CHAPTER 6

Wireless Process Instruments

16.1 Introduction

This chapter will look at smart wireless instrumentation. The chapter will look at installation
procedures, how wireless networks operate and how they are configured to operate in
industrial plants. Furthermore, the chapter will address some of the smart functionality of
wireless instrumentation and how they are used in the self-organizing networks to ensure
data security and functionality. The chapter will also look at this instrumentation and the
ability to generate certain diagnostic information through HART® or Foundation Fieldbus
communication protocols.

6.2 Wireless Instrumentation

What is the wireless communication?

Wireless communications is the transmission of voice and data without cable or wires. In place
of a physical connection, data travels through electromagnetic signals broadcast from sending
facilities to intermediate and end-user devices.

Wireless infrastructure and wireless instrumentation can dramatically affect plant operations
by vastly improving visibility across a plant facility or facilities. These solutions seamlessly
integrate wireless technologies with existing wired networks to provide a complete and open-
standard network. Using wireless technology it will digitally transform the facility with wireless
architecture that is secure, reliable, easy-to-use, and engineered to improve workforce
productivity and plant management [55].

6.2.1 Typical WirelessHART® system components

Wireless solutions for plant operation applications include key components that all work
together to deliver a secure, consistent and reliable wireless infrastructure scalable to fit any
need from a single application through plant-wide implementation. Investing in the
appropriate infrastructure is the foundation for digital transformation success which is the
latest trend in technological advanced to ensure more secure and robust control networks
[55]

WirelessHART® gateways

Emerson wireless gateways are designed for straightforward installation, easily connecting to
existing process technology and legacy host systems. Wireless gateways manage networks
automatically and do not require configuration of communication paths and enabling devices
to be added easily to the network. This scalable technology allows operations to expand and
strengthen their wireless networks in challenging, hazardous and remote process locations,
such as installations without a junction in outdoor locations. A tank farm installation is an
example where this technology is used successfully [55].

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This Wireless Gateway portfolio provides users customizable networks and flexible installation
options when creating a wireless field network to fit the needs of the application and site
requirements including:

 Control the size of the field network

 Select form of data transformation
 Gateway installation method
 Smart antenna location

Figure 145: Different types of Emerson WirelessHART® gateways [55]

Figure 146: Typical Emerson WirelessHART® gateway installation in an industrial plant [55]

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Power Modules

Emerson™ SmartPower™ modules offer versatile power solutions for your Emerson based
WirelessHART® field instrument devices. With up to 10 years of predictable power life,
SmartPower modules are intrinsically safe and robust, allowing for routine maintenance in
hazardous areas. These modules include short circuit protection and keyed connections for
easy and fail-safe replacement.

Figure 147: SmartPower™ module for WirelessHART® instrumentation [55]

Figures 148, 149, 150 and 151 indicates some wireless field instruments and typical
installations on a plant or equipment [55].

Figure 148: Wireless guided wave radar device [55]

Figure 148 is a typical method used to measure tank level, an application particularly well
suited for wireless as connecting a wired device would be difficult due to the hard to access
location [55]

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 Figure 149: Typical wireless flow measurement instruments [55]

Figure 150: Typical wireless instruments [55]

Figure 151: WirelessHART® equipment [55]

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 Figure 152: Emerson Wireless 775 THUM™ Adapter [56]

Emerson Wireless 775 THUM™ Adapter

Make any HART® device wireless with the Emerson Wireless 775 THUM™ Adapter, an adapter
that retrofits onto existing 2-, 3- or 4-wire HART devices, in almost every area, from
intrinsically safe to explosion proof. The THUM Adapter wirelessly transmits HART
measurement and diagnostic information from new or previously inaccessible measurement
points. With the self-organizing WirelessHART® network, multivariable devices can remotely
be managed, monitor device health and gather data with >99% data reliability.

6.2.2 Emerson Smart Wireless solution

Emerson Smart Wireless solution is a self-organizing wireless network, featuring tight

security, infinite configurability and data reliability that rival wired systems. Figure 153
indicates a typical self-organizing wireless network interfaced to a WirelessHART® gateway
and to s specialized WirelessHART® interface card on the control system architecture [55].

