Simple, Safe and Secure Wireless Solutions by Honeywell: Simple, Safe and Secure Wireless Solutions by Honeywell John Schnake Manager, Product Marketing November 2005


Slide2: Honeywell Wireless Vision Why use Wireless? Wireless Solutions that are Simple - Product Offering Wireless Solutions that are a Safe Investment - Proven Installation & Case Studies - Why Honeywell? Wireless Solutions that are Secure - FHSS Technology Roadmap Questions & Answers Presentation Agenda


Innovation through wireless technology: Honeywell is able today… To offer reliable secure wireless measurements Enabling efficient monitoring of remote assets Driving forward standardization of industrial wireless technologies Committed to open and uncompromised wireless solutions Innovation through wireless technology Innovation is at the heart of everything we do…


Honeywell’s Wireless Vision: Honeywell’s Wireless Vision Additional and Accurate Data for Asset/Process Optimization Integral Part of System for Easy Installation and Usage Open Network to Choose Best Sensor and Tools Sensors and Tools to Enable Applications & Optimization Applications System Network Sensors/PCs/ Tools/Terminals Enabling Services Data Knowledge Provide the complete wireless solution….


Why Wireless Sensors?: Why Wireless Sensors? US Department of Energy, December 2002 “Industrial Wireless Technology for the 21st Century” Study, page 1 “Wireless sensors could improve industrial production efficiency by 10% and reduce emissions by more than 25%” Only 20% of site points are being monitored, increasing this level to 50-55% will produce the improvements identified above.


Slide6: Transmitter cost Wiring Engineering, Installation, Equipment, Maintenance costs Wire cost Solution Savings of $10 to $40 per foot Wireless Instrumentation Drivers


Wiring - The Cost Culprit! : Wiring - The Cost Culprit! Cost of Wires and Installation = $10 to $80/Foot


Where are the real costs?: Where are the real costs? Towers Trenching Concrete/Blacktop Scaffold & Trays Cable Access Conduit Permits Delays All Associated Labor Engineered Savings!!!


Slide9: SIMPLE Easy to Install – Simple Commissioning Easy to move around – Mobile Sensing Easy to add or change sensors – Scalability Easy to maintain – Long Battery Life SAFE Honeywell is a leader in Process Automation, Measurement & Control Honeywell Protects your investment - Forward Migrateable, Backwards Compatible 100% Proven and Tested - We guarantee XYR 5000 will work. Proven RF Technology = Reliable Communications SECURE Proven FHSS Technology – Inherently Secure CRC - Checksum Coding Password Protection Our Wireless Solutions are Simple, Safe, Secure. Honeywell XYR 5000 Wireless Solutions are


Slide10: Wireless Transmitters - XYR5000 Honeywell Wireless Solutions are Simple! Easy to Install – Simple Commissioning Easy to move around – Mobile Sensing Easy to add or change sensors – Scalability Easy to maintain – Long Battery Life


Network Architecture: Modbus or 4-20mA interface Wireless Management Toolkit Bi-directional Wireless Link 902-928 Mhz FHSS RS232 interface Wireless Transmitter DP, P, T, AI. 600 meters range Self powered – Up to 5 year battery life Event Driven Base Radio RF Data Access Point Easy System Integration Up to Fifty Transmitters Network Architecture


Product Offering: Product Offering PRODUCTS Differential Pressure Acoustic Temperature Integrated Temperature Dual TC Analog Input/Dual Switched Input Gauge Pressure Absolute Pressure Multiple Ranges Serial/Analog Outputs Hi-Gain Units


Product Basics: Product Basics Battery Powered/ 5 years (+) 0.1% Accuracy Multiple Ranges in Each Style Field Transmitter Output Choices – Serial, Analog & Digital Integration Capabilities Self Diagnostics Self Alarming Sleep Mode Analog Outputs Scalable Distances up to 2 miles NIST certifications Available Class 1 Div 1 NEMA 4X 100% Tested NIST


