Emerson, Cisco team on wireless; Emerson makes machine vibration monitoring smarter

Collaboration between Emerson Process Management and Cisco could lead to more rapid development of open-standard solutions for wireless process and plant management applications that install easily and operate reliably in the challenging process manufacturing environment. In addition, Emerson extended its PlantWeb Smart Machinery Health Monitoring capabilities to include API 670 protection, Sept. 10, the opening day of the Emerson Global Users Exchange, held here this week.
By Control Engineering Staff September 10, 2007

Dallas, TX —Collaboration between

Emerson Process Management



could lead to more rapid development of open-standard solutions for wireless process and plant management applications that install easily and operate reliably in the challenging process manufacturing environment. In addition,


extended its PlantWeb Smart Machinery Health Monitoring capabilities to include API 670 protection, the American Petroleum Institute’s globally accepted definition of industry best practices for turbomachinery protection. These and other announcements came Sept. 10, the opening day of the

Emerson Global Users Exchange

, held here this week.

Emerson says it will project-manage and deliver the wireless solution to customers by working with Cisco and taking advantage of their joint expertise. Emerson and Cisco have developed a services plan to design, specify, install and support wireless solutions for customers worldwide. The companies expect the efforts to provide end users with a competitive edge through open-standards wireless technology and a complete network platform that ensures they can start with any application and easily expand as the technology evolves. The companies expect to “deliver a complete solution that improves productivity, safety, and operational efficiency for manufacturing customers,” they say.

Emerson’s wireless process applications use self-organizing field networks for increased monitoring of plant data for control and asset optimization; they also offer mobile operator and maintenance worker applications. Cisco wireless plant networks offer applications including those for worker mobility, voice over IP communications, tracking of personnel and assets, and video applications.

“Since introducing Smart Wireless field networks a year ago, we’ve been excited at the high customer interest and their quickly realized business results,” says John Berra, president of Emerson Process Management. “We are pleased to be working with Cisco to extend our offering to include wireless plant network solutions with the security and reliability required in the process environment. The combined field and plant communications platform supports current and future applications that help enable faster and more effective business management over the life of the plant. Additionally, Cisco’s commitment to open standards makes it an ideal partner for Emerson and our customers.”

“Networks and mobility are dramatically transforming our customers’ businesses and in-plant processes,” adds Maciej Kranz, vice president of product marketing for Cisco’s Wireless Business Unit. “By delivering a combined wireless architecture from Emerson and Cisco, we are enabling our manufacturing process customers to deploy flexible, scalable and safe wireless solutions and mobility applications in rugged plant environments.”

Many Emerson customers use Cisco’s wired plant network applications today and will realize an advantage by extending their relationships to include wireless applications, Emerson added.

Emerson’s wireless platform will extend the Smart Wireless capabilities of PlantWeb digital plant architecture to include wireless plant networks. The networks use the Cisco Unified Wireless Architecture offering, including industrial-class wireless access points, controllers and network management software, and plant applications such as communication, tracking and worker mobility tools.

Emerson plans to use the Cisco Unified Wireless Architecture to provide ubiquitous, highly secure wireless LAN coverage and integration within the plant’s existing IT infrastructure; this integration eliminates the need for a complex wireless overlay network. Cisco’s Wireless Control System will centralize the configuration and management of the plant’s Wi-Fi network, reducing overall cost of ownership.

“We envision that the open-standard wireless infrastructure and applications jointly architected with Cisco will simplify the implementation of value-added wireless automation projects and reduce risk,” Berra says. “The age of wireless will be advanced as process and IT improvements are smoothly integrated, and the canyons of steel and limits of wiring are removed as obstacles to the imagination of customers.”

Emerson’s Smart Wireless solutions are an extension of its PlantWeb digital architecture and engineering, project management, and asset optimization skills that are delivering efficiency and uptime advantages in thousands of installations globally and across the process industries. The company says its self-organizing mesh wireless field networks and wireless services help enable reliable, highly secure connection to process data that was physically out of reach or too expensive for wiring. Installed costs of wireless points are reduced by up to 90% over wired approaches, according to Emerson.

