Paper Title: Wireless Networking Technologies for Automation in Oil and Gas Sector Theme: Suggested Area No. 12: IT applications in Oil and Gas Sector Author:
Affiliation:
Jignesh G. Bhatt
Instrumentation & Control Engineering Department,
QIP M. Tech. (M&I) Scholar
Faculty of Technology, Dharmsinh Desai University,
Electrical Engineering Department
Nadiad 387 001, Gujarat, India.
Indian Institute of Technology Roorkee
Email:
[email protected]
Roorkee 247 667, Uttarakhand, India. Keywords: Automation, IT enabled Industrial Solutions, Industrial Process Management, Wireless Networking Technologies Abstract: Previously, wireless solutions were not viable and preferred choice for offshore monitoring in Oil and Gas sector for many reasons like – Emerging, Non-robust and Immature technology, Security concerns, Incomplete or conflicting Standards, and clashing wireless frequencies and communications protocols. Today, much has changed. Advances in safety, security, affordability, and maintainability within the constraints of frequency allocation now enable organizations to take full advantage of wireless technology for challenging industrial environments. Novel distributed signal processing algorithms, energy-efficient medium access control and fault-tolerant routing protocols, self-organizing and self-healing sensor network mechanisms, etc. have contributed immensely in growth of these technologies. Recent developments like WirelessHART and ISA SP100.11a have provided exceptional boost to this novel technology. In terms of user’s perspective, now significant paradigm shift can be observed from traditional wired technologies to upcoming wireless technologies and these can be very well endorsed by rise in demand for Wireless technologies in recent time. Interesting case studies of installations in Leading Oil and Gas Plants of Indian and foreign countries with their techno-managerial outcomes are discussed in brief. Recently emerged concepts of Overall Asset Management for Oil and Gas Engineering, Procurement and Construction (EPC) Operators are also briefed. The concepts discussed are now globally used tools for management of Petroleum businesses across the value chain-from exploration to production to distribution. The paper also discusses briefly how wireless technologies can be leveraged in advantages of the Oil and Gas sector in contexts of Process Monitoring, Asset Management, Meeting Regulatory Requirements, Safety & Security, Productivity Enhancement, Plant Management and such other related issues. Yet, optimizing every facet of the solution is vital and imperative. There are some issues and challenges that are identified as topics of future research work in the area by the author.
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Wireless Networking Technologies for Total Automation in Oil and Gas Sector Jignesh G. Bhatt 1. CURRENT SCENARIO IN OIL & GAS SECTOR[1] The economic slowdown has had a significant impact on demand and the price of oil. Despite this, huge investments are still required to ensure the industry has enough production capacity to meet future demand. Automation expenditures by the upstream oil and gas sector, which includes exploration, production, and pipelines, are expected to grow at a compounded annual growth rate (CAGR) of nearly 7% over the next 5 years. After a challenging 2008, which saw falling demand and a fall down in once lofty oil prices, the industry is looking Figure 1.1 Total Shipments of Automation Solutions to the Oil & Gas Industry[1]
forward as the economy starts to come out of the recession, and oil prices recover some of their lost gains. Though oil
and gas companies have made some adjustments in response to the downturn by stepping back from some large projects, they still plan to make major investments in coming years to build capacity for an inevitable increase in demand over the long term. An increase in demand over the long term will continue to drive significant growth in capital investments and automation expenditures in the global oil & gas industry. According to estimates, demand for petroleum products will increase substantially as the economies in developing regions improve and per capita energy consumption increases. Today’s production and processing capacities struggle to keep ahead of the demand curve and both upstream and midstream facilities will need to be expanded. New sources, such as tar sands, shale oil, and coal-to-liquid gas, will require new midstream and production facilities to be developed, increasing demand for automation systems and field devices. Regionally, the highest growth rates will occur in Asia and Latin America. Asia’s share of sales will reach 25 percent, and while expenditures in Latin America will nearly double over the forecast period, the region will still remain a relatively small portion of the overall market. Despite the strong growth in developing regions, the Middle East, home to the world’s largest conventional oil and gas deposits, will grow at average rates. 2. POTENTIAL AREAS REQUIRING AUTOMATION IN OIL & GAS SECTOR Some potential areas that need automation in oil and gas sector facilities are identified below: 1. Process Control Systems, (like SCADA, DCS, PLC, etc.) – to deliver accurate measurement and control. 2. Productivity Enhancement Systems, with Intelligent Field Instrumentation. 3. Integrated Intelligent Motor Control Centres, for faster start-up & Enhanced Maintainability to improve diagnostics. 4. Safety Shutdown Systems, compliant to IEC 61508 protect personnel, process & equipments. 5. Fire & Gas Solutions, to provide precise detection and quick suppression of fire. Page 2
6. Integrated Communication Systems, incorporating plant data networks, voice & video and security systems. 7. End-to-end Control Solutions, including flow metering integration, wellhead controls, Bulk fluid handling and pumping controls. 8. Unit Control Systems, for Gas compression applications that include engine & turbine control, compressor surge control and condition monitoring. 9. On-site Power Generation and Distribution systems, with electrical power management solutions that includes load sharing, load management, fast load shedding and switchgear management subsystems. 10. Performance Centric Design Centres, to deliver Operability, Accurate control and human factor engineering, Productivity tools with integrated & intelligent applications, Tools for verification of reliability of hardware, software and communication systems, Maintainability tools for standardization, Advanced diagnostics & traceability, Tools for scalability & flexibility for online modifications and expansions. 11. Adv. Productivity solutions for process historian, production reporting, data analysis, Key Performance Indices (KPIs) calculations, Alarm & Process optimization. All these and many more possible areas require well integrated real-time automation system that will maximize life cycle Return On Investment (ROI) by optimum end-to-end system integration for an oil and gas industry. 3. GLOBAL MARKET TRENDS[2][3][4] The emergence of standards-based solutions for wireless communications has dramatically changed the market's perception of the technology. Of the many benefits that a standards-based solution offers, a key advantage is interoperability. The emergence of standards such as ISA100 and WirelessHART, which are targeted at RF applications requiring low data rate, long battery life, and secure networking, have equally changed the market's perception of wireless technologies for industrial networks. The key catalyst for this growth is the availability of integrated solutions at market affordable prices. Technology consultants VDC Research Group recently completed a worldwide market study on wireless and wireline industrial networking infrastructure products which includes a user technology opinion survey that also covers the industrial wireline and wireless networking infrastructure markets for each major geographical region of the world. 3.1 Wired Networking Market Forecasts[4] The global market for the industrial wireline networking infrastructure products under study is expected to increase at a 24.6% CAGR from $1874m in 2007 to $5630m in 2012. Wireline regional markets Wireline product market is more mature in the EMEA region, particularly in Western Europe, and is expected to be the slowest growing. Again, the Asia-Pacific market is the smallest, but forecast to be the fastest growing. Table 3.1: The 2007 and forecast 2012 shipments to major regional markets for the industrial wireline networking infrastructure products, $US, millions[4]
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In 2007, the largest consuming worldwide industries of wireline networking infrastructure products for use in industrial facilities (ranked in descending order) were Automotive, Electric Power, and Food/Beverage and Water/Wastewater Utilities. These industries are forecast by VDC to remain the largest consuming segments through 2012. The IEEE 802.11 Wireless Local Area Network (WLAN) market has grown exponentially during recent years. WLAN technology has transformed from high-tech niche into main-street commodity, which is evident by the simultaneous increase in shipment and decrease in price as shown in Fig. 3.1. The green curve illustrates the exponential decrease in unit price, while the orange curve shows the exponential increase in unit shipments.