The AMS Machinery Manager and the AMS Device Manager are software system tools used to
monitor the diagnostic information received via the WirelessHART ® self-managing networks.
This is part of the asset management solutions utilizing WirelessHART ® technologies [55].

Figure 153: Self-organizing wireless network [53]

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Continuously advancing network analytics allow for centralized monitoring of wireless
networks across industrial facilities. The Plantweb™ Insight Network Management application
offer strategic analysis that enables teams to prioritize maintenance and make informed
decisions fast. Ensure adherence to network best practices with tools such as a network mesh
diagram for a consolidated view of network health and diagnostics to identify issues and areas
for improvements. Figure 152 is an example of the diagnostic information displayed to
monitor the condition of the wireless equipment in the WirelessHART ® networks installed on
the plant or plants [55].

Figure 154: Plantweb™ Insight Network Management application

Process plant plot plans are uploaded to the Emerson’s AMS Wireless SNAP-ON software and
the wireless network is overlaid on these plans. The software check design validity, and
monitor the wireless networks after installation [55].

Figure 156 indicate a typical integrated digital plant utilizing wired and wireless networks. The
control network is where all the different interface cards are connected to the plant equipment.
This can be wired equipment that is physically wired to the field instrumentation via the IO
cards (Analog In, Analog Out, Digital In, Digital Out, Foundation Fieldbus, Profibus, Serial
through Modbus) [55].

The WirelessHART® field network that are interfaced with the WirelessHART ® field devices is
connected to the wireless plant network via the WirelessHART® gateways to the plant control
network. The wireless field network including the self-organizing networks are linked via
gateways to the wireless plant network that consist of the field data backhaul, the safety
mustering, the mobile worker, the process monitoring/physical security and people/asset
tracking applications [55].

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 Figure 155: Plant layout indicating the placement of WirelessHART® equipment [55]

Through a wireless gateway, the wireless plant network either are connected to the plant
network or control network. In the control network the diagnostic information from all the
devices on the different wireless networks are managed by the Asset Management systems
allowing operations and maintenance staff to monitor the health conditions of the various
wireless equipment on the different wireless networks [[55].

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 Figure 156: Digital plant with integrated wired and wireless equipment [55]

Figure 157 indicates a typical Smart WirelessHART® network system that are used for two
different sites. The one is for the onsite plants and the second is for an off shore plant and in
this case off share wells that is located in the sea.

The figure shows the different wireless paths of the wireless signals interfaced to a DeltaV
Wireless redundant I/O card, which is interfaced to the control network on a basic process
control system (BPCS). From the figure, that the data received from the different instruments
through the wireless networks are stored in a historian for retrieval of secure data when
needed for various requirements like maintenance data, production data and many other data
related queries [55].

The different types of WirelessHART® Field Instruments are connected to show the different
connection paths, the different types of instrumentation and the use of the Emerson Wireless
775 THUM™ Adapter to enable non-wireless field devices to be part of the WirelessHART ®
field devices to be part of the wireless in a plant [55].

Figure 157 shows how the smart wireless technology is used to connect different wireless and
wired networks to allow for remote access to remote sites in in this case to wellheads that
sits off site in the sea. Remote access is also possible through satellite communication to
these sites through the WirelessHART® technologies, which is secure and reliable. With the
need for more secure data, wireless networks provide for this secure data transfer, which also
add to the reliability of plants in these environments [55].

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 Figure 157: Smart wireless network over two sites [55]

Figure 158: Different wireless communication networks [55]

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6.2.3 WirelessHART®

WirelessHART® combines HART technology with wireless capabilities to create an adaptable

wireless communications protocol for process automation applications. Designed as a self-
healing, mesh technology that ensures 99.99% data reliability, this protocol enables
communication between devices, eliminating the need for direct device communication to the
gateway. Unlike other protocols, WirelessHART® offers simple installation and robust, layered
security to ensure network protection [56].

IEC62591 WirelessHART® Field Instruments

IEC 62591:2016 specifies a wireless communication network in addition to the Type 20 in

IEC 61158-3-20, IEC 61158-4-20, IEC 61158-5-20, IEC 61158-6-20 and a Communication
Profile CP 9/2 in addition to IEC 61784-1, CPF 9.

