significant reductions in installation cost, commissioning time and subsequent maintenance expenses. Another
advantage of wireless lies in the ease of long-term expansion. For example, if two transport lines are added in the future,
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wireless transmitters can be directly installed and (after authorization) automatically included in the existing wireless network
for communication.
Wireless solutions are also used in a number of other diverse operations within petroleum refineries and chemical plants.
Common applications include wireless transmitters for monitoring process parameters in tank areas, industrial wireless
cameras for wireless video monitoring, and wireless mobile workstations for real-time acquisition of static or dynamic data from
the DCS.
If the space reserved for cable bridges, holders and cabinets in a plant retrofit project has all been used, wireless technology
allows measurement points to still be added rapidly.
The deciding issues in an industrial wireless project typically include process, technical and cost factors. Other considerations
include scalability, sustainability and interoperability of wireless applications in the future (one platform in support of multiple
wireless applications, field instruments with multiple communication protocols and open standards), safety of wireless
instrumentation, reliability of wireless communication, battery life, timeliness of the wireless network (instrument update speed,
network delay time), frequency band of wireless communication, network scalability and data integration with wired control
systems.
Multi-function wireless network vs. single-function wireless network
During selection of an industrial wireless technology, users should consider the future scalability of the wireless network. One
of the key decisions to be made is whether a single-function wireless network or a multi-function wireless network should be
adopted.
A single-function wireless network only supports instrumentation with a certain communication protocol and single wireless
application. If other wireless applications are required in the future, multiple wireless network platforms will need to be built,
which increases project costs, complicates network management and wastes existing investments.
Conversely, if a multi-function wireless network is selected, creation of a single architecture can support field instrumentation
for multiple applications and communication protocols. This not only reduces unnecessary disturbances between devicesimproving the reliability of wireless communication, but also minimizes associated costs. Plant operation and maintenance
personnel no longer have to worry about managing multiple, independent and single-function wireless network platforms.
Honeywells OneWireless solution serves as a multi-functional wireless network using a single platform to support applications
ranging from process parameter monitoring to safety video monitoring, mobile operations, pipeline corrosion monitoring and
diagnosis of equipment status. This single platform also supports field instrumentation employing multiple communication
protocols such as HART, Modbus, Foundation Fieldbus and 4-20 mA.
ISA100 vs. WirelessHART
Current wireless technology in the industrial control field can be categorized in two groups: instrument wireless mesh solutions
meeting the WirelessHART standard and node mesh wireless solutions compliant with the ISA100 standard. To achievewireless application functionality at the industrial level, both approaches integrate mesh multi-path and FHSS communications
and utilize techniques based on precise time synchronization and data collision. However, these two industrial wireless
methodologies have major technical differences and value propositions for end users.
Important considerations when comparing ISA100 and WirelessHART solutions include safety of wireless networks, battery
supplies for wireless instrumentation, timeliness of communications, wireless frequency band, network scalability and data
integration with wired control systems.
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Instrumentation mesh wireless network
The main characteristic of a WirelessHART-based instrumentation mesh network is its routing function for field
instrumentation, which allows each battery-powered wireless device to not only measure its own process parameters,
but also provide routing for communication of other meters. Typically, one gateway is configured to enable data
integration with the DCS. FHSS communication is performed at 2.4 GHz public frequency band. The wireless network
is easy to implement due to its self-organization and self-healing nature.
However, this type of technical solution also has an obvious disadvantage. Because wireless network communication
is done with routing of transmitters, communication speed is limited. For example, the refresh speed of transmitters
cannot reach a high value and typically remains at 16 or 8 seconds. The time delay of the entire network can be as
much as 16 or 60 seconds. A lower defined refresh speed corresponds to longer time delays in network
communication.
Routing by wireless transmitters also contributes to a shorter battery life, which is normally five years at 30 s refresh
interval or even shorter at 8 s or 1 s intervals. Even if battery voltage can be displayed at any moment, the routing
number determines the low-voltage alarm threshold. Hence, it is difficult to predict the service life of batteries as long
as the routing of devices requires significant power consumption.
Additionally, the need to reduce battery usage restricts the transmission power of wireless meters resulting in shorter
communication distances between instruments. If the devices are 2.4 GHz micropower devices, the restrictions on
transmission power vary depending upon different countries. According to SRRC, for example, the transmission
power of micropower wireless devices should be less than 10 mW, which corresponds to a communication distance
of about 100 m between devices.
