1、Wireless Control Foundation:Continuous and Discrete Controlfor the Process IndustryWirelessControlFoundation-2015.book Page i Friday, September 5, 2014 8:51 PMWirelessControlFoundation-2015.book Page ii Friday, September 5, 2014 8:51 PMWireless ControlFoundation:Continuous and Discrete Controlfor th
2、e Process IndustryTerrence L. BlevinsDeji ChenMark NixonWilly WojsznisWirelessControlFoundation-2015.book Page iii Friday, September 5, 2014 8:51 PMNoticeThe information presented in this publication is for the general education of the reader. Because neither the author(s) nor the publisher has any
3、control over the use of the information by the reader, both the author(s) and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular application.Additio
4、nally, neither the author(s) nor the publisher has investigated or considered the effect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the infor
5、mation presented.Any references to commercial products in the work are cited as examples only. Neither the author(s) nor the publisher endorses any referenced commercial product. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the author(s) nor the
6、 publisher makes any representation regarding the availability of any referenced commercial product at any time. The manufacturers instructions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication.Copyright 2015 International So
7、ciety of Automation (ISA)All rights reserved. Printed in the United States of America. 10 9 8 7 6 5 4 3 2ISBN: 978-0-876640-88-3No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwi
8、se, without the prior written permission of the publisher.ISA67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709Library of Congress Cataloging-in-Publication Data in process.WirelessControlFoundation-2015.book Page iv Friday, September 5, 2014 8:51 PMDedicationThis book is dedicated to
9、our wives, Karen Blevins, Qing Li, Nancy Nixon and Susan Wojsznis, who have provided encouragement and support throughout our careers.WirelessControlFoundation-2015.book Page v Friday, September 5, 2014 8:51 PMWirelessControlFoundation-2015.book Page vi Friday, September 5, 2014 8:51 PMviiAcknowledg
10、mentsThe authors wish to express their appreciation to Grant Wilson and Peter Zor-nio, Emerson Process Management, for supporting our work on this book. We would also like to express our deepest thanks to Bob Karschnia, Vice Presi-dent Wireless, Rosemount for his inspiration and support of research
11、and development of wireless control. Through our research of wireless control, we have benefited from communications with Eric Rotvold and Kelly Orth, Rose-mount; Kurtis Jensen and Mitch Panther, Fisher Controls; and Wally Pratt, HART Communication Foundation on wireless communication and control to
12、pics. We have benefited greatly from the cooperation with professor A.K. Mok, University of Texas (UT) at Austin and assistant professor Song Han, University of Connecticut as we have explored the use of wireless devices in process control over the years. The authors (as will the readers) appreciate
13、 the smart and user-friendly website, which was made operational by Jennifer Norris, Brad Vanhove, Larry Griffin, Rey Delos Santos, Ann Feitel and Debbie Franke. Katie Tackett and Ellie Morgan designed a creative book cover that we all liked. Joan Forbes made the first draft review of the book, whic
14、h the authors found to be very helpful. We are thankful to Scott Bogue for his detailed and highly professional final review of the book, and want to express our special gratitude to Susan Colwell, Publications Development Manager, ISA, for her support in the publication of this book and her relentl
15、ess efforts to publish the book on a tight schedule. Over the years we have benefited from working with many others in the test-ing and implementation of wireless control. The authors extend their thanks to Peter Wojsznis, Mike Ott and Klaus Erni for their participation in integrat-ing PIDPlus capab
16、ility into the DeltaV control system to support wireless con-trol. Tim Forsythe, Shabbir Bharmal and Ken Krivoshein worked in implementing the DeltaV systems support for wireless control, and Craig Sydneys group did the configuration and testing. WirelessControlFoundation-2015.book Page vii Friday,
17、September 5, 2014 8:51 PMviii WIRELESS CONTROL FOUNDATIONWe gratefully acknowledge the support of the customers we have worked with in field testing wireless control. The following individuals in particular supported the evaluation of wireless control: professor Frank Seibert, UT Aus-tin, who instal
18、led and tested wireless control of steam flow and stripper col-umn pressure, and Scott Broadley, Broadley-James Corporation, who used wireless pH and temperature measurements in bioreactor control. We would also like to thank Kurtis Jensen, Mitch Panther, Ron Hager and Sean Raymond for their support
