Report on Installed Wireless Technology

Introduction: As a pioneer in the todays implementer of future technology, ONGC Uran took the initiative to implement wireless based system for acquiring process data so as to have confidence in the latest technology and harness maximum benefit out of it. After overcoming the initial challenges we could successfully implement wireless based solution and integrate it with our Honeywell based DCS.

Drivers : Congestion at the existing control room making it difficult to bring additional critical process data to C/R through the conventional wired approach. Flexibility in collection of various additional process data for monitoring & analysis. Adoption of state-of-technology to leverage maximum benefit out of it and geared for future technology.

The implemented systems details like system architecture, system components etc. are described below.

SYSTEM ARCHITECTURE
OPC Server EST

US

US

FTE

LCN

NIM
Multinode UCN

Gateway

Modbus RTU
Lantronix Gateway

HPM

Standards: As technologies are moving towards more open standards and architectures, Ethernet is slowly becoming the standard by coming at par with the industrial standards like Modbus, Profibus etc. for data

transmission in process industry. But though there are wide ranges of wireless Ethernet implementations on the market, and there is no single globally acceptable wireless Ethernet standard for process industry. Wireless Ethernet solutions typically fall into one of two classes of over-the-air protocols: those based on IEEE 802.11 (usually 802.11b), and those based on proprietary protocols designed specifically for industrial environments. However efforts are on to design robust reliable wireless network standard to benefit all industries. The core of these efforts is the IEEE 802.15.4 standard, which targets low-data rate applications requiring wireless interconnections between measurement, analysis, and control devices. Standards like ZigBee, Wireless HART and ISA 100.11a were designed using the base of IEEE802.15.4. Out of these ISA 100 based standard 11a and its latest ver. 12 is gaining wider acceptance and can soon become the global standard. Implementation Methodology: Initially as a pilot project, it was decided to implement wireless based solution in GSU/EPRU area of the plant. The GSU/EPRU area is being controlled by Honeywell make DCS TDC3000 and the wireless solution thus planed to be integrated with the existing DCS. Wireless technology was considered to be implemented to acquire field data and displayed at Honeywell DCS console. At initial stage only open loop were considered. The implemented architecture is given at Fig below.

As can be seen in the figure the implemented solution has the typical architecture of wireless Ethernet based solution. A typical wireless Ethernet has two parts, the radio interface that enables the wireless link and the wired Ethernet connection. Using a standard IEEE 802.3 interface, the wired side connects to a network or directly to Ethernet-enabled devices. The hardwired port on the wireless Ethernet device must clearly comply with the IEEE 802.3 standard in order assure interoperability among Ethernet devices. The wireless part has two major elements and mentioned as shaded portion in the figure. The elements are wireless sensors/transmitters, and the multinode. The wired part in our case is the Lantronix make gateway that converts the modbus TCP to Modbus over serial RS232C for legacy system interface i.e the DCS TDC3000. An array point and Modbus registers are configured in the DCS to display the real time data received from the wireless transmitters. The main Gateway in the shaded part of the figure acts as interface between wireless and wired architecture. The role of each of these elements is described below.

Wireless Sensor/Transmitter: Wireless Transmitters are equipped with both Sensor to measure the process parameter and a radio to communicate the information. Some Wireless Devices (in case of Emerson) also serves as routers for other devices. They identify the network, join it and self organize the Communication with nearby Multinode or a series of Multinode creating a MESH structure. These wireless field devices pass the information to the System Gateway through Multinode. Transmitter power

is supplied by two D size lithium batteries with an expected lifetime of up to 5-6 years. Transmitter range with the integral antenna is 1000 (305 m) under ideal conditions (clear sight distance). The field devices may be AI, DI or DO type. These wireless transmitters meet Regulatory Requirements, help to access which are remote, help to monitor real time basis which were earlier monitored manually, help to access where power is not available and help to monitor which require frequent configuration. Success on the closed control loop using wireless technology is yet to be established.

