Engineering Guide: System Engineering Guidelines IEC 62591 WirelessHART®
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System Engineering Guidelines
Engineering Guidelines
00809-0100-6129, Rev AB
February 2016
IEC 62591 WirelessHART
®
February 2016
1.1 Preface
These “System Engineering Guidelines” apply to end user adoption of WirelessHART self-organizing mesh networks to automate process manufacturing. Following the guidelines will help
users take full advantage of WirelessHART systems.
The document provides complete technical guidance for using WirelessHART devices and
applications. The information presented applies to all IEC 62591 WirelessHART installations,
independent of brand. Vendor-specific ‘value added’ features are not included.
PART I of the guideline addresses use of WirelessHART technology in project execution from the
Appraise (conceptual design) stage through to the Pre-FEED (Front End Engineering and
Design), FEED, Execute and Operation stages. PART II describes the Field Network components
that comprise WirelessHART networks.
The guidelines describe WirelessHART system functions and capabilities, networks and alternate
modes of operation, and step-by-step procedures for system access and use. This document
assumes the reader is proficient with HART
unique aspects of deploying WirelessHART systems. Unless stated otherwise, the reader should
assume the project phases and steps are the same for HART and WirelessHART instrumentation.
Engineering Guidelines
00809-0100-6129, Rev AB
®
instrumentation. Therefore it focuses on the
This guideline summarizes the essential pre-requisites and general guidelines necessary for
smooth execution of the project that contains WirelessHART Technology. The guidelines are
applicable for small and large scale projects.
The technical guidelines are for use only by qualified personnel capable of observing the safety
instructions from device manuals. The document is provided on an “as is” basis only and may be
subject to future revisions without notice. The authors and contributors will not be responsible
for any loss or damage arising out of or resulting from a defect, error or omission in this
document or from personnel use or reliance on this document.
We want to hear from you
Your comments and suggestions will help us to improve the quality of system engineering
guidelines. If you have any suggestions for improvements, comments, recommendations or a
query, feel free to send feedback to a Wireless Specialist at WSEGSupport@Emerson.com.
1.1.1 Definitions and acronyms
The following definitions are used within this document.
Ancillary device
Any device that does not contain measuring sensor or output to the process for actuation.
Gateway
Enables communication between wireless field devices and host applications connected to an
Ethernet, Serial, or other existing plant communications network; management of the wireless
field network; and management of network security. Conceptually, the Gateway is the wireless
version of marshaling panels and junction boxes. The Gateway functionality may also exist in
native WirelessHART I/O cards with field radios.
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Host system
Any system accepting data produced by the WirelessHART Field Network (WFN). This could be a
DCS, PLC, RTU, Data Historian, asset management software, etc.
Join key
A 128 bit security key used to authenticate wireless field devices when joining the network,
including encryption of the join request.
A common Join Key may be used among all devices on a given network, or each device may have
a unique join key.
Note
When displayed in hexadecimal format via a browser or handheld, this results in a 32 character
hexadecimal field.
Network ID
February 2016
Each Gateway at a facility or location should be programmed with a unique Network ID. All
authenticated wireless field devices with the same Network ID will communicate on the same
network and Gateway.
Update rate
The user specified interval at which a wireless field device will detect a measurement and
transmit the measurement to the Gateway (i.e. sample rate). The update rate has the largest
impact on battery life due to the powering of the device sensor. Update rate is independent of
radio transmissions required for mesh peer-to-peer communication, “hopping” via multiple
devices to transmit a measurement back to the Gateway, and downstream communications
from the host system to the wireless field device.
Wireless adapter
Enables an existing 4-20 mA, HART-enabled field device to become wireless. Adapters allow the
existing 4-20 mA signal to operate simultaneously with the digital wireless signal.
Wireless field devices
Field device enabled with a WirelessHART radio and software or an existing installed
HART-enabled field device with an attached WirelessHART adapter.
Wireless field network
A self-organized network of wireless field devices that automatically mitigate physical and RF
obstacles in the process environment to provide necessary bandwidth for communicating
process and device information in a secure and reliable way.
Wireless repeater
Any wireless field device used to strengthen a wireless field network (by adding additional
communication paths) or expand the total area covered by a given mesh network.
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1.1.2 Acronyms
The following acronyms are used within this document.