19、 in testing control in the Fisher Controls flow lab, which included a wireless throttling valve. It has been gratifying to work with Wally Pratt, HCF; Ludwig Winkle, Sie-mens; Robin Pramanik, Siemens; Tomas Lennvall, ABB; Eric Rotvold, Rose-mount; Stefano Galimberti, Pepperl+Fuchs; Yuri Zats, Dust N
20、etworks; Marty Zielinski, Emerson; Jose Gutierrez, Transocean and Rick Enns (consultant) in the development of the WirelessHART specification and the adoption of this specification as an international standard, IEC 62591 WirelessHART. We have benefited from their input and insight into the applicati
21、on of wireless technol-ogy in the process industry.WirelessControlFoundation-2015.book Page viii Friday, September 5, 2014 8:51 PMixAbout theAuthorsTerrence L. “Terry” Blevins has been actively involved in the application and design of pro-cess control systems throughout his career. Terry was instru
22、mental in the initial establish-ment of Emerson Process Managements Advanced Control Program in 1992. From 19982005 Terry was the team lead for the development of DeltaV advanced control prod-ucts. From 19942013 he was the Fieldbus Foundation team lead for the development and maintenance of the Func
23、tion Block Specifica-tion and editor of the SIS Architecture and Model Specifications. Terry is the U.S. expert to the IEC SC65E WG7 function block committee that is responsible for the IEC 61804 function block standards. He is a voting member and chairman of the ISA SP104-EDDL (Electronic Device De
24、scription Language) committee and is the technical advisor to the United States Techni-cal Advisory Group (USTAG) for the IEC65E subcommittee. He is also a member of the U.S. National Committee (USNC) Technical Advisory Group (TAG) (IEC/SC65 and IEC/TC65). Terry coauthored the ISA bestselling books
25、Advanced Control Unleashed (2002), Control Loop Foundation (2010) and Advanced Control Foundation (2012). He has over 50 patents and has written over 80 papers on process control system design and applications. Terry received a Bachelor of Science in Electrical Engineering from the University of Lou
26、isville in 1971 and a Master of Science in Electrical Engineering from Purdue Univer-sity in 1973. In 2004, he was inducted into Control Magazines Process Automa-WirelessControlFoundation-2015.book Page ix Friday, September 5, 2014 8:51 PMx WIRELESS CONTROL FOUNDATIONtion Hall of Fame. Terry is an I
27、SA Fellow. At present, Terry is a principal technologist in the applied research team at Emerson Process Management.Phone: (512) 418-4628E-mail: Deji Chen recently joined Tongji University as a professor at the Computer Science Department. His research will be focused on Industrial Inter-net, which
28、is the continuation of his work at Emerson Process Management where he was a member of the DeltaV future architecture team. Deji has been involved in process automation for almost two decades. He was among the first cre-ators of OPC. He has worked on different field-buses including Foundation Fieldb
29、us. He coauthored the first definitive book on Wire-lessHART, WirelessHART: Real-Time Mesh Net-work for Industrial Automation (2010) and translated the ISA bestselling book Control Loop Foundation Batch and Contin-uous Processes into Chinese (2012). In 1999 he received his Ph.D. from the Uni-versity
30、 of Texas at Austin; his thesis was “Real-Time Data Management in the Distributed Environment.” Deji is an IEEE senior member and an ISA senior member.Phone: +86 15618704250E-mail: Webpage: http:/www.cs.utexas.edu/cdjMark Nixon has been involved in the process industries throughout his career. Mark
31、 started his career as a systems engineer working on projects in oil focus on customer requirements; promote effective standards, regulations and practices; and quantify and communicate the benefits and potential impacts of wireless technologies. The ZigBee Alliance (see Zigbee link) soon defined up
32、per layers on top of IEEE 802.15.4. The Zigbee Alliance has had great success with smart metering and home automation products. Although late to the race, the industrial automation industry has also demonstrated the huge impact of wireless networks. Wireless networks have matured to the point that t
33、hey can now be safely applied in various industrial moni-toring, control and asset management applications (Willig, 2008; Caro, 2004). Wireless technology provides a cost-effective, simple and reli-able way to deploy new points of measurement and control without wiring costs or the need to completel
34、y change existing systems. It also provides an infrastructure for both central and mobile users to access their process and process equipment, which is collectively referred to as pervasive sensing (see ISA100 link).WirelessControlFoundation-2015.book Page 7 Friday, September 5, 2014 8:51 PM8 WIRELE