Due to time delays during network communication and limitations on communication speed, the number of routings
for the wireless mesh network has to be restricted. In other words, communication time delays could be very long if
the number or routings exceeds a defined value. Time delay issues also impact the size and scale of the wireless
network infrastructure. The number of wireless meters driven by a gateway can be very limited if the devices refresh
at 1 s interval.
A single WirelessHART-based architecture only supports instrument communication for one communication protocol
(which must be HART type). This approach is subject to limitations since it cannot support instrumentation of other
protocols and wireless applications.
Node mesh wireless network
In an ISA100-based wireless network, nodes create a mesh backbone with very high communication speed. The
backbone is self-organizing and self-healing, and supports multiple types of wireless field instrumentation,
applications and communication protocols. Wireless meters in the field can automatically choose to communicate
with any random node in self-organization and self-healing mode, but without configuration of routing functions. In
general, any node can be used independent of, or in conjunction with, other devices and gateways to facilitate data
integration with the DCS. Batteries supply power to the wireless transmitters and FHSS communication is performed
at 2.4 GHz public frequency band.
The advantage of the node mesh wireless network lies in its very fast transmitter refresh rate (typically 1 s or 0.25 s),
which is due to the mesh backbone created by nodes. With this approach, it only takes one hop for wireless
transmitters to transmit data to the wireless backbone, significantly minimizing any associated communication time
delays.
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As none of the wireless transmitters provide routing for each other, their batteries have a long service life (typically
five years at ambient temperature at 1 s refresh interval). The absence of a routing configuration also allows display
of battery voltage at any time and supports low-voltage alarms, which means battery life is predictable.
Extended battery life also results in flexible transmission power for wireless meters, as well as longer communication
distance between wireless field equipment. According to SRRC, for example, the transmission power of 2.4 GHz
spread-spectrum communication devices should not exceed 500 mW, and the communication distance between
devices can be up to a few tens of kilometers.
In addition, the ISA100-based wireless network architecture is very scalable; a single network can support up to
1,000 wireless meters, as well as multiple wireless protocols and applications.
Reliability and Safety Issues
When it comes to reliability and safety, wireless technologies used in the industrial monitoring and control field differ from
traditional point-to-point wireless communication technology. To ensure robust performance on an industrial level, ISA100 and
WirelessHART have both adopted mesh multi-path and frequency-hopping techniques and wireless communication protocols
based on time synchronization/data collision detection.
With this network configuration, if a wireless device is disturbed by signals in a frequency band other than 2.4 GHz, the
reliability of communications will not be affected. If the disturbance frequency band is 2.4 GHz, the wireless device will
automatically select the next optimal communication channel for frequency hopping. The user can define the number of
repeated attempts at data packet communication. If communication cant be completed by means of frequency hopping, the
device automatically selects the next optimal communication path. Furthermore, wireless communication is very fast and only
requires 15 mS for one data transmission cycle. A wireless device can even complete data transmission within the 15 mS time
window during disturbances.
Honeywells end-to-end communication control technology allows active data transmission from wireless transmitters as well
as data requested by the system from wireless field devices, thus ensuring reliability of communication data.
As far as network security is concerned, Honeywells OneWireless solution features a single wireless management software
platform controlling safety authorization for the entire wireless network. All devices included on the wireless network have to be
authorized. A unique authorization password is obtained from the management platform before the device in question is
authorized through a wireless transmitter and IR port of multinodes. Authorized devices are automatically included in the
wireless network for communication. Other configurations will be completed as well, including communication certification and
verification, data package encryption, data source validation, CRC cyclic code check, replay protection, frequency hopping and
password management.
OneWireless Advantages
Honeywells OneWireless offering is a multi-functional wireless network based on the ISA100 technical path. With this solution,
users employ multinodes to create a wireless mesh backbone with communication speeds up to 54 Mbps. Wirelesstransmitters automatically choose to perform redundant and frequency hopping wireless communication with any multinode.
Plus, the systems wireless network management and diagnosis platform can be configured for visualized real-time monitoring
of network communication status, central safety management, remote online configuration and checking of wireless
transmitters.
Honeywells wireless solution offers a mesh backbone created by multinodes which can be connected to a wide range of
industrial wireless transmitters operated at 2.4 GHz, which is the internationally recognized public frequency band for
frequency hopping communication. Wireless access to 802.11 Wi-Fi devices is also possible. Each multimode can either be
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used as a gateway or configured for redundancy to perform seamless communication with the DCS without single-node faults.
This approach supports 802.11a/b/g WLAN communication, communication between wireless devices, and self-organization
and management of devices, thus creating a universal, safe, easy-to-manage and easy-to-maintain wireless network.