It specifies the following:

- Physical layer service definition and protocol specification
- Data-link layer service and protocol
- Application layer service and protocol
- Network management
- Security
- Communication profile
- Wireless procedures and Gateway
- Gateway commands were added
- A Quarantined State was added
- CCA Modes were extended to be more in-line with IEEE 802.15.4
- Clarifications on whitelist and blacklist management were added
- Clarifications on join (e.g. only require a single neighbour) were added
- Clarifications on use of join links, table management, and defaults were added
- Corrections and updates were made.

6.2.4 WirelessHART® functional design requirements

During the initial stage of a wireless network design, the owner-operator’s functional
requirements must be translated into the network infrastructure (figure 156), device
characteristics, host interfaces and applications. These requirements need to be documented
in the design specification; also include boundary conditions (e.g. all monitoring points on this
project will be wireless) associated with WirelessHART applications.

WirelessHART® functional requirements

Develop the WirelessHART® design, including the following:

 Network environment and area classification

 WirelessHART system architecture
 Operational requirements
 Data requirements Interfaces
 Testing
 Spares consideration
 Documentation requirements
 Training
 WirelessHART® network security, reliability and interoperability requirements

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WirelessHART® infrastructure requirements

Conduct plot plan reviews and determine the infrastructure requirements for the following:

 System architecture
 Wireless
 Field network design including IEC62591 WirelessHART® Field Instruments
 Automation
 Host system interface
 Process control network interface
 Asset management system diagnostics including those for field device and the field
network configuration

Operational requirements

Determine operational requirements for the following:

 Process monitoring and signal types

 Device diagnostics Loop response time
 DCS HMI Redundancy WirelessHART® network components
 Reduction in field inspections of physical wired infrastructure (IECC60079)
 Elimination/reduction of operator rounds

6.2.5 Wireless device selection based on process measurement

WirelessHART® devices are available for various process measurement applications including
those described below:

Process monitoring and control

 Hard to reach locations

 Process efficiency calculations
 Better insight into the process
 Ad-hoc measurements
 Additional measurements from multivariable devices
 Calculated variables in devices

Equipment measurement

 Vibration
 Corrosion
 Oil pressure
 Air flow

Health and safety systems

 Gas detectors
 Analysers

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Environmental

 Steam traps (energy usage)

 Water/discharge treatment
 Flow
 pH
 Stack emissions
 Relief valves

Device integration

With the different venders producing different types of field instruments, interfacing become
a real issue since many of the field devices only communicated to their own propriety control
systems, which made it very difficult to use these field instrumentation outside the control
systems [56].

Field Device Integration (FDI) builds the right foundation to expand visibility into a plant. It
simplifies installation and management with a single host package for every field device.
Manufacturers found it easier to innovate and consumers have a simpler path to
implementation in plants.

Figure 156: Different layers of WirelessHART® implementation [55]

5.2.6 What is FDI?

The FieldComm Group - a global standards-based organization focused on digital open

standards in the process industries has collaborated with industry foundations and suppliers
like Emerson to develop FDI, an internationally standardized solution for process automation
device and systems integration. A single FDI device package includes the device definitions,

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user interface plug-ins, certificates, and useful documentation to simplify integration with field
devices and FDI host-enabled plant, enterprise, and cloud-based systems [56].

5.2.7 Why FDI?

FDI takes the best features of the Electronic Device Description Language (EDDL) (the
standard device description language at the core of software used with various intelligent
device protocols like HART, Foundation Fieldbus, and Profibus) and FDT/DTM (Field Device
Tool/Device Type Manager) and combines them in one common standard, making it easy to
select, install, and configure the right devices for plant systems [56].

FDI provides increased security, prepares for future devices, and supports multiple protocols
and FCG registration to ensure interoperability between systems and devices from different
manufacturers [56].

Figure 157 shows a typical FDI integration process. The FDI device package retrieve the data
from the field device and import the FDI device data into the FDI server and from the FDI
server the converted files are transferred to the FDI clients for mobile devices, asset
management for engineering and operator station and finally to the Cloud where data analysis
can be conducted in the filed with new field equipment. [56].

Figure 157: FDI integration [56]

Figure 158 indicated the 200+ downloadable files available for common flow meter as
example. With the new FDI developed package it is now possible to use 1 FDI device package
per protocol (HART, FF or Profibus)

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 Figure 157: FDI integration [56]

Increase security through digitally signed certificates.