XYR Wireless Transmitter Offering: Differential Pressure 0-100”/ 0-300 psi 0.2% Accuracy Gauge Pressure: 0-2 bar / 0-345 bar 0.1% Accuracy Absolute Pressure: 0-2 bara / 0-17 bara 0.1% Accuracy Temperature: TC and RTD 0.1% Accuracy Analog Input: 4-20mA / 0-10V 0.1% Accuracy Base Radio: Up to 50 Sensors per base radio. Modbus RTU or 4-20mA output interface to System Wireless Management Toolkit: Monitoring/Trending + Configuration XYR Wireless Transmitter Offering


Slide15: Wireless Transmitters - XYR5000 Interfacing XYR Base Radio to Host Systems RS-485 – Analog Outputs – Host Systems RS-485 – Digital Outputs – Host Systems Modbus RS-485 to Host Systems Same BR 485 to WIM with all of the above – No Problem


Slide16: Analog Outputs – Quad Module 4 Analog Outputs per Module – Ordered with Base Radio 24Vdc power BR 485 to AO Module Same BR 485 to WIM – No Problem Each Quad AO must be powered Analog output can be trimmed – Output Calibration Example – when 4 mA, it will output 4 mA. Terminals are removable – Wiring not disturbed with AO Module changeout


Slide17: Digital Outputs – Quad Module Each module consists of 8 output switches – on/off Configure On when detected or Off when detected Configurable from the WMT Switches can be set to monitor the following: Monitor Process Variable Level Monitor diagnostics – Low batter as example Monitor the Base Radio – example, connected or not. Enable or Disable switch


Wireless Interface to HC900: XYR 5000 Wireless Transmitters XYR 5000 Base Radios … 16 per HC900 PC Configuration Toolkit RS232 interface Bi-directional Wireless Link 868 or 900 Mhz FHSS Wireless Interface to HC900 HC900: C30 CPU 50 per Base Radio 186* per HC900 Ethernet * Assumes Status and PV, 2 variables, from each transmitter communicated to HC900


Slide19: Wireless Transmitters - XYR5000 Honeywell Wireless Solutions are a Safe Investment! A leader in Process Automation, Measurement & Control Honeywell Protects your investment 100% Proven and Tested - We guarantee XYR 5000 will work with a Site Survey Proven RF Technology with Reliable Communications in hundreds of installations 100 + patents in wireless technology Funded by Department of Energy - Driving for a Secure, Open, Wireless Standard Members of WINA, Zigbee and ISA SP100 “2004 Product of the Year Award” “2004 Editors Choice Award”


Tank Farm: Tank Farm Issue: Wiring cost prohibitive $250K+ Explosion-proof area Volume at high customer demand Spills are frequent and costly Current Measurement: Poly tube-style site glass Readings are visual with error Safety to Personnel Inventory management impossible Solution: Wireless pressure transmitter Ethanol Plant Application Tank Level in Explosion Proof Area “We have not had a single spill or safety violation since the installation!” ~Production Mgr


Compressor Application: Compressor Application 7 Large Rotary Compressors Locations not near control room No available wiring Trenching or suspended wiring required 200 –1,000 foot runs/Est. $120/ft ($800K/min) Existing instrumentation inadequate Each Compressor equipped with thermocouple and local indicator Operators must make rounds to document temperature hourly Sometimes units are non-accessible Installation needed to be completed immediately Cost to plant significant upon failure - Est. 1,000,000/day


Refinery Issues: Refinery Issues Safety Recent explosion of a unit could have resulted in serious human injury or death, control room needed more concise information. Lack of material inventory information Application: Installation needed to be immediate No available wiring to control room from Compressors. Savings to installation cost and time was significant. Future: In the future rebuilds will require less time due to not having any wired units at these specific points to extract.


