Because of limited human resources, instrument personnel generally do not have enough time to manually inspect, clean, or maintain all process equipment in the factory to prevent breakdowns and parking. It is no longer sufficient to rely on existing automation methods based on wired control methods that have been designed in the P&ID diagram. Therefore, applying the second-level automation that we call “ outside of the P&ID diagram †means that wireless communication is used to make up for missing measurement points in the past, and automatic detection of process equipment can improve the efficiency of the maintenance department.
People do not want the application of wireless instruments to change the existing working methods of the instrument personnel. Therefore, the HCF Foundation has introduced the IEC62591 (WirelessHART) standard, which allows us to use the same communicator that is used to maintain wired HART devices and field bus devices. And calibrate wireless transmitters.
Pipe plugging and equipment failures in the process equipment have a great impact. The production plant had to either clean or repair the equipment by reducing production or parking. If it happens on the main device, it will seriously affect the production. Moreover, the cost of repairing these equipment is high, which also makes maintenance resources tense.
The reduction of energy use efficiency increases the fuel consumption. On the other hand, in order to prevent jams or malfunctions, prematurely shutting down to clean process equipment can also increase downtime, manpower, and maintenance costs. What's more, if you do not know the health status of your equipment, if you use limited human and material resources to maintain equipment that is already in good health, it may cause equipment that really needs maintenance to be ignored.
Most production facilities only use the instruments necessary for safe production. However, it is difficult to arrange maintenance effectively without knowing the state of the process equipment. Most of these process equipments are only periodically inspected, which leaves operators and maintenance personnel with insufficient equipment health information. Usually these devices are maintained using a preventive solution: we often say that "regular maintenance."
Wireless solution
Plants around the world are now adding sensors to their process equipment to obtain missing measurement points from the initial design to help process engineers, maintenance and reliability personnel understand the operation of process equipment. More factories are using wireless technology to automate their asset management.
The installation of wireless transmitters requires only minimal effort and resources because wireless technology does not require opening cable trays and junction boxes for installation. This reduces the number of hours worked in the production area and reduces the potential for personal safety.
The instrument's raw data was captured and pre-built asset health software was used for data integration and analysis. The asset health software included pumps, heat exchangers, air-cooled exchangers, cooling towers, fans, unmonitored compressors, and filters. Pipeline and container and prefabricated analysis software, embedded with multi-parameter algorithms, can provide asset health status information very professionally and intuitively.
Similarly, smart meters, such as control valve positioners with valve diagnostic information and flowmeters with metering functions, can now be retrofitted with wireless adapters if they were not digitally integrated into the control system in the past. The way to integrate health diagnosis information into smart device management software.
For example, after the wireless adapter is used, it is possible to conduct a comprehensive inspection with the regulating valve being put into use to determine which needs to be overhauled and which are not needed, which greatly facilitates the planning and execution of the overhaul.
For a flow meter, we can evaluate it while it is in use and find out which flow meters need to be calibrated. In this way, the valves that need to be repaired and the flowmeters that need to be calibrated can be maintained during the overhaul, avoiding the need to remove them during production and ensuring a longer “online timeâ€: this also increases the equipment in the pipeline Or work on the container, reducing the time spent in the workshop.
Wireless sensors help reduce the number of test and inspection operations. By “checking in the software first†approach, the maintenance team can implement data-driven “desktop maintenance†plans by using asset health information from wireless sensors to better schedule routine maintenance and reduce the number of plants in the factory. Unplanned production cuts and parking, energy savings, and reduced maintenance costs are possible.
Technicians can determine the health status of pumps and other assets on their computers, eliminating the need to go to on-site inspections and prevent major repairs from interrupting production.
In addition, in the event of a failure, maintenance technicians can be targeted to obtain relevant information on the process equipment (such as searching through the Internet) before going to the field for maintenance, to understand the problem and solution.
Manage more sensors
The application of wireless technology is a trend of measurement and development in the industrial field. In the future, more wireless sensors will be installed on the process equipment to acquire more measurement points that are not involved in the initial design or even technical transformation design.
In addition, in order to improve the long-term reliability of the equipment and reduce the number of inspections, wireless technology also provides monitoring methods for energy saving metering, safety showers, and safety eye washers for HS&E equipment.
The increase in the number of sensors has also led to an increase in the number of meters in the factory. This has made it impractical to use HART and switch signal transmitters with I/O cards. As a result, the factory has adopted a digital communication network to deploy digital sensors on site. Wireless communication has become the easiest way to use digital sensor networks in existing factories.
About implementation
Through the gateway interface, WirelessHART can be seamlessly integrated into any system that supports Modbus/RTU, Modbus/TCP, Ethernet/IP or OPC. In other words, the original system will not be able to integrate WirelessHART because the version is too low, so there is no need to replace or upgrade the existing control system in order to use WirelessHART. Even wireless gateways do not necessarily need to come from system vendors.