Before installation of an FDI Device Package begins, AMS Device Manager will check the
software’s certificate to ensure the files have not been tampered. With all of the device’s
necessary files contained in one package, users will not need to search multiple places for the
files they require. Plant personnel can rely on one trusted repository for their needs [56].

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6.3 SUMMARY

The chapter looked at typical self-organizing wireless networks and WirelessHART® field
instrumentation and how they are interfaced to plant control systems. The different types of
wireless devices and how they are used in the wireless networks were discussed. The chapter
also looked at the design requirements to design a wireless network taking into account
various aspects of plant requirements to design and build the wireless network architecture.
Some of the integration packages like FDI was discussed.

The next chapter will address hazardous areas, what is intrinsic safe and flameproof
equipment.

6.4 NOTES

None

6.5 REFERENCES

[55] https://www.emerson.com/en-us/
[56] https://www.emerson.com/en-us/catalog/emerson-sku-775-wireless-thum-adapter

6.6 QUESTIONS

6.1 Point out how a wireless network affect plant operations and what are the benefits
of such an installation (8)
6.2 Point out the benefits of using a wireless gateway (6)
6.3 When using a wireless gateway device, point out the installation options when
creating a wireless field network to fit the needs of the application and site
requirements (4)
6.4 Point out the key features of Emerson™ SmartPower™ modules (5)
6.5 Point out how the Emerson Wireless 775 THUM™ Adapter is used to convert normal
instrumentation to wireless instrumentation (7)
6.6 If we refer to a smart wireless solution, point out the features of such a wireless
network (4)
6.7 Use a diagram to point out how a wireless network would be interfaced to a basic
plant control system. Indicate the different wireless equipment connections and
how the wireless instruments would be linked to the BPCS (4)
6.8 With reference to the Plantweb™ Insight Network Management application, point
out why would you use this specific tool? (4)
6.9 Use a diagram to point out the different methods that are used in wireless
networks and refer to the wireless field network and the wireless plant network.
Indicate how they are interfaced to the plant and control network (8)
6.10 Use a diagram to point out how smart wireless networks can be used to manage
two sites. Indicate how the different the types of field instruments are interfaced
to the BPCS, Asset Management and historian systems (8)
6.11 Use a diagram to point out how the different wireless technologies can be used for
remote access to different sites and operation centres (8)
6.12 When designing a WirelessHART® network, examine the functional requirements
that will be needed for such a design (9)

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6.13 When infrastructure need to be designed for implementation of a WirelessHART®
network, what infrastructure requirements must be determines? (7)
®
6.14 When planning and designing a WirelessHART network, point out what typical
operational requirements must be taken care off (5)
6.15 With reference to wireless device selection based on certain process
measurements, indicate the four main categories that need be looked at (4)
6.16 With reference to process monitoring and control instrumentation being part of a
WirelessHART® network, point out what need be addressed (6)
6.17 With reference to equipment measurement in a WirelessHART® network, what
need be addressed (4)
6.18 With reference to health and safety systems in a WirelessHART® network, point
out what need be addressed (2)
6.19 With reference to environmental equipment in a in a WirelessHART ® network,
point out what need be addressed (6)
6.20 Point out what you understand as WirelessHART . Refer to the different aspects
®

that are covered (8)

6.21 Point out why field device integration (FDI) is required (5)
6.22 Use a diagram to point out how you would implement the main layers of
WirelessHART® in a plant. Refer to the wireless plant applications and wireless field
applications (2)
6.23 With reference to the IEC62591 WirelessHART® Field Instruments, point out the
typical aspect that are covered by the standard. Refer to 5 aspects (5)
6.24 Point out what your understanding is of Field Device Integration (FDI) (6)
6.25 Point out what is the main function of FDI (6)
6.26 Use a diagram to point out the typical method that are used to achieve FDI
integration between the field device and FDI clients. (7)
6.27 Use a diagram to point out how the 200+ downloadable files available for field
instruments is managed by the FDI package used for a specific protocol (14)
6.28 With reference to the FDI integration model, point out what protocols is addressed
with FDI (6)
6.29 Point out what other features do the FDI integration provide to field instrument
venders (2)

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