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Wireless Instrumentation in the Pharmaceutical Industry

Wireless Instrumentation in the Pharmaceutical Industry. Andy Wallace Smart Wireless ® Solutions Product Manager UK & Ireland. Agenda. Intro to wireless networks Star, Star Mesh and Mesh Network topologies Simplified overview of Mesh Networks & TSMP

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Wireless Instrumentation in the Pharmaceutical Industry

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  1. Wireless Instrumentation in the Pharmaceutical Industry Andy Wallace Smart Wireless® Solutions Product Manager UK & Ireland

  2. Agenda • Intro to wireless networks • Star, Star Mesh and Mesh Network topologies • Simplified overview of Mesh Networks & TSMP • Case study for reliability and redundancy • Application of wireless in a 4 storey pharma building • Unlocking the ‘Hidden Plant’

  3. Wireless Sensor Networks

  4. Operating Frequency 2.4Ghz • License-free but regulated frequency band • Shares ‘space’ with many other wireless devices in that spectrum for example • Bluetooth • Radios • Cordless Phones • WiFi • IEEE 802.15.4 – 16 channels • (Home wifi is 802.11) • The key is • Ensuring ‘your’ message gets through

  5. Wireless Network - Must Haves • Reliability • Path Stability • Better than 99.9999% • Security • Avoid fake and random attacks • Low Power • Only operate when needed – preserve battery life • Scalable • Capable of expansion without architecture changes • Flexible • Bandwidth Control - speed • Power Control – limit number of jumps • Channel Control – blacklisting if necessary • Latency Control

  6. Challenges for Wireless Networks • RF environments are dynamic – they change • RF mirroring from infrastructure • Doors opening/closing • Portable plant • Change over time; people, weather, temp structures • A link that is strong today may be weak tomorrow or even the same day! • Three major failure modes: • Interference from other ‘wireless’ devices • Changes in the physical environment that block communication links • Loss of individual network nodes in some topologies

  7. Star Networks Central base-station communicates directly to sensor nodes - Generally mains powered. All routes are ‘linear’ where each node only has one possible communication path – good distances The failure of an individual link means that information is lost.  Generally requires site surveys and link-level configuration.  Each node must be positioned correctly and each point-to-point link tuned for maximum reliability.

  8. Star Mesh (Cluster Tree) Star-mesh networks have redundant routing at the core (blue) and star routing at the edge – typically with mains powered routing nodes and optionally battery-powered end nodes.  Does not allow for true end-to-end redundancy nor do they eliminate the installation challenges of star networks.

  9. Mesh Networks Full-mesh networks provide fully redundant routing to the edge of the network.  Increased reliability, easy network installation and long-term predictability Every device has the same routing capabilities.  Lower power consumption True self-organising and self-healing without constraints imposed by device type and architecture Easy network expansion

  10. Self Organising Mesh Networks WirelessHART Networks

  11. Modbus, Ethernet, WiFi, OPC, ToHost In-Plant Smart Wireless® Solutions are Easy to Install, Use and Are Reliable! Self Organising! Self Healing! Gateway ‘grooms’ network for speed and loading

  12. Together We Deliver Complete, Best-in-Class Wireless Solutions for the Process Industries • Cisco Unified Wireless Architecture • Industrial-class Mesh IEEE 802.11 Access Points • Wireless Control System for centralized network and security management • Plant applications include video, voice, mobility, tracking • Leverage Cisco’s extensive partner network • Customer chooses preferred partner

  13. Your Smart Wireless Opportunities Are without Limits…

  14. The Device Join Process Has Almost Zero User Interaction ------ Simple • Put JOINkey into the WirelessHART Field Device (WFD) using standard tools (375, AMS, etc.) • Listen to neighbours • Connect to a neighbour using JOIN key to authenticate • Neighbour uses NETWORK key to pass message up to gateway • Gateway determines optimised schedule • Schedule is flooded to the devices

  15. Developing Neighbours • Typically 2 Parents • 3 Children – Load Balanced • Many Neighbours (identified redundant paths) N N C P C P C N N