35、SS CONTROL FOUNDATIONThree prominent standards that address the more restrictive security and reliability requirements of the automation industry are Wire-lessHART (see HART link; Song, 2008), ISA100.11a (see ISA100 link) and WIA-PA (see WINA link). From a technology perspective, all three are simil
36、ar, and their similarities are described in this book. Although we use WirelessHART in this book when exploring the details, we remind readers that what we describe is mostly representa-tive of all three standards. When we do not mention WirelessHART in particular, we refer to wireless technology in
37、 the industry automation in general.In the next section we use WirelessHART as an example argument for the legitimacy of wireless technology in industrial automation. Section 2.2 describes the architecture of an industrial wireless network, includ-ing each communication layer and the data management
38、 and network management functions. Section 2.3 presents a case study of a Wire-lessHART network in the Separations Research Program (SRP) at the J.J. Pickle Research Campus (PRC) of the University of Texas in Aus-tin, Texas. Section 2.4 provides some comments and we conclude the chapter with a works
39、hop.2.1 About WirelessHARTThe HART (Highway Addressable Remote Transducer) fieldbus standard has been in existence since the late 80s. It is a bi-directional communication protocol that provides data access between smart field devices and host systems. It is administrated by the HART Communi-cation
40、Foundation (HCF). In its initial release the HART Field Com-munications Protocol was superimposed on a 420mA signal, providing two-way digital communications with smart field instru-ments without compromising the integrity of the measured data. In 2007 HCF ratified WirelessHART, which expanded the c
41、apabilities of the existing HART protocol while protecting the global installed base. With the latest evolutionary enhancement to the global HART stan-dard, the Foundation took the proven field communications, network-ing and security protocols and integrated them into a simple, reliable and secure
42、wireless standard. In 2010 WirelessHART, IEC 62591, became the first IEC standard for industrial wireless networks.As shown in Figure 2-1, the HART protocol has evolved from a 420mA based protocol to the current wired and wireless-based technol-ogy with extensive features supporting security, unsoli
43、cited communi-cation of field device parameters, event notifications, block mode transfers and advanced diagnostics. Diagnostics now include informa-WirelessControlFoundation-2015.book Page 8 Friday, September 5, 2014 8:51 PMCHAPTER 2 HISTORY AND BACKGROUND OF WIRELESSHART TECHNOLOGY 9tion about the
44、 device, the equipment the device is attached to, and in some cases, the process that is being monitored. The WirelessHART standard leverages existing standards such as the HART standard, the IEEE 802.15.4 standard, the AES-128 encryption standard (AES, 2001) and the Data Description Language (DDL)/
45、 Elec-tronic Device Description Language (EDDL) IEC 61804 standard (see EDDL link). Three words define industrial wireless technology: simple, reliable and secure: Simple: The networks self-organizing and self-healing features simplify installation and maintenance of a wireless installation. The net
46、work can automatically adjust to changes in plant infrastructure; for example, when a new instrument is added to the network. Reduced wiring leads to lower material costs and easy installation and commissioning. Without wires, the net-work can be easily extended to remote areas. Instru-ments can be
47、mounted on moving assets and on rotating stationary equipment. Reliable: The WirelessHART standard includes many features in different communication layers to provide reliable communications. At the physical layer, the Figure 2-1. Evolution of HARTWirelessControlFoundation-2015.book Page 9 Friday, S
48、eptember 5, 2014 8:51 PM10 WIRELESS CONTROL FOUNDATIONWirelessHART standard uses both Direct Sequence and Frequency Hopping Spread Spectrum (DSSS and FHSS) techniques to spread communications among different transmission frequencies. At the data link layer, the WirelessHART standard employs CCA (Cle
49、ar Channel Assessment) tests on the targeted channel before trans-mission. Acknowledgement and retransmission mecha-nisms are applied to ensure on-time reliable message exchange. At the network layer, a WirelessHART network is a true mesh network with multiple access points. It moni-tors paths for degradation and repairs itself, finds alter-nate paths around obstructions and randomly communicates on different channels. If an obstruction is introduced into the network, data will continue to flow because the obstructed device al