Emerson says the wireless field networks are based on IEEE 802.15.4 and designed to be compliant with


. They provide connectivity for Emerson’s broad portfolio of wireless sensing, condition monitoring and diagnostics devices that are embedded within the process to deliver process data for control and asset management. Cisco Unified Wireless solutions comprise Cisco industrial-class 1500 Series wireless mesh access points and Cisco Wireless Control System for wireless network management, supported by Cisco Secure Services for network security.

Emerson Services and Solutions will team with Cisco Advanced Services to deliver integrated, customized wireless solutions, establishing highly secure and scalable infrastructure with optimized, reliable messaging for coexisting communications.

Emerson’s Smart Machinery Health Monitoring integrates with process automation environment, enabling maintenance and operations personnel to maximize equipment reliability and plant performance. The new CSI 6000 Machinery Health monitor protects critical machinery from catastrophic failures, permitting orderly shutdown of equipment and related processes.

Turbomachines are critical assets in power plants, oil and gas production facilities, refineries, pulp and paper mills, chemical and petrochemical plants. These multi-million dollar assets weigh hundreds of thousands of pounds; their blades spin at near supersonic speeds and they often operate at more than 1,000 degrees Fahrenheit and over 3,000 psi. They can quickly self-destruct if not protected, potentially causing injury, environmental incidents along with significant economic impacts.

“Turbomachinery is at the heart of every process plant and, to operate with confidence, our users need predictive diagnostics, performance monitoring and protection systems integrated with process automation,” says John Berra, president of Emerson Process Management. “By delivering these capabilities through the PlantWeb digital plant architecture, Emerson enables users to improve machinery performance over the lifecycle of a plant.”

In addition to technology offerings for turbomachinery, Emerson also provides comprehensive services to assist users with system design, installation, configuration and startup, training, and ongoing support.

Asset Optimization

is a division of Emerson Process Management.

Other key announcements from Emerson at the user meeting include:
* Several highly successful applications of its Smart Wireless Solution at the Wheeling-Pittsburgh Steel Corp., a major producer of carbon flat rolled products for the construction, container, appliance, converter/processor, steel service center, and automotive markets. Easily installed wireless transmitters are delivering previously unattainable data on conditions in the 80-in. hot strip mill in Mingo Junction, OH, enabling operating personnel to improve product quality and increase productivity.
* That PPG Industries has installed and commissioned Emerson Process Management’s Smart Wireless solution at its expansive Chemical Division facility in Lake Charles, LA. The production installation follows field trials of Emerson’s self-organizing wireless networks conducted by a PPG cross-functional process and corporate IT personnel team. The team verified the reliability and coexistence performance of the network, and also deployed it in the plant.
* That it applied a Smart Wireless Solution to the problem of monitoring rising temperatures in railcars containing chemicals at Croda Inc., an international specialty chemical manufacturer. No matter where the railcars may be positioned at the Mill Hall, PA, plant, a wireless temperature transmitter on each car sends minute-by-minute temperature readings to a central host. Croda uses this information to improve the performance and safety of their facility. The wireless system contributes to overall plant safety, making operators aware of any unexpected temperature rise, while saving the company about $15,000 per year in reduced maintenance.
* Unveiling of the CSI 9420 Machinery Health Transmitter.
* Application of its wireless self-organizing field network to monitor remote system and equipment buildings operated by Milford Power, a 500 MW gas-fired turbine facility in Milford, CT. Emerson’s Smart Wireless Solution enabled the power company to avoid as much as $75,000 in capital and installation costs while advancing the protection of water pumping and circulation equipment against freeze damage that could cost $20,000 to repair or replace.

—Edited by Mark T. Hoske, editor in chief
Control Engineering Weekly News

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