  16. Mesh Networks offers scalability….. Animation courtesy of Dust Networks

  17. Customer Site: Devices Scattered Throughout the Process Facility With No Direct Line of Sight • High Data Reliability • 99.75 to 100.00% • Readings every 10 seconds • Data Latency Varies • 0.66 to 6.22 seconds • 3.22 seconds Average • “Device Hop Depth” • Demonstrated capability of up to 9 hops for at least 256 unique paths back to the gateway

  18. Expansion is Simple: Added Online Devices to the Network also Increases Network Reliability • High Data Reliability • 100.00% • Readings every 10 seconds • Data Latency Varies • 0.82 to 5.20 seconds • 2.44 seconds average • “Device Hop Depth” • Demonstrated capability of up to 12 hops for at least 4096 unique paths back to the gateway

  19. Self-organizing Wireless Network in a Process Building Major Pharmaceuticals MfrFour-story pilot lab

  20. Customers Are Solving Real Plant Problems:Major Life Sciences Company • Application: Moving platform/skid measurements • Eliminate need to continually re-configure process systems for instruments that move with portable process skids • Pumps, filtration, milling, CIP/SIP packages • Startup and installation of all devices was completed in < 8 hrs • Initial trials achieved 100% reliability throughout 12” reinforced concrete building with five floors • Moving platforms never had a measurement drop off the system • Platform brought in from another storage building joined network withoutoperator assistance

  21. Trial #1: How Many Floors from a Single 1420 Wireless Gateway? • Rosemount Model 1420 Wireless Gateway mounted on wall outside Third Floor Control Room. • 12 Rosemount Model 648 Wireless Temperature transmitters used to form network. • Devices T1 – 11 placed from First Floor to Roof. • Device T12 held in reserve.

  22. Trial Building: Reinforced concrete construction Built 1993. Main building dimensions: 246’ x 70’ East Wing Process bays/suites: Wide: 24’ w x 27’ d Narrow: 17’ w x 27’ d Other areas: Aisle: 92’ l x 16’ w Mech/Util: 7’ w x 27’ d Trial site from column #5-12: 153’ x 70’ East Wing (column 7-11): 92’ x 70’

  23. Device Placement: T7 in Mech/Util room on floor Suite C-1 Bay D-1 M/U 7 M/U Bay H-1 Bay J-1 Suite K-1 First Floor

  24. Device Placement: No devices on Second Floor Suite C-2 M/U Bay D-2 M/U M/U Bay H-2 M/U Bay J-2 M/U Suite K-2 Second Floor

  25. Device placement (all dimensions are height from floor): 1420 Wireless Gateway (WG) to right of Control Room door on wall - 76” T1 in Mech/Util room on panel - 60” T5 on vessel in Bay D-3 - 30” T2 between vessel and wall in Bay H-3 - 18” T6 on shelf in stairwell - 54” T3 on vessel in Bay H-3 - 18” T8 in Mech/Util room on panel - 60” T4 on mezzanine (“Floor 3-1/2”) in Bay D-3 - 96” T12 on shelf in Aisle - 60” PT and TT (PT-1160 & TT-1160) in Control Room awaiting trial #2: Moving Cart 4 8 Suite C-3 M/U Bay D-3 M/U 5 6 12 WG PT 1 TT 2 M/U Bay H-3 M/U Bay J-3 M/U Suite K-3 Control Room 3 Third Floor

  26. Device Placement: T11 in Mech/Util room on panel - 60” T10 inside roof access door (“Fifth Floor”) on floor T9 on roof; steel roof access door closed Bay C-M Bay D-M M/U M/U 11 10 9 Bay H-M Bay J-M Suite K-M M/U M/U M/U Fourth Floor

  27. 11May07 Test #1: TT-1160 & PT-1160 in Control Room; balance of devices per dwg

  28. Trial #2 – “Moving Cart:” Moving an instrumented platform through a formed network The set-up, 11May07: • “Cart” was a 4’ x 3’ x 9” high castered utility cart with 55-gal drum for mass. PT-1160 (3051S) and TT-1160 (648) on cart at opposite corners. • Model 775 Wireless Upgrade Module (‘thumb”) added to spare 3144P (tag # TT80H280). Device kept in Control Room [process bay/suite area classification is Cl. 1/Div. 1]. • Testing done in stages:2A – No devices moved; Trial #1 set-up used; Cart starts @ position “A” on Third Floor moves to position “B.”2B – All instruments re-positioned to Third Floor. Cart moves from “B” to “C.”