Figure 3.1-Worldwide WLAN Market size[3]
3.2 Wireless Market Forecasts[4] a) The global market for the industrial wireless networking infrastructure products under study is expected to increase at a compound annual growth rate (CAGR) of 25.4% from $299.3m in 2007 to $928.1m in 2012. Strong growth rates are forecast for each product category. b) Main reasons for these wireless growth expectations include attractiveness of mobility in industrial facilities, increasing awareness of wireless technology and the benefits associated with it, increasing trust in wireless networking and perceived ease of implementation. c) Average selling prices for all these wireless products are expected to decline globally through 2012. Wireless regional markets The market for industrial wireless networking infrastructure products has developed more rapidly in the Americas, and particularly in the United States, than in the EMEA and AsiaPacific regions. Table 3.2: The 2007 & forecast 2012 major regional markets for the industrial wireless networking infrastructure products, $US, millions[4]
These products hold the potential for improving the efficiency of operations and reducing costs. The largest overall shipment growth rate is forecasted for the Asia-Pacific region. Market growth rates are expected to be high in all three major geographic regions, however, the market in the Americas is by far the largest, and is expected to remain so through 2012. In 2007, the largest consuming industries worldwide for the wireless networking infrastructure products under study (ranked in descending order) were - Oil & Gas, Automotive, Electric Power and Water/Wastewater Utilities. These industries are also forecasted to remain the largest consuming segments through 2012.
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4. ASSET MANAGEMENT IN OIL & GAS SECTOR[5] Data retrieved from smart field devices are stored, processed and organized by asset management software and made available to plant personnel in functional graphics that simplify maintenance tasks. Personnel can use this tool to determine the status of a field device and even the operating condition of equipment to which it is attached. They can view, configure and troubleshoot any device. Since the diagnostic data are available in both the control room and the maintenance shop, all personnel can see the same information. Device diagnostics are useful in troubleshooting an instrument that operators may suspect is malfunctioning or not sending accurate information. The conventional method of checking out such a device located in remote safety zone would be to obtain a work permit; dispatch an operator with a sniffer to ensure the area is clear of explosive gases; and send an instrument technician to evaluate the condition of the device with a handheld. After the device is either declared operational or replaced, the work order can be closed. This generally takes at least two hours to complete, and in most cases, no problem is found. With asset management, troubleshooting suspected process problems can normally be done from the maintenance shop and is therefore, faster than sending technicians out to remote areas. This is a great time-saver practice, allowing maintenance personnel to concentrate on keeping the process running. Advanced diagnostics can be accessed from devices in the same way, enabling maintenance personnel to identify conditions that can cause potential problems such as a plugged impulse line or sticking valve that might cause a failure or severe process upset. Such information can be used by maintenance personnel to predict when a device – or the equipment to which it is mounted – may need maintenance to continue operating without interruption. In some cases they may need to act quickly to defuse a potential issue to avoid unscheduled downtime. The practice of predictive maintenance relies on the availability of accurate information about the condition of field devices. Knowledgeable person can use this information to estimate how long this equipment is expected to operate satisfactorily. Predictive maintenance of high priority equipment is much more economical than traditional preventive maintenance. Managers soon become believers when they realize how much money can be saved when they make repair/replace decisions based on good intelligence. Asset management systems can manage periodic device calibration, alerting operators when signs of change appear and accurately documenting maintenance events for every device in the system. Thus, valuable diagnostic information collected can be used by asset management systems to improve efficiency, reduce maintenance costs and enhance productivity and ultimately profitability of the organization. 5. EMERGANCE OF WIRELESS TECHNOLOGY[6] The largest percentage of field devices (even smart field devices) uses the smart protocols as configuration type inputs. Foundation Fieldbus was the only technology prior to wireless technology that was designed to be control ready and control capable. Configuration and diagnostics protocols are generally used for configuration. In a very small percentage of facilities they are used for meaningful online diagnostics. A much smaller percentage of facilities use them for control. Page 5