Abbreviation Description
™
AMS
CSSP Control Systems Security Program
DCS Distributed Control System
DD Device Descriptor
DSSS Direct-Sequence Spread Spectrum
FAT Factory Acceptance Test
FEED Front End Engineering and Design
HART Highway Addressable Remote Transducer
HMI Human Machine Interface
LOS Line of Sight
NFPA National Fire Protection Association
PDF Process Flow Diagram
P & ID Piping and Instrument Design
PLC Programmable Logic Controller
RF Radio Frequency
RSSI Received Signal Strength Indicator
SIT Site Integration Test
SPI Serial Peripheral Interface
SPL Smart Plant Layout
TSMP Time Synchronized Mesh Protocol
TSSI Temporal Single-System Interpretation
UDF User Defined Fields
WFN WirelessHART Field Network
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Asset Management System
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Contents
1Section 1: Introduction
2Section 2: Project Concepts
Contents
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1.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
1.1.1 Definitions and acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
1.1.2 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3 WirelessHART in project execution lifecycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2.1 Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.2 Traditional approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.3 WirelessHART approach: technology assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3Section 3: Appraise
3.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.2 Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.3 Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.5 Appraise phase documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5.1 Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.5.2 Deliverables from the philosophy document . . . . . . . . . . . . . . . . . . . . . . . . . 9
4Section 4: Pre-FEED
4.1 Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.1.1 WirelessHART for control and monitoring applications . . . . . . . . . . . . . . .12
4.2 Cost benefit study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.3 Preliminary design basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.4 Project references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.5 Pre-FEED documentation and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.5.1 Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Contents
4.5.2 Deliverables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5Section 5: Front End Engineering Design
5.1 Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.2 Scope definition of engineering execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
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5.3 Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.4 WirelessHART functional design requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.4.1 WirelessHART functional requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.5 WirelessHART infrastructure requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.6 Operational requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5.7 Design inputs documents review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5.8 Development of basis for design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5.8.1 Design guidelines for WirelessHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5.8.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
5.8.3 Proof of concept test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
5.9 Initial design review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6Section 6: Execute
6.1 Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.2 WirelessHART Field Network – Design Engineering Overview. . . . . . . . . . . . . . . .25
6.3 Design resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.4 Wireless device selection based on process measurement . . . . . . . . . . . . . . . . . .25
6.4.1 Process monitoring and control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.4.2 Equipment measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.4.3 Health and safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.4.4 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.5 Design criteria development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.6 Identify candidate measurement points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.7 Database field for wireless network assignment . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.8 Network design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.8.1 WirelessHART field network – design guidelines . . . . . . . . . . . . . . . . . . . . .29
6.9 Scoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.10Detailed design specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
6.10.1 Designing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
6.10.2 Post installation considerations for control and high speed networks . .37
6.10.3 Minimizing downstream messages for wireless output control devices.38
6.11 Spare capacity and expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
6.12 Fortifying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
6.13 WirelessHART availability and redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6.14 WirelessHART security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.15 Alarm handling with WirelessHART devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.15.1 Alarm recommendations for process plant . . . . . . . . . . . . . . . . . . . . . . . . .42
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6.15.2 Alarm priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6.16 Data sheet parameters for WirelessHART transmitter. . . . . . . . . . . . . . . . . . . . . .43
6.17 Tools and documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.17.1 Functional design specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.17.2 Instrument index/database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.17.3 Instrument data sheets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.18 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.19 Factory Acceptance Test (FAT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.19.1 Factory staging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.19.2 Assumptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.19.3 FAT requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.19.4 FAT network configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.19.5 Wireless network troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.19.6 FAT procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.19.7 FAT tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.19.8 FAT documentation and reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.20 Site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.21 Site installation plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.21.1 Installation considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.22 Network installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.23 Wireless connection test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
6.24 Network checkout procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
6.25 Lightning protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
6.26 Device parameter configuration verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
6.27 Loop checkout/site integration tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
6.28 Bench simulation testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.29 Provision of spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.30 Removal of redundant equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.31 Pre-commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.31.1 Pre-commissioning requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.31.2 Defining WirelessHART pre-commissioning methods and acceptance .53
6.32 Site Acceptance Test (SAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
6.33 Commissioning and start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Contents
6.33.1 Wireless network integration with HMI and loop check . . . . . . . . . . . . . . .54
6.33.2 Integrating host and field networks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
6.33.3 On-site wireless network reliability tests. . . . . . . . . . . . . . . . . . . . . . . . . . . .55
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7Section 7: Operate
7.1 Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
7.2 Asset monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
7.3 Alarm and alerts philosophy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
7.3.1 Configure process alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
7.4 Data management concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