The modernization of the wireless network can be gradually carried out, for example, as part of the entire plant modernization project. The project begins with the investigation of the existing site, followed by scoping, detailed design, installation and commissioning.
For the entire plant modernization project, the original EPC design can well support a wide range of upgrades, because the original isometric pipeline maps, 3D models, and other documents can reduce the mechanical installation of the sensor.
As a result, sensors such as vibration, temperature, and sound waves are non-invasively installed, requiring only minimal mechanical installation work. When there are fewer new plant projects, EPC can send more resources to modernize the plant.
The great thing about digital sensor networks, especially wireless networks, is that adding each sensor does not require separate wiring and I/O channels, so the network expansion is very simple.
The integrated wireless transmitter includes pressure, flow, level, valve opening, pH, conductivity, switch contacts, vibration, temperature, multi-point temperature, and transmitters for sound waves, level switches, and switch valve actuators Wireless adapters for wired devices, etc.
All the above devices can exist in the same wireless network, configure the specified update rate to meet specific applications and maximize battery life requirements. Multi-point temperature transmitters reduce the number of temperature transmitters, especially for heat exchangers and boiler piping monitoring. These multi-parameter devices are ideally suited for digital communications and are not suitable for use with legacy HART traditional single-parameter meters.
Simple to use
WirelessHART devices are very helpful for the maintenance department. But there is one reason why technicians are so quick to use wireless transmitters: Wireless transmitters are very easy to use.
Just like HART-enabled HART transmitters and FOUNDATION fieldbus devices, wireless transmitters also require configuration/configuration, calibration, and maintenance/diagnostics. In order to join the wireless network safely, the wireless transmitter also needs to do the configuration work.
That is, the operation on the wireless transmitter is almost the same as on the HART or FOUNDATION fieldbus transmitter. Therefore, wireless transmitters use the same tools as HART and FOUNDATION fieldbus, making learning WirelessHART easy.
Before the wireless transmitter joins the wireless network, it needs to set the network ID and secure access password. This process is called configuration. Because of security reasons, the configuration work needs to be kept confidential, so it is not performed wirelessly. After the configuration is completed, the wireless transmitter has the necessary security certification for secure wireless communications.
For WirelessHART, joining the password can be automatically generated by the system, so users do not need to manually generate a password, and the password will not be seen by others. The passwords for all transmitters in the network can be the same, or a separate password can be used for each transmitter. This is the security mode known as Access Control List (ACL).
Once the WirelessHART transmitter has joined the network, the system will automatically detect the transmitter according to the tag. There is no need to transfer any "profiles" to the gateway at all. If the WirelessHART network ID changes, the gateway automatically notifies all transmitters in the network. So no need to configure the transmitter.
Therefore, all WirelessHART transmitters have a standard maintenance interface. We are familiar with the handheld configurator for debugging, configuration, calibration, and diagnostics of HART and FOUNDATION fieldbus devices, as well as the software on the notebook. Interface configuration.
The same tool can be used for all WirelessHART transmitters, regardless of the manufacturer, so the technicians do not need to be familiar with new tools and software. Each manufacturer's special infrared tool is not needed for WirelessHART, and the technicians do not need to carry a heavy notebook to work in the field, but only need to bring a portable handheld device.
Handheld devices also have the advantage of one-handed operation and long battery life. Even standard calibrators for HART and FOUNDATION Fieldbus devices can be used with WirelessHART devices.
Another benefit of using the same configuration tool to configure the WirelessHART transmitter is that the WirelessHART device uses the same setup/configuration, calibration, and diagnostics as HART and FOUNDATION fieldbus devices. The factory already has these tools, and the technicians already know how to use them.
HART, Foundation Fieldbus, and WirelessHART all use Electronic Device Description Language (EDDL). With the aid of the electronic device description language EDDL (. Org), HART, FOUNDATION Fieldbus, and WirelessHART have very similar user interfaces. This makes managing mixed devices very simple, even if they are using different signal transmission methods.
In order to ensure that the type and version of the device are up-to-date, EDDL files need to be downloaded to the system for the device. The steps for downloading and updating are the same for WirelessHART, HART, and Foundation Fieldbus devices.
Investment significance
Installing HART or a switching signal sensor for an existing plant can affect production and bring about the danger of damaging existing plant equipment. Therefore, for the second-level automation of applications outside the P&ID diagram, the wireless method can be a good alternative to the traditional hard-wired method. WirelessHART can speed up the deployment, allowing low-risk deployment of second-level automation systems during short repair periods and even during plant operation. This modernization of maintenance does not affect process control, alarm or safety systems – it is the second level of automation that goes beyond P&ID.
The maintenance department has a special interest in the asset health information brought about by the WirelessHART transmitter because it eliminates unnecessary maintenance work and the WirelessHART transmitter does not require special tools other than the factory-existing HART and fieldbus devices. Tools, easy to install and use.
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