It would be impractical to suggest that a plant would rip out its installed base of instrumentation and install new equipment to gain those values that the diagnostics can offer. Furthermore it would be more then idealistic to suggest that they modify their control system to enable control of that technology. Wireless offers the ability to add the data in a very quick, scalable fashion. You can simply start with a handful of devices at critical points. Integrate them with an age old standard like Modbus or some other serial interface. Then grow your network as you see fit from that point. Complete projects of 10-15 points have been initiated, installed, commissioned and integrated in less then three hours. And now they have smart dynamic digital communication out to the sensor location. Foundation Fieldbus is by far the most robust protocol and industrial sensing and control standard built to date. There is a wealth of functional capabilities that are now offered at the sensor than ever before. This was truly a protocol that was designed to be control ready. One of the main driving forces behind the Fieldbus Foundation was to reduce the amount of wiring. Early in its conception phase communications offered the capability to have multi-drop bidirectional type networks and reduce the overall wiring cost of the project. They added control and function block programming to the devices at the sensor level as well. However for the largest part of the installed base they are utilizing the deterministic protocol response from the field device and still maintaining control in the operator station. If you look at wireless, it adds something to the Fieldbus network that really empowers a plant. For example, 1. Wireless eliminates the need for wires (Fieldbus multi-drop) reducing significant project cost. 2. The wireless sensor and Ethernet network can now include Fieldbus through Ethernet converters (or any bus). 3. The network can be meshed or built with multiple redundancy points without the cost of wiring. 4. The network can act as your fibre optic points to RTUs for control. Wireless, like bus technologies such as Foundation Fieldbus (FF), offers reduced installation cost, plus easy access to multiple process and diagnostic variables per device. Integrating FF can be problematic when the installed control system is old or at capacity, so this technology is usually considered for Greenfield installations or significant plant expansions. With wireless, incremental devices can be easily added to any existing installation, even where the existing wired infrastructure is full. New wireless points can be seamlessly integrated, with full access to multiple variables and device diagnostics. Total installed cost of a traditional point to-point wired measurement can be two to-ten times the acquisition cost of the transmitter itself, where an individual wireless device can provide multiple process variables. Additional benefits come from reduced physical space requirements, increased flexibility and ease of expansion of a wireless system.
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6. WIRELESS TECHNOLOGIES FOR INDUSTRIAL AUTOMATION 6.1 Essential Requirements from Wireless Technologies for Industrial Applications[3][7] Industrial WLAN users have requirements that differ from those originating from within enterprise and home environments. These include: a) Strict delay requirements Enterprise VoIP applications - Delay latency of up to 150ms (up to 1% data corruption in transit due to adaptive play-out control and error concealment algorithms). For field device applications – 10 ms; for motion control applications - < 1 ms b) Deterministic performance guarantee Runtime performance degradation is not permitted at all for mission-critical applications. This requirement is also enforced during device roaming, which requires for real-time handover while network to network rollovers. c) Support for large and varying number of devices Each wireless access point is expected to serve a large and varying number (in the order of hundreds) of field devices and sensors, manufactured by different vendors without overload. d) Network security An industrial WLAN must meet industrial safety and security regulations. These requirements include premises protection, and detection of rogue clients and access points. e) Network commissioning Industrial networks place special emphasis on network commissioning because runtime network failure is unacceptable. For industrial WLANs, the commissioning requirements include auto-commissioning where a large number of devices are to be used, and the execution of radio planning and assisted site surveys. 6.2 THE ISA100.11a STANDARD[8][9] ISA100.11a is an open-standard wireless networking technology developed by ISA. The official description is "Wireless Systems for Industrial Automation: Process Control and Related Applications". The ISA100 committee is part of ISA and was formed in 2005 to establish standards and related information that will define procedures for implementing wireless systems in the automation and control environment with a focus on the field level. The committee is made up of: – Over 400 automation professionals – From nearly 250 companies around the world, – Representing end users, wireless suppliers, DCS suppliers, instrument suppliers, PLC suppliers, technology suppliers, system integrators, research firms, consultants, government agencies, and consortiums, – Lending their expertise from a variety of industrial backgrounds. In 2009, the ISA Automation Standards Compliance Institute established the ISA100 Wireless Compliance Institute also known as the WCI. The ISA100 Wireless Compliance Institute owns the 'ISA100 COMPLIANT' certification scheme and provides independent testing of ISA100 based products to ensure that they conform to the ISA100 standard. Honeywell Process Solutions offer ISA100.11a compliant starter kits and complete systems. Page 7
In May 2009, the ISA100 standards committee voted to approve ISA100.11a, "Wireless Systems for Industrial Automation: Process Control and Related Applications". On September 9th 2009, ISA officially released ISA100.11a standard. ISA100 allows you to deploy a single, integrated wireless infrastructure platform for your plant. The standard network can simultaneously communicate with many existing application protocols wirelessly throughout your plant. This includes protocols such as HART®, FOUNDATION™ Fieldbus, Modbus®, Profibus®, Common Industrial Protocol (CIP™), and more.
Figure 6.1-The ISA100 Family of Standards for Interoperability[9]
Figure 6.2-Timeline for development of various ISA100 Standards[9]
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Technical Overview[9] The network configuration has a series of wireless field devices, some of which can and will route messages, and some of which may not have routing capabilities or may not be configured to use routing capabilities. The network is attached to a user application at a gateway. The gateway provides the transition from ISA100.11a into the users’ application.