7.5 Maintenance practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
8Section 8: Project Management
8.1 Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
8.2 WirelessHART project management overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
8.2.1 Customer requirements, compliance, and assumptions . . . . . . . . . . . . . .59
8.3 Work breakdown structure and cost estimation . . . . . . . . . . . . . . . . . . . . . . . . . . .59
8.4 Subcontractor scope management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
8.5 Project scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
8.6 Responsibility and skills matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
8.7 Managing project change requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
8.8 Progress reviews and reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
8.9 Customer deliverables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
8.10 Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
8.11 WirelessHART procurement and contract plan. . . . . . . . . . . . . . . . . . . . . . . . . . . .61
8.12 Material requisitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
8.13 Documentation requirements in project execution. . . . . . . . . . . . . . . . . . . . . . . .62
8.13.1 ISA documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
9Section 9: Field Device Requirements
9.1 Support for WirelessHART functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
9.1.1 Device diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
9.2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
9.2.1 Device mounting considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
9.2.2 Antenna position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
9.2.3 Mounting high gain remote antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
9.3 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
9.3.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
9.3.2 Energy harvesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
9.3.3 Wired power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
9.4 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
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10Section 10: Ancillary WirelessHART Devices
11Section 11: Measurements and Choosing WirelessHART
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9.5 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.6 Accessibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.7 Manufacturer documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.1 Section overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.2 Gateways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.3 Wireless repeaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.4 WirelessHART adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.5 WirelessHART handheld communicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Devices
11.1 Use of WirelessHART® for multivariable process measurements . . . . . . . . . . . 73
11.2 Use of WirelessHART in various process applications. . . . . . . . . . . . . . . . . . . . . . 74
12Section 12: Host System Requirements
12.1 Use of standard protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12.2 Wireless host system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
12.3 Host integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
12.4 Interoperability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
12.5 Host system support for WirelessHART functionality . . . . . . . . . . . . . . . . . . . . . 78
12.6 Device descriptions files (DD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12.7 Configuration tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12.8 Control system graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12.9 Node addressing and naming conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12.10 Alarms and alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12.11 Maintenance station and asset monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12.12 Historian. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
13Section 13: Documenting in Intergraph SPI 2009
13.1 Section overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
13.2 User defined fields (UDF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
13.3 Filtered views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Contents
13.4 Creating instrument types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
13.5 Loop drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
13.5.1 Loop drawings for WirelessHART adapters . . . . . . . . . . . . . . . . . . . . . . . . . 87
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13.5.2 Gateway cable block drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
13.6 Drawings in smart plant layout (SPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
13.7 Documenting security information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
AAppendix A: Example ISA Specifications
BAppendix B: Design Resources
B.1 Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
B.1.1 Network design tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
CAppendix C: Wireless Spectrum Governance
DAppendix D: References
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WirelessHART® Project Execution
Section 1: Introduction
February 2016
PART I
Introduction
1
Section 1: Introduction
February 2016
Section 1 Introduction
WirelessHART is a global IEC-approved standard (IEC 62591) that specifies an interoperable
self-organizing mesh technology in which field devices form wireless networks that dynamically
mitigate obstacles in the process environment. The WirelessHART field networks (WFN)
communicate data back to host systems securely and reliably, and can be used for both control
and monitoring applications.
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The similarities between traditional HART
training of existing process organizations when adopting WirelessHART. As a result, change is
minimized. In addition, the reduced installed cost of WirelessHART extends the benefits of
automation to end user applications that previously were out of reach since they could not
justify the costs associated with typical wired capital projects.
The opportunity for long-term benefit makes it compelling for end users to expand process
manufacturing project planning to evaluate the impact of WirelessHART on maintenance,
safety, environment, and reliability. Additionally, by removing the physical constraints of wiring
and power as well as reducing weight and space, wireless networks increase flexibility in project
execution, providing solutions which can mitigate risk and improve project schedules.
1.1 Purpose
This IEC 62591 WirelessHART System Engineering Guideline applies to end user adoption of
WirelessHART self-organizing mesh networks to automate process manufacturing projects of
any size. The guidelines are intended to help users take full advantage of WirelessHART systems.
1.2 Scope
The guidelines apply to use of WirelessHART technology through all stages of project execution
as well as throughout the lifecycle of facility operation.
®
and WirelessHART allow end users to leverage the
Differences between HART and WirelessHART specifications and device types are highlighted.
1.3 WirelessHART in project execution lifecycle
Figure 1-1 illustrates a typical framework for project execution. It will be used as a basis for
describing application of WirelessHART in each phase of a project. Although WirelessHART can
be introduced at any phase, a strategic benefit is realized by its introduction during the early
part of the project execution cycle.
Figure 1-1. Project Execution Lifecycle
2
Introduction
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Section 2 Project Concepts
Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3
Traditional approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3
WirelessHART approach: technology assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4
2.1 Section overview
As described in this section, use of WirelessHART® over traditional technology reduces project
risk during execution and provides greater flexibility and benefits to the plant during its life
cycle.
2.2 Traditional approach
Section 2: Project Concepts
February 2016
Traditional methods of wired control networks make use of conventional communications like
4-20 mA, HART
Installation of these wired networks is complex due to inflexibility of wiring. Significant effort is
required in the pre-FEED and FEED phases for planning long run cables including room for spares
to accommodate changes during project execution. Beyond laying long run cables, wired
system complexities include cable routing, connectors, and additional materials associated with
wired technology that are greatly simplified with wireless.
