February 1, 2009

Wireless Technology Unlocks Possibilities

Jeff Becker

Applications for the Power Industry

Access to the right process data can significantly enhance operational efficiency and extend access to critical process information beyond the control room. A wireless system can include anything from a network of transmitters monitoring a single, specific application to a full-scale wireless network deployed across an entire site to handle multiple applications, including monitoring and supervisory control (Figure 1).

1.On-site computing. Wireless mobility tools provide a fully functional PC environment that personnel can interact with directly from a handheld device while performing maintenance rounds, data collection, and inspections. Source: Honeywell Process Solutions

Modern wireless networks are formed by a series of wireless access points, or radio nodes, placed strategically in a facility. Many networks support a "mesh" infrastructure, in which each radio node communicates to at least one other node in range, providing backup communication should communication from one node be interrupted. The coverage area of the radio nodes working as a single network becomes a mesh "cloud."

The first generation of wireless products were sensor-specific and not designed to cover entire plants, which limited them to smaller implementations. Today’s generation of products is more appropriate for wider plant deployment. These systems are optimized for specific end-user applications, ranging from read-only access over an intranet by multiple casual users to secure system access for mobile operators. The wireless collaboration that such systems enable can improve decision-making, production uptime and process monitoring, and incident avoidance.

Handheld access to process data allows technicians in the field to view the latest plant information to help identify failures and causes that may previously have gone unrecorded. It also can open the door for further investigation of a system’s reliability. Users can integrate field data with data from multiple other sources, including production, control, and work management systems. Wireless systems also can provide mechanical and engineering data and support the calibration of instrument databases. Using wireless technology in the field helps management improve the tracking and reporting of inspections, tests, and repairs for pumps, actuators, valves, vents, pipes and other plant process equipment.

The new breed of wireless transmitters enables plant workers to obtain data and create information from remote and hazardous locations without the need to run wires, where running wire is cost-prohibitive and/or the measurement occurs in a hazardous location (Figure 2).

2. Wireless solution. An example of a transmitter installed at a facility. These wireless transmitters bring back data from remote areas of the plant into the control system to improve safety and efficiency. Source: Honeywell Process Solutions

There are countless remote applications in power plants that can benefit from wireless technology. For example, one Nebraska power plant is using wireless technology to monitor its remote oil tanks. In addition, plant staff are now able to efficiently monitor water run-off where electricity is unavailable. Battery-powered transmitters transmit data over long distances back to a powered node.

Other power plants are considering applications such as:

• Supervisory control and data acquisition.

• Emissions monitoring.

• Flame sensing with transmitters, or even a remote wireless video.

• Control applications, such as turbine control, boiler control, or motor control.

• Monitoring the health of rotating assets.

Another example of remote usage is over large areas such as wind farms. Many have ineffective or no means to determine wind speed or kW/MW power production. Battery-operated wireless devices enable data collection and accurate power production calculations.

Furthermore, wireless multiplexers are a simple and reliable means of implementing a wireless solution for applications with high-density input/output (I/O) concentrations. They provide the lowest cost per wireless measurement point, which enables new applications that save millions of dollars on wiring costs. This can help with substation monitoring and communicating information back to a central monitoring station.

Wireless technology is also an innovative, cost-effective alternative for measuring the health of water or corrosion from fluid in tanks and pipes. For example, remote analytical pH readings enable plant operators to monitor water quality. And, with a wireless corrosion-monitoring system, online and real-time corrosion monitoring now becomes cost-effective.

A wireless system can carry process and maintenance data over the same network. Correlation with maintenance and operator tasks is possible by enabling mobile workers with wireless technology, which saves them from sifting through maintenance logs and matching tasks with corrosion data. All the information can be integrated into one set of data.

Most importantly, wireless technology improves safety. By enhancing new opportunities for integrating asset tracking, people location data, or real-time data and supervisory control, wireless technology can provide:

• A real-time location system throughout a facility to monitor employee locations and ensure safe procedural operations.

• Safety shower monitoring.

• An infrastructure that supports emergency responders.

• Wireless leak detection and repair support.

• Integration with existing control and safety systems.

• Continuous wireless monitoring of equipment and field devices for diagnostic equipment health assessments.

• Voice-over-Internet protocol (VOIP) for in-plant voice communications.