Figure 6.3-Technical overview of ISA100.11a Standard[9]
Scope of ISA100.11a Standard[9] (i) Be an open standard for anyone to implement and deploy. (ii) Be simple to use and deploy for end users. (iii) Assure multi-vendor device interoperability. (iv) Be focused on–(a) serving process industry applications supporting architecture for wireless factory automation, (b) LANs rather than MANs or WANs, (c) Choosing radio bands and security techniques that are deployable globally. (v) Provide technology to address Class 1 (Non-critical) to Class 5 applications such as monitoring (critical and extremely time sensitive applications to be served in later releases). (vi) Include only 2.4 GHz IEEE 802.15.4-2006 radios. (vii) Use channel hopping to support co-existence and increase reliability. (viii) Adhere to comprehensive coexistence strategy: This is an ability of wireless networks to perform their tasks in an environment where there are other wireless networks that may or may not be based on the same standard. For example, the wireless networks based upon Wi-Fi, WirelessHART, ZigBee, Bluetooth, etc. (ix) Offer field device meshing and star capability. (x) Use a single application layer providing both native and tunnelling protocol capability for broad usability. Native device protocols allow efficient use of the bandwidth and provide longer battery life of nodes. Tunnelling protocol allows the ISA100.11a network to carry existing protocols such as Foundation Fieldbus, HART, Modbus, etc. (xi) Provide simple, flexible and scalable security addressing major industrial threats leveraging IEEE 802.15.42006 security. 6.3 WirelessHART[10][11][12] WirelessHART (WiHART) is an open-standard wireless networking technology developed by HART Communication Foundation. The protocol utilizes a time synchronized, self-organizing, and self-healing mesh architecture and supports operation in the 2.4 GHz ISM Band using IEEE 802.15.4 standard radios. Page 9
Developed as a multi-vendor, interoperable wireless standard, WirelessHART was defined specifically for the requirements of Process field device networks. The standard was initiated in early 2004 and developed by 37 HART Communications Foundation (HCF) companies that included ABB, Endress+Hauser, Emerson, P+F, Siemens and others. The underlying wireless technology is based on the pioneering work of Dust Networks, and the company's TSMP technology is considered a foundational building block of the WiHART standard. WirelessHART was approved by a vote of the 210 member general HCF membership, ratified by the HCF Board of Directors, and introduced to the market in September 2007. WirelessHART - How it works[11] WirelessHART (WiHART) is a wireless mesh network communications protocol for process automation applications. It adds wireless capabilities to the HART Protocol while maintaining compatibility with existing HART devices, commands, and tools. Each WirelessHART network includes three main elements: 1. Wireless
field
devices
connected to process or plant equipment. This device could be a device with WiHART built in or an existing installed HART-enabled device with a WiHART adapter attached to it. 2. Gateways
enable
communication between these devices and host applications connected
to
a
high-speed
backbone or other existing plant communications network. 3. A
Network
Manager
is
responsible for configuring the network,
Figure 6.4-Architecture of WirelessHART Standard[11]
scheduling communications between devices, managing message routes, and monitoring network health. The Network Manager can be integrated into the gateway, host application, or process automation controller. The network uses IEEE 802.15.4 compatible radios operating in the 2.4GHz Industrial, Scientific, and Medical radio band. The radios employ direct-sequence spread spectrum technology and channel hopping for communication security and reliability, as well as TDMA synchronized, latency-controlled communications between devices on the network. This technology has been proven in field trials and real plant installations across a broad range of process control industries. Each device in the mesh network can serve as a router for messages from other devices. In other words, a device doesn't have to communicate directly to a gateway, but just forward its message to the next closest device. This extends the range of the network and provides redundant communication routes to increase reliability. Page 10
6.4 COMMERCIALLY AVAILABLE WIRELESS NETWORKS FOR INDUSTRIAL AUTOMATION 6.4.1. Honeywell’s OneWireless Network[13][14] Multi-Level Network Topology Honeywell has utilized ethernet technology for business applications and process control applications, manufacturing facilities protect their network from external and internal threats using a multi-layered approach by dividing the overall architecture into three segregated networks: 1. The Business Information Network, also referred to as the Level 4 network in the Purdue Model of Process Control, supports traditional administrative functions such as human
resources,
accounting
and
procurement. 2. The Control-Level Network, also referred to as the Level 2 and Level 3 network, connects control and monitoring devices including controllers,
I/O
racks,
human-machine
interfaces, plant historians and advanced control applications. Figure 6.5 Typical architecture of Honeywell OneWireless Network System[13][14]
3. The Device-Level Network, also referred to as the Level 1 and Level 0 network, links the plant floor’s I/O devices, such as sensors (such as transducers and flow meters) and other automation equipment. At each segregated network, switches connect the various devices associated to the same level network. A single interconnection is used to securely exchange information between these networks as illustrated in Figure 1. The suggested topology is to have two segregated wireless networks, one for business-level applications and one for the process control application. The process control network and business network are connected to each other through the wired network which is air-gapped. In this topology, the process control wireless network supports both control-level applications as well as device-level applications, capable of communicating with wireless transmitters and Wi-Fi devices. The process control wireless network is basically an extension of the process control network. The topology will rely on W-VLAN technology to create a logical network for L2 and L3 applications such as L2-based HMI process displays and L3 electronic operator round applications. These single interconnections are composed of a firewall and a router; and quite often the firewall and router are two different hardware devices. A single interconnection improves the network security by allowing IT managers to monitor a single connection for security threats. It also eliminates a hacker’s ability to address systems not intended to be externally addressable. This security model of isolating networks is also referred to as the ‘air gap model’. Should either network have an issue, the networks may be quickly disconnected to preventing either network from impacting the other, thus creating the air-gap.