Use of traditional technology also restricts measurement of parameters in locations inaccessible
to cable trays and therefore wired connection. Such wired measurements could improve
operations but are eliminated from the design process as being too costly to implement.
Since use of wired connections reduces the number of measurements and instruments during
the initial execution phase, modifications may be needed to add some of these at a later stage.
Increased spares would be needed to allow the expansion. In a typical project environment,
frequent changes in I/O database, addition/deletion or reallocation of instruments, change in
instrument types, delayed or late changes in package vendor data etc negatively impact project
time and cost.
If instruments and therefore I/O points need to be added/changed/moved during operation,
then lengthy procedures need to be followed for wired signals such as HSE, work permits,
correct isolation procedures, and requisite cabling to connect the field instrument to the
control system. These activities require coordination between multiple plant departments.
Furthermore, routine inspection to ensure that the cable and associated infrastructure continue
to operate trouble free, can be costly and time consuming and divert valuable resources away
from operating the plant.
®
, FOUNDATION™ Fieldbus, PROFIBUS® and other bussed solutions. Planning and
Project Concepts
3
Section 2: Project Concepts
February 2016
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2.3 WirelessHART approach: technology assessment
WirelessHART technology may provide an opportunity to execute and build a more efficient
plant compared to the traditional approach.
The project technical authority can decide whether to use wireless based on the following
criteria:
Economic advantages
Application capability
Operational savings
Benefits of additional process insight from new measurements previously out of reach
economically or physically - example: monitored safety showers
Benefits of flexibility in project execution – example: ease of moving or adding I/O
points during construction to cost effectively manage onsite changes
The high cost of traditional field wiring limits the number of points that are able to be connected
in a project for process monitoring, control and safety applications. However, as the project
proceeds and over the lifecycle of the plant, additional points may need to be added to resolve
critical problems. Since WirelessHART does not require wires for communication or power, the
lower costs enable inclusion of more process points during the project. The financial
impediment in determining whether a point is automated or not is redefined,
Special consideration should be given to automation needs of new process plants. WirelessHART
may provide significant advantages in enabling automation to ensure they meet stricter safety,
environmental, reliability and performance criteria. Below are a few examples:
Many new plants are designed to operate with fewer personnel. Upgrading simple
gauges to wireless field devices can automate the manual collection of data from the
field in order to increase worker productivity and reduce field trip exposure to
hazardous environments.
Many existing facilities have been modified in order to meet emerging environmental
regulation. Real time monitoring of volatile organic compound release (VOC) from
wireless monitoring of pressure safety valves and of conductivity and temperature of
effluent waters can ensure environmental compliance.
Wireless remote monitoring of safety showers and gas detectors during construction
and operation can provide new levels of safety response.
New environmental regulation often requires redundant monitoring systems on assets
like tanks that were not required in the past. WirelessHART can provide a cost effective,
reliable secondary communication and monitoring method.
Wireless monitoring of steam traps and heat exchangers can provide real time
information for minimizing plant energy consumption.
Cost effective field information accessible via WirelessHART field devices enables non-traditional
end use of automation to be considered in the FEED and design phases. A designer should be
aware of initiatives for safety, environmental protection, energy consumption, and reliability in
addition to the traditional considerations for process automation. The WirelessHART
architecture extends the benefits of automation to multiple plant initiatives without the need
for multiple forms of I/O infrastructure.
4
Project Concepts
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Traditional wired architecture is limited in ability to mitigate risk of project execution.
Innovative WirelessHART architecture provides greater flexibility with minimum engineering
effort and greater savings in cost and time during any project phase, as compared to the
traditional approach.
Active projects should optimize measurement and control technology by establishing design
rules to define which points are suitable for WirelessHART versus traditional technology. These
design rules will help to enable consistent and efficient engineering for subsequent project
phases.
Section 2: Project Concepts
February 2016
Project Concepts
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Project Concepts
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Section 3 Appraise
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Appraise phase documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
The Appraise phase (conceptual design) requires high level customer requirements or project
constraints as input. In this phase a simple statement of requirements with identified
constraints or objectives will suffice. Selection of wireless technology in this phase allows a
simple generic design philosophy statement to be made on how the architecture can be used to
meet the needs of both the business and the project. Figure 3-1 shows the inputs and outputs of
the Appraise phase.
Figure 3-1. Conceptual Design Phase
Section 3: Appraise
February 2016
During the Appraise phase it is likely that a summary of the technology and its application will
be required by the project stakeholders in order for them to formulate a practical view of
applicability to the project. Plant personnel engaged