Multinode: An industrial access point capable of communicating with Wi-Fi devices and ISA100 Ready wireless field I/O. It sends process data received from battery-powered wireless transmitters to control applications via Modbus, OPC or HART while allowing a mobile workforce to access process and maintenance data in real-time from their mobile devices. The multinode is preconfigured with three radios: two radios compliant with IEEE 802.11a/b/g and one for wireless transmitters (Frequency Hopping Spread Spectrum radio or ISA100-ready IEEE 802.15.4 based radio) and features two Ethernet cables for optional connection. The device can be installed with omni-directional, parabolic antennas and yagi antennas. Each multinode can be configured either as a Wireless System Gateway (WSG) in which the multinode acts as a gateway connecting field devices to the wired control system; or as a Multinode an access point that transmits, receives and routes data between wireless field devices and the system gateway. Each multinode accepts signals from up to 20 wireless transmitters reporting at 1second, and up to 400 transmitters reporting at slower rates.

Wireless System Gateway (WSG): A multimode configured to connect wireless field devices to the wired control system. The WSG receives process information from the multinodes & nearby transmitters

and sends the data via modbus over TCP or TCP/IP over Ethernet to the wired network. We have used the Modbus over TCP to interface with the DCS as the DCS doesnt have facility of open connectivity. Up to 20 multinodes can be implemented in the same infrastructure.

Lantronix Gateway: Gateway of Lantronix make was used to convert Modbus over TCP signal to

Serial/RS232C over TCP so as to connect to the Serial Interface of the DCS TDC3000. One-Wireless Server: - A PC-based server which hosts the Wireless Server tools used to configure and monitor all wireless field devices, i.e. wireless field I/Os and multinodes, Lantronix /Switch etc. The server also support advanced Security strategies such as Message Authentication, Verification & Key Management. Security keys generated by the server are fed into all wireless devices i.e multinodes, gateways & transmitters etc. for secured data communication. The generation and feeding of keys is one time affair and in the event of any changes new key is generated and fed into the respective devices. Without proper authentication through the key, the devices dont communicate to ensure secure data transfer. Challenges Faced: This being a new technology and first time installation at Uran Plant using wireless for real time data acquisition we faced multiple problems for successful installation and commissioning. Two of the major challenges faced and the way they are overcome are discussed below. Due to the difficult topography ( different level of elevations) of the plant there were lot of RF fading and we were not getting proper signal at the multimode, installed on the roof of control room, although the distance was well within 300mtrs. Then we were forced to go for another multimode with high gain antenna to enhance the signal strength and had wider coverage. The gateway and the multimode with high gain antenna were relocated to have proper signal strength from the remotest point of data acquisition. The gateway was so located (on the pipe rack outside of control room) that the multimode can be shifted suitably to different location for acquiring data from different location for different analysis.

Though we could successfully get the data from the wireless field transmitters in the wireless server we were facing lot of difficulties in getting the data in to the DCS Honeywell TDC 3000, as it doesnt support Ethernet connectivity. Then it was planned to interface through a gateway that convert Modbus over TCP to Modbus over serial. Lantronix make gateway was chosen for this purpose. The multimode/gateway was configured to transmit at Modbus over TCP protocol and Lantronix gateway was also properly configured for conversion to RS232 serial format so that it can be interfaced at SI interface of the DCS. An array point was configured in the DCS to capture the Modbus data coming over RS232C at its SI interface. Study carried out: The signal strength from CFU-II plant, C2C3 cooling water, C2C3 Air compressor house, Lean Gas compressor shed, C2C3 sphere areas had been carried out. It had been observed that for every locations additional installation of one or two multimode must be required to receive proper signal strength at control room Wireless System Gate Way. Disruption of communication between field devices and control room system gateway has also been observed during monsoon period resulting in loss of data. Each multimode installation requires separate 110VDAC ups voltage supply from control room thus increases the cost for data communication from each area defeating its inherent advantage.

Multinode on the C1201

Conclusion The decision to implement wireless based solutions for process control applications is a strategic one and varies depending upon the requirements. Mainly due to topographical problem, the clear sight distance is not available. Disturbance of wireless communication from field to control room during rainy season is not clear and remained unexplained. Trouble shooting on re-establishing the network requires more expertise, even from OEM also. Moreover, the different make wireless transmitter are not compatible with each other. S K Mandal