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Technical Specifications: Network Architecture: 1. Integrated multi-functional 802.11 mesh network supporting handheld and field sensor devices, including wireless transmitters, PDA, Mobile HMI, real-time location applications and other 3rd-party devices 2. Control ready with built-in redundancy and managed message routes Network Security Management: End-to-end security: WPA2, AES-based, device authentication, FIPS 140-2 based encryption Network Communications: 1. Frequency hopping spread spectrum 2. Built-in sensor redundancy for assured communication 3. Integrated 802.11 high-speed, self-organizing mesh network 4. Class 1, Div 2 for general plant deployment 5. Full performance, flexible channel allocation for plant wireless governance 6. Up to 6 miles (10 km) multinode to multinode communication(with optional antennas); sensor to multinode designed for over 2,000 ft (0.6 km) 7. Built-in read-write messaging for configuration and priority alarms - optimized performance for all functionality 8. Radio receivers with high selectivity for co-existence 9. Protocol tolerant to missing packets with automatic repeat requests 10. Multi-speed monitoring – 1 second reporting with latency control and the ability to configure sensors on the same network at different rates Network Protocols: 1. 2.4 GHz-based for use in facilities worldwide 2. Open protocol - connects to any system Network Sizing: 1. Minimum: One sensor 2. For control or high-speed sensing: Up to 1,000 sensors per network (@ 1 sec updates) 3. For general purpose sensing: - Up to 10K sensors/network (@10 sec updates) - Up to 30K sensors/network (@30 sec updates) 4. For other applications: 54Mbps max mesh link speed (9Mbps effective throughput) 5. For other applications: 54Mbps max mesh Figure 6.6(a) Wireless Mobile HMI for mobile process monitoring[13][14]
link speed (9Mbps effective throughput)
(b) IntelaTrac PKS based PDA for automated field data collection over wireless network[15]
Sensor Power Management: Self-contained and predictable power management designed for 10-year sensor battery life (rain or shine) Page 12
6.4.2. Emerson’s SmartWireless Plant Solution[16]
Figure 6.7 & Figure 6.8 Typical architectures Source: Emerson Process Management[16]
Standard Specifications (Table 6.1)[16] ATTRIBUTE
DESCRIPTION
Radio Standard
IEEE 802.15.4-2006 @ 250 kbps
Frequency Band
2.4 GHz
Frequency Management
Frequency hopping on a per packet basis
Power
Battery Powered-1 to 10 years depending on implementation
Topologies
Mesh, Star or combined Star & Mesh
No. of devices
Limit not specified. No. devices depends on application requirements and any gateway constraints
Based
on
Industrial HART – IEC 61158, EDDL–IEC 61804-3, Radio & MAC-IEEE 802.15.4-2006
Standards Burst Rate
Adjustable rate – 8 seconds to 1 hour
Key security features: 1. RF security: Detects and avoids 802.11i RF interference, controls unwanted signal propagation. 2. WLAN intrusion prevention & location: Detects and locates rogue access points or field devices 3. Network Access Control (NAC): Enforces policies pertaining to access point configuration and behaviour to help ensure that only recognized sensors can gain access to the network. 4. Secure mobility: Maintains the highest level of security in mobile environments with Cisco Proactive Key Caching, an extension to the 802.11i standard and precursor to the 802.11r standard. 5. Certificates: Use of X.509 certificates and AES encryption for LWAPP transactions. Page 13
6. In addition, identity-based networking enables individualized security policies for sensors with different access rights, device formats, and application requirements. Physical strength: Ruggedized enclosures that protect against harsh industrial conditions as well as rain, lightning, wind, and vibration from storms or road traffic. Well-designed wireless mesh architecture transparently adapts to changing environments, allowing long-term operation with little or no maintenance. This technology is able to provide extremely high reliability and predictability for up to years at a time, without constant tuning by technicians. Benefits: (i) Low Installation Cost - Up to 90% savings in installation cost per measurement. (ii) Easy Installation-Smart Wireless field network devices are easy Figure 6.9 Cost savings claimed by Emerson[16]
and painless to install, and quickly deployable.
(iii) No Site Surveys - Emerson’s field network devices are self-organizing, so there’s no need for a site survey no matter how dense or obstructed the area is. (iv) Start Anywhere - The Smart Wireless approach gives you the freedom to choose your path. You can have as much or as little as you want, where you want. 6.4.3 Architecture of Process Plant Post Wireless Technology Deployment Typical architecture resulted post deployment of wireless technology in an offshore oil plant is shown below in form of conceptual photographic image (Figure 6.10) and diagram form (Figure 6.11) for better understanding.
Figure 6.10 Conceptual Photographic architecture post wireless technology deployment
Different areas of application of wireless technology are identified clearly and shown precisely with names of wireless technology implemented in that area. Page 14
Figure 6.11 Typical architecture diagram illustrating wireless technology deployment[17]
7. CASE STUDIES OF APPLICATIONS OF WIRELESS TECHNOLOGIES IN OIL & GAS SECTOR INDUSTRIES
7.1 Classification
Industrial Applications of Wireless Technologies
(A) Process Monitoring Application s
(B) Asset Management Applications
(C) Applications for meeting regulatory requirements
(D) Safety, Health & Environment Applications
(E) Productivity Enhancement Applications
(F) Plant Management Applications
This is just a broad classification of most widely observed wireless technology applications in industry. However, it is to be noted here that the use of this technology in industrial applications is not limited to this list and keeps growing at rapid pace in novel areas.