Safety Showers: Safety Showers Customer Situation OSHA is driving new requirements on shower monitoring for all new installations! Flow switch indication on all Safety Showers Cost to run wire @ $120/ft Average run over 600’ this equates to about $75,000 pre run. 17 Showers 17 Wireless = $21,000 Simple Economics No more fear of litigation


Butane Spheres: Butane Spheres Customer wants pressure measured from top of sphere for level est. Specific cost is undetermined for area. Est. $100/ft = $500,000(+) Longest shot 1,200 feet Shortest is 600 feet Installation time for field devices minimal 7 Tanks $12,000 total project cost


Spent Alcohol Tanks: Spent Alcohol Tanks Current Result –Clipboard Measurement Safety – 10,000gal spill of pharmaceutical used isopropyl alcohol. Major safety Major fines Expensive clean-up Situation 1,400 foot runs @ $50/ft Trenching 12 tanks Est. – $300,000 Wireless Solution Static Pressure $15,000


Rotary Kilns: Rotary Kilns Measurements on Rotary Equipment Application Process Monitoring Kiln Issue: Requires ad-hoc designed electro-mechanical links to transmit the signal Readings are not reliable (dust, dirt, grease, etc) Links require maintenance Adding measurement points is expensive Current IR solution 50-75K/Kiln Solution: Provided Wireless field device to give constant process data Cost 5K/Kiln


Inventory Management: Inventory Management Tank Level Modernization for Local Inventory Management Application Wireless 4-20 mA enabled level transmitter or switch Wireless head pressure level transmitter Issue: Retrofit of mechanical/pneumatic level gauges Concern for EPA and spill data Manual inventory control: Done visually, with stick or gauges Spills and costly cleanup Cost to install wired in XP area $3MM Solution: Wireless @ $175K Return in profitability $2.8MM “It could make the difference whether the plant stays open or not” the Senior Engineer.


Honeywell Wireless Solutions are Secure!: Honeywell Wireless Solutions are Secure! Proven FHSS Technology developed by the Military – Originally patented by Actress Hedy Lamarr CRC - Checksum Coding Password Protection


DSSS: DSSS 2.400 MHz 2.483 MHz 1st PLC Server Frequency Power/dB Message spread out over entire Spectrum, combined at reception Moderate RF Interference – Pretty Good Signal Reception Heavy RF Interference – Totally Blocks Communication


Slide30: Time/mSec Power Watt Frequency 928MHz 902MHz Frequency Hopping SS 869.4 MHz 869.65 MHz


FHSS - Security: 902MHz 928MHz FHSS - Security 869.4 MHz 869.65 MHz


Frequency Hopping and Interference: Frequency Frequency Hopping and Interference Each message (data) sent at a different frequency over the spectrum Moderate RF Interference – Pretty Good Signal Reception Heavy RF Interference – Acceptable Communication


Is our XYR Technology Secure? Yes: Is our XYR Technology Secure? Yes Common Wireless Technologies – BB/WLAN – No Published, Well-Known Protocol Possible Receiver (Hacker) is in Range XYR FHSS – Inherently Secure Protocol from Device to Radio – Not a Published Protocol Different Frequencies at different times CRC 16 bit Error Checking Base Radio and Device Password Protected Low Power – may not go outside the plant Hacker in the plant – you have a different problem


RF Communications through Obstacles: The Fresnel Zone: RF Communications through Obstacles: The Fresnel Zone Optimal low-power RF communications are achieved with obstruction-free Fresnel Zone Line of Sight


Omni / Dipole: Omni / Dipole


Yagi Antenna: Yagi Antenna


Topology: Topology


XYR 5000 Product Roadmap: XYR 5000 Product Roadmap Smart Cable Switch Input (contact closure) Level Field Unit EU Extended/Remote Sensor Base Radio Repeater Analytical – Integration into XYR AO Device Release to Europe Any Suggestions?


Slide39: SIMPLE Easy to Install – Simple Commissioning Easy to move around – Mobile Sensing Easy to add or change sensors – Scalability Easy to maintain – Long Battery Life SAFE Honeywell is a leader in Process Automation, Measurement & Control Honeywell Protects your investment - Forward Migrateable, Backwards Compatible 100% Proven and Tested - We guarantee XYR 5000 will work. Proven RF Technology = Reliable Communications SECURE Proven FHSS Technology – Inherently Secure CRC - Checksum Coding Password Protection Our Wireless Solutions are Simple, Safe, Secure. Honeywell XYR 5000 Wireless Solutions are


Slide40: Questions & Answer Session


Slide41: www.honeywell.com