Figure 2
Honeywells multifunctional industrial wireless network supports a variety of industrial monitoring and control applications.
Compatible devices include transmitters, valves, Wi-Fi devices, mobile workstations, real-time location devices, smokedetectors and more. The network can be used with a choice of leading instrument protocols, including HART, Foundation
Fieldbus, Profibus, DeviceNet and Modbus (see Figure 3).
In summary, the features of Honeywell OneWireless include:
Rapid wireless backbone with self-organization and self-healing functions that can include up to 40 multinodes. Wireless
transmitters automatically choose any multimode to perform multi-path, redundant and frequency hopping communication.
A multinode can also serve as a gateway to perform data integration with the DCS (standard communication interfaces
include Modbus TCP/OPC/RTU/HART).
Each wireless transmitter only collects its own process parameters. It can automatically choose to communicate with any
multinode, but does not provide routing for other wireless devices. The refresh interval of wireless meters is 1 s, 5 s, 10 s,
30 s, or even 0.25 s in the future.
Each multinode can either drive 400 wireless transmitters (30 s refresh interval), 100 transmitters (5 s refresh interval) or
20 transmitters (1 s refresh interval).
Maximum communication distance between two multinodes is 1 km (or 10 km with high-gain antenna), which can be
extended through meshing. The maximum communication distance between a transmitter and a multimode is 610 m (or
3-4 km with high-gain antenna).
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Service life for wireless transmitter batteries is either 4.5 years (1 s refresh interval) or 10 years (5 s refresh interval). Four
types of universal safety batteries are available and are field replaceable in normal sites (on-site replacement in
dangerous areas is not recommended). Wireless transmitters also ensure explosion isolation and intrinsic safety.
Wireless network has been approved by SRRC and uses FHSS communication devices operated at 2.4 GHz public
frequency band.
Single architecture supports diverse wireless applications and communication protocols. Application examples include
safety video monitoring, support of mobile operations, real-time location of mobile equipment, pipeline corrosion
monitoring and diagnosis of equipment status such as vibration. Supported technologies include HART, Modbus,
Foundation Feldbus and 4-20 mA.
Forwards and backwards compatibility. Honeywell provides on-site installation of all current wireless products. Software
can be downloaded for the entire plant to allow online network upgrades and compliance with the latest ISA100 standard.
Management platform provides visualized management of the field wireless network, support for online remote
configuration of wireless transmitters and centralized control of wireless network safety. This solution is simple and easy
to use, requiring no complicated on-site survey.
Conclusion
The application of industrial wireless technology on the Zhenhai Refining & Chemical Engineering Co., Ltd. ethylene transport
pipeline project eliminated the restrictions of traditional cable connectivity and allowed remote acquisition of process
parameters in a more flexible and convenient way. Wireless technology was seamlessly integrated with an existing, cable-
based DCS to further extend the breadth and depth of the process control network. The benefits include a higher level of
pipeline transport safety monitoring, increased construction efficiency, and significantly reduced installation cost,
commissioning time and maintenance expenses.
Another advantage of the wireless solution lies in the ease of further expansion. The installation of a multifunctional wireless
network will prevent existing technology investments from becoming outdated in the future.
The primary considerations for end users undertaking an industrial wireless application include process, technical and costfactors. Among the key technical considerations are selection of wireless instruments, reliability and safety of wireless
communication, battery supply of wireless instrumentation, timeliness of wireless communication, network scalability and data
integration with the wired world.
Current industrial wireless offerings can be categorized in two groups: instrument wireless mesh solutions represented by
WirelessHART and node mesh wireless solutions represented by ISA100. While both of these approaches have important
strengths, an ISA100-based wireless solution is most appropriate for industrial environments requiring rapid data refresh
speeds and scattered measurement points.
References
1. Tiansheng, J., One Wireless Platform Supporting Multiple Applications and Field Instrumentation of Multiple
Communication Protocols, China Instrument and Meter, April 2009
2. Topology of Wireless Instruments, Control Engineering China (http://www.cechina.cn)
OneWireless is a trademark of Honeywell International Inc.
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More Information
For more information on Honeywells wireless
solutions, visit www.honeywell.com/ps/wireless or
contact your Honeywell account manager.
Automation & Control Solutions
Process Solutions
Honeywell
1860 W. Rose Garden Lane.
Phoenix, AZ 85027
800-822-7673
www.honeywell.com/ps
WP-10-16-ENG
December 2010
2010 Honeywell International Inc.