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Table 7.1: Classification chart and Comprehensive chart summarizing industrial applications of wireless technologies[18]
7.2 Process monitoring applications 7.2.1
Improvement in data collection, process monitoring, analysis[19][20] Lyondell Chemical Company is one of the world’s largest chemical companies, with approximately $18 billion in assets. Lyondell is a global manufacturer of basic chemicals and derivatives, including ethylene, propylene, propylene oxide, titanium dioxide, styrene, polyethylene and acetyls. It also is a refiner of heavy, high-sulphur crude oil and a significant producer of gasoline-blending components. With headquarters in Houston, Texas, Lyondell operates on five continents and employs approximately 11,000 people worldwide. Lyondell Chemical Company provided field operators at its Texas olefins plant with the most updated information to efficiently track and integrate valuable field data enabling them to make smart, proactive business decisions. Lyondell implemented Honeywell’s wireless IntelaTrac PKS system for field data collection and intelligent asset management, enabling its users to integrate field data with data from multiple sources, including production, process control and work Page 16
management systems. Field operators were armed with tools for the accurate capture, collection and use of time-critical data through the use of ruggedized computers, RFID tags and other peripheral devices, such as temperature guns, vibration probes and NDT testing devices. Relying on this system and intelligent asset management software, the following benefits are realized: i. Improved process condition monitoring using non-DCS instrumented data ii. Field operations support when and where needed iii. Product guidance available through mobile data tracking iv. Integrated field data with data from multiple sources, including production and process control, for more proactive decision making v. Improved and maintained integrity of data downloaded in the field vi. Captured time-critical field data and time/date-stamped for improved accuracy Tata Chemicals Limited is India’s leading manufacturer of inorganic chemicals, fertilizers and food additives. Incorporated in 1939, the company has an annual turnover of over Rs 5,800 crore and is part of the $28.8 billion Tata Group, India’s foremost business conglomerate, operates one of the largest and most integrated inorganic chemicals complexes at Mithapur, Gujarat, India and produces for main product groups: soda ash, chloro-caustic group, marine chemicals and salt, and cement. Tata was experiencing problems accessing data in the cement plant control room. In addition to data problems, maintenance and troubleshooting of the signal were challenging. Tata implemented Honeywell’s OneWireless™ solution to overcome these issues. Since implementing OneWireless, Tata can now reliably tap transmitter signals from remote locations and bypass the entire looping of signals. The company has gained improved data accessibility and reliability, and has cut the costs of expensive instrumentation cables. Other benefits include: i. Improved safety and compliance ii. Decreased installation, operational and maintenance costs iii. Control network can securely access remote locations iv. Increased reliability and improved production efficiency through more accurate data enabling better decision making v. Reduced maintenance requirements compared to wired transmitter alternative 7.2.2
Improved Monitoring Gas Transmission Pipeline System[21] Along with gas and electricity supply to the Irish market, Bord Gáis, the state owned energy provider is also responsible for the maintenance and upkeep of the countries natural gas distribution network. As part of the pipeline renewal program, a remote Above Ground Installation (AGI) located at Middleton, near Cork, was to undergo an upgrade of its hard wired instrumentation that are usually installed in ducting to protect them from the environment and from external damage. The site has an added challenge in that it is divided by a public road, requiring additional trenches to bury the cables. Although there is minimal traffic on the road dissecting the site, it was felt that a line of sight wireless solution could not be used as the signal may be interrupted by passing cars affecting the Figure 7.1 Site location Photograph [21]
reliability of the communication.
Rosemount® wireless transmitters, including five measuring pressure, one differential pressure, and one temperature have been installed and are sending measurements back to the control room via the onsite Remote Terminal Unit (RTU). Page 17
For the upgrade at Middleton, Emerson’s Smart Wireless plant network promised to cost less than a traditional wired installation, offered faster installation and start up, and easy Modbus integration into the existing RTUs. The Smart Wireless devices have redundant communication to the RTU via two or three routes thereby overcoming the problem of signal interference by cars. Following benefits are realized: i. Redundant wireless network ensures data integrity despite the site being divided by a public road. ii.
Cable integrity issues in Ex areas removed thereby reducing the number of site inspections required. Figure 7.2 Installation Photograph[21]
7.3 Asset management applications 7.3.1
Wirelessly Measuring the Compressor Motor Bearing Temperature in an Alki-Unit[22] A refining customer suspected that past compressor failures were due to failing bearings. The cost of compressor failure and replacement is estimated at over $1 million per unit. The most accurate way to confirm the problem would be to monitor the bearing temperature. By monitoring bearing temperature, the customer could predict failure and potentially prevent it by implementing a preventive maintenance program. Because hazardous gases are present near the compressor unit, the application must be treated as explosive, and wiring between the compressor and the control room must meet Class I, Div 1 spec. This makes the wiring costs extremely high and the time needed to wire the transmitters quite lengthy. The cost to hardwiring the 32 transmitters required to monitor the critical temperatures soon became prohibitive. Honeywell XYR 5000 wireless transmitters were the obvious solution. They eliminated nearly $100,000 in wiring costs and enabled the customer to bring the critical temperature information into the existing DCS system for monitoring and alarming. This system provides the field data needed at a fraction of what a hard-wired solution would cost. The installation and commissioning time was also greatly reduced. The following benefits are realized: i. Reduce installation, maintenance and operating costs ii. Improve product quality iii. Meet regulatory requirements iv. Ensure high uptime v. Enhance flexibility
7.3.2
Improved Wellhead and Heat Exchanger Monitoring on Offshore Platform[23] Successfully application of wireless self-organizing mesh field network to monitor wellhead annular pressure and heat exchanger pressures on the Grane offshore platform, operated by StatoilHydro, stationed in the Norwegian Sea off the coast of Bergen, Norway is used to remotely monitor wellhead and heat exchanger in harsh, difficult to reach areas. The wellhead area is crowded with metal pipe work, metal walkways above and below, together with other metal obstructions resulting in inaccessible location to reach.