  29. Device placement (dimensions shown are height from floor): WG to right of Control Room door on wall - 76” T1 in Mech/Util room on panel - 60” T5 on vessel in Bay D-3 - 30” T2 between vessel and wall in Bay H-3 - 18” T6 on shelf in stairwell - 54” T3 on vessel in Bay H-3 - 18” T8 in Mech/Util room on panel - 60” T4 on mezzanine (“Floor 3-1/2”) - 96” T12 on shelf in Aisle - 60” PT and TT (PT-1160 & TT-1160) in Control Room awaiting trial #2: Moving Cart 2A B 4 8 Suite C-3 M/U Bay D-3 M/U 5 6 12 WG A PT 1 TT 2 M/U Bay H-3 M/U Bay J-3 M/U Suite K-3 Control Room 3 775 Third Floor PT Cart TT

  30. Device placement (dimensions shown are height from floor) : WG to right of Control Room door on wall - 76” T1 in Mech/Util room on panel - 60” T7 on shelf in Aisle - 60” T2 on vessel in Bay H-3 - 18” T8 on panel in Bay J-3 - 48” T3 on vessel in Bay H-3 - 18” T9 in Mech/Util room on panel - 60” T4 on mezzanine (“Floor 3-1/2”) in Bay D-3 – 108” T10 on vessel in Bay J-3 - 30” T5 on vessel in Bay D-3 - 30” T11 on shelf in Aisle - 60” T6 on mezzanine (“Floor 3-1/2”) in Suite K-3 – 96” T12 on shelf in Aisle - 60” PT and TT (PT-1160 & TT-1160) on Moving Cart 775 is TT80H280 (spare 3144P, no RTDs) 2B B 4 8 Suite C-3 M/U Bay D-3 M/U 5 6 11 12 WG 1 2 M/U Bay H-3 M/U Bay J-3 M/U Suite K-3 9 Control Room 3 775 C 10 Third Floor PT Cart TT

  31. 775 Diagnostics! 1st application was to a 3144P with no RTD installed.

  32. Unleash the hidden Plant

  33. Why Predictive Intelligence? Catch Problems Before They Occur 100% Equipment Health Advanced Warning = time to respond before it causes a shutdown FAILURE 0% Time A digital plant architecture that uses the power of wireless field intelligence to improve plant performance

  34. Equipment and Plant Availability Increased with Vibration Monitoring • Measurements delivered wirelessly through 1420 gateway • Available early 2008 - Trials in progress • Predictive and timely indication of failure trends • Delivers accurate and actionable data more effectively than monthly snapshots • Gives Peakvue and overall vibration readings Send Maintenance ONCE to repair … … Not 20 TIMES to CHECK In-plant equipment or remote, hazardous, or unmanned area

  35. Operating Costs Reduced with High Resolution Online Corrosion Monitoring System detects an increase in the corrosion rate of pipelines, heat exchangers, distillation columns…. • Corrosion related leaks, spills, and accidents are a serious concern in aging infrastructure • Hard-wiring to install online systems is often difficult in mature assets • RCS Microcor Wireless Transmitter (MWT) enables cost effective, near real-time corrosion rate • Emerson partnering with Rohrback Cosasco Systems (RCS) to bring technology to the market • Measurements delivered wirelessly through 1420 gateway or ROC 800 gateway • Available early 2008

  36. 775 Diagnostics! 1st application was to a 3144P with no RTD installed.

  37. Upgrade Installed HART Devices to Redundant Wireless Communications • Connect to already installed transmitters • 2 versions • One for valves • One for other devices • Self contained power • Uses energy from loop wiring • Or encapsulated battery • HART comms pass through • AMS connectivity • IS approval 775 HART Upgrade Module

  38. Self Organizing Networks Will Unlock Stranded Diagnostics in Legacy Plants Wireless upgrade modules will unlock these diagnostics and extend ROI 20 million installed HART devices have underutilized diagnostics because the plant doesn’t support a digital architecture LegacyHost

  39. Thank You Questions

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