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Figure 7.3: (a) Site location photograph (b) Installation photograph[23]
The benefits realized are i. Wireless technology delivered 100% reliability and stability in the crowded metal wellhead environment ii. Easy integration of wireless data even into third party system iii. Customer identified operational improvements as a result of increased process visibility iv. Eliminated the need for daily visits to the wellhead to manually record gauge readings v. Continuous monitoring enables unusual readings to be identified earlier 7.4 Applications for maintenance of regulatory requirements 7.4.1
Improvement in smoke detection and communication-reporting[24] Headquartered in Columbus, Ohio, Hexion Specialty Chemicals is the global leader in thermoset resins. Hexion serves the global wood and industrial markets through a broad range of thermoset technologies, specialty products and technical support for customers in a diverse range of applications and industries. As the world’s largest producer of binder, adhesive, coating and ink resins for industrial applications, the company employs more than 7,000 people globally, has 126 production facilities and distribution channels in 25 countries. At its production site in Pernis, Netherlands, which was acquired from Shell, Hexion faced dealing with a legacy communication, reporting and Figure 7.4 Site location Photograph [24]
smoke detection system. Hexion has three warehouses onsite that must
meet safety requirements such as fast smoke detection for the storage of certain chemicals. Hexion selected Honeywell’s XYR 5000™ wireless transmitters to improve reporting, meet regulatory requirements and enable real-time detection in case of any incidents. The following benefits resulted: i. Wireless transmitters installed at less than one-third of the estimated costs of the project ii. Reliable, immediate and accurate data helped meet and maintain regulatory requirements iii. Easy access to multiple warehouse data and improved reporting and communication to central control room for improved safety and performance Page 19
iv. Reduced operational and maintenance costs 7.4.2
Cost Effective Leak Detection and Repair Monitoring of Fugitive Emissions[25] Finding hazardous leaks and fugitive emissions in a refinery or chemical plant is a huge but critical job to ensure regulatory compliance, safety, and to prevent costly fines. Each plant can have over 35,000 valves and as many as 200,000 monitoring points. Both refineries and chemical plants have seen the cost of their Lead Detection And Repair (LDAR) Programs skyrocket as the number of monitoring points has increased. With ever increasing labour costs, an increasing number of points to monitor and the high cost of wiring in hazardous locations, the traditional wired methods quickly become cost prohibitive and expose the plant to potential violations. At a minimum of $40/foot for most hazardous areas, the cost of wiring can quickly exceed $30,000 for a 750 foot run per monitored point. Most plants need to monitor multiple points and these costs become prohibitive. In many places, periodic inspection is simply not enough but it may be cost prohibitive to run the necessary wiring. Battery powered industrial wireless solutions enable monitoring of potential leak points and emissions without the cost of wiring or the vulnerability of manual and handheld methods. These instruments brings these measured data points into the control room enabling customers to make knowledgeable real-time decisions with information at a fraction of the cost of handheld or wired solutions. This provides the security of knowing leak points are monitored on continual basis to ensure regulatory compliance and safety while eliminating costly violations and fines. Such a solution enables real-time leak detection monitoring while also providing the following benefits: i. Maximize the number of points monitored for less than the cost of one wired solution ii. Bring all points back to a central location for real time monitoring and action iii. Eliminate potential violations and fines iv. Increase plant safety
7.5 Safety & Security applications 7.5.1
Wireless Video System Improves Plant Safety and Security[26] The OneWireless multi-functional network supports closed-circuit television (CCTV) cameras in areas that previously could not be justified financially. When used to manage and perform remote operations, this scalable, wireless digital closed-circuit television solution allows you to maximize value, performance, and lifecycle ownership. Reinforce Process Monitoring Eliminating the need for coaxial or CAT5e cables and providing unmatched camera portability, cameras can monitor flares, remote unmanned locations and other areas of the process unit. The wireless CCTV data feeds into the Experion system through Honeywell’s Digital Video Manager (DVM), enabling plant operators to view the status of key equipments directly from their consoles. The system includes event and alarm-activated recording features that allow the site to capture only the needed footage when most required. Footage can be viewed real time and historically. For a better overall picture of the incident, recordings can be programmed to provide images leading up to and following an incident. Reinforce Plant Security Wireless CCTV is a cost effective way to improve and re-enforce security at critical infrastructures, such as a petrochemical plant or a gas pipeline. With this solution, the security team doesn’t need to leave their station to replace the tape in a VCR, activate a recording, or search for stored videotape. Through the intuitive interface, the security staff can control individual cameras’ Pan, Tilt, Zoom Page 20
(PTZ) functions, enter recording commands, and simultaneously view high-quality live images and record and play stored video from a single camera Digital Video Manager DVM is a scalable, digital, closed circuit TV surveillance system that is tightly integrated with Honeywell’s Experion PKS as well as its integrated security system, Enterprise Building Integrator (EBI). DVM allows operators and security staff to view remote locations without the need for separate monitors. In the case of a safety type application, operators, using the camera controls, can visually monitor any part of an entire operational facility.
Figure 7.5 digital video manager: hmi view[26]
7.6 Productivity Enhancement applications 7.6.1 Enhanced Production at Offshore Platforms[27][28]
Figure 7.6: A typical oil platform[27]
Figure 7.7: Where wireless fits on the oil platform[28]
StatoilHydro was occasionally losing flow from the producing wells at its Gullfaks A, B and C platforms, caused by a loss of wellhead pressure. No flow-metering devices are installed so temperature readings are used to detect loss of flow. Typical well fluid is 60° C so the pipe feels warm, but should flow be interrupted the pipe drops back to the ambient temperature. However, the manual readings taken by an operator placing a hand on a pipe were only collected at the start and end of a shift, so flow interruption could easily go undetected for long periods and production would be lost. An automated solution was required but the wellhead was already a very crowded area and for safety reasons the introduction of additional equipment such as new cabling, cable trays and junction boxes was not possible. Metal pipe work, walkways above and below, and many other metal obstructions, added difficulties in obtaining a line of sight necessary for wireless solution. Company initially implemented a pilot installation of Emerson’s Smart Wireless technology on the Gullfaks A, B & C platforms. Rosemount wireless temperature transmitters were installed, providing an indication of flow at forty wells. In contrast with the once-a-shift manual recordings, wireless transmitters now transmit readings back to the existing control system every 30 seconds providing operators with the real time information they need to react quickly to any change in flow. Despite the difficult working environment and the lack of line of sight between the transmitters and the gateway, there were Page 21
no connection problems. The `plug and play’ nature of Smart Wireless made it easy to install and to quickly establish a connection with newly installed devices. Early detection of the loss of flow is enabling operators to rebuild the pressure and quickly start the flow again, improving throughput and significantly increasing production over time. An automated solution is helping to improve safety as the need for personnel to enter this hazardous area is reduced. StatoilHydro has now implemented additional Smart Wireless devices on Platforms A, B and C, bringing the total to 90 wireless transmitters covering all production flow lines at Gullfaks. The resulted benefits are: i.
Automated solution provides flow measurements every 30 seconds
ii.
Early detection of loss of flow now possible
iii.
Improved throughput and over time significant increases in production
iv.
Number of manual measurements in hazardous areas reduced
7.7 Plant Management applications 7.7.1 Wireless Solutions Ensure Accurate Inventory Management in Offsite Tank Farm Locations[29] Most process plants have tanks that hold feedstock or finished products. As an example, a 150Kbbl/day refinery may have more than 50 tanks near the plant. Each of these tanks could be 50 feet wide and 60 feet high, holding approximately 25K bbl of gasoline worth more than $2 million. These tanks may be located from 500 feet to two miles from the process units. Monitoring and controlling the volume of tank liquid is important to ensure data accuracy used for financial statements and for refinery planning and scheduling. Inaccurate measurements may result in suboptimal capacity usage, accounting errors and even environmental incidents through spills. The traditional work practice of monitoring tank inventory levels involves two operators, one in the field and one in the control room. The field operator takes the reading from a tank level gauge and tells the control room operator to start/stop the pumps. This practice is expensive, resulting in hundreds of thousands of dollars every year. In addition, it exposes the field operator to hazards, including falls and hydrocarbon vapours. Tank Farm Automation Due to the costs and risks mentioned above, a plant would chose to automate the tank farm processes. They may need to integrate the tank level information and the tank farm pump data with a central control room. The Honeywell Enraf SmartRadar series offers the perfect solution for measuring tank level, delivering contact free measurement without moving parts. The accuracy of the Enraf 976 IS SmartRadar gauge under reference conditions is 3 mm over the entire measuring range (over 95 feet). Overall, the device provides a wide operating range of -40ºC to 80ºC and is certified intrinsically safe for use in Class 1 Div 1 areas. In this 50 tank example, the costs of wiring the radar level gauges and pumps could estimate $5 million, including the cost of laying fibre optic cables, and the project could last more than three months to create 5,000 feet of cable trenching. Using proven measurement with a wireless infrastructure improves business performance while also saving costs. Benefits include: i.
The Honeywell OneWireless network provides a flexible and long range network, while the XYR 6000 transmitters provide reliable and predictable battery life up to 10 years.
ii.
Figure 7.8 Installation Plan [29]
Reliable and secure performance using Frequency Hopping Spread Spectrum (FHSS).
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iii.
A network that is scalable up to 30,000 nodes and capable of supporting multiple applications like wireless worker and location system applications.
iv.
Reliable network that provides redundancy both at the field instrumentation and backbone level.
v.
The OneWireless multi-functional network provides one infrastructure to support multiple applications. With this infrastructure in place, it’s now easy to equip operators with Honeywell’s Mobile Station to provide access to critical process information, historical data, graphics and other key field functions. In addition, to further enhance safety, it’s easy to add gas detectors and CCTV over that same efficient network.
8. CONCLUSION Previously, wireless solutions were not viable for offshore monitoring for many reasons. (a) The technology was still emerging and security was variable at best. Standards were incomplete or were often in conflict with one another, and wireless frequencies and communications protocols clashed as well. (b) There was also general concern that wireless communications were not yet robust enough for industrial strength communications and there was no clear migration path and comprehensive technical support. Hence, due to so much uncertainty surrounded, this emerging technology was not a preferred choice for years. Today, much has changed. Advances in safety, security, affordability, and maintainability within the constraints of frequency allocation now enable organizations to take full advantage of wireless technology for challenging industrial environments. Yet, optimizing every facet of the communication protocols is therefore vital and imperative. Novel distributed signal processing algorithms, energy-efficient medium access control and fault-tolerant routing protocols, selforganizing and self-healing sensor network mechanisms, etc. have contributed immensely in growth of WSN. Recent developments like ISA100 and WirelessHART standards provided exceptional boost to this novel technology. In terms of user’s perspective, now significant paradigm shift can be observed from traditional wired technologies to upcoming wireless technologies, very well endorsed by rise in demand for wireless networks in recent time. 9. FUTURE SCOPE The list of major issues and challenges given below suggests the future scope of work to be done, however not limited to, in the area.
9.1 Major Issues 1. Energy Concerns
2. Security Problems
2. Latency Concerns
4. Interference, Environment, Coexistence and Building Material
5. Network Organization and Coverage Problems
3. Compatibility
6. Cost
9.2 Major Challenges The following are the challenges that emerge in path of successful deployments of wireless technologies for industrial applications: 1. Design level challenges: (i) Simple, flexible programming abstraction, (ii) Power and bandwidth efficient distributed signal processing, (iii) Robustness to sensor device failures Page 23
2. Installation level challenges: (i) Selection of most suitable technology for given industrial application, (ii) Optimal placement of wireless devices, (iii) Reach to inaccessible, hard-to-reach, unaffordable parameters of a plant, (iv) Latency, (v) Clock Synchronization, (vi) User-Friendly Deployment 3. Configuration level challenges: (i) PID Tuning in a Networked Control System (NCS) is still a challenge; the challenge gets amplified when the Wireless Networked Control System (WNCS) is employed. (ii) Enhanced data collection, expansion of security perimeters and to bring the plant to a new level of efficiency and productivity, keeping minimum “wake up” time for nodes. (iii) Network organization must be self-organizing and self-healing, minimizing maintenance costs and ensures consistent availability of information. (iv) In case of jamming, network must automatically find most optimal alternative path for data traffic. 4. Maintenance level challenges: (i) Maximize network lifetime, (ii) Redundancy, (iii) Openness at tools level and interoperability-interchangeability 5. Other challenges: (i) Highly skilled manpower requirement at all levels, (ii) Overall Cost and affordability, Payback periods of investment. 10. ACKNOWLEDGEMENTS The author stays indebted and grateful to his Guide Prof. (Dr.) H.K. Verma, Professor & Group Head (M&I), Electrical Engineering Department, Indian Institute of Technology Roorkee, Roorkee 247 667, Uttarakhand, India, for his valuable guidance and help and thankfully acknowledge his kindness extended by sharing his knowledge and experiences. 11. REFERENCES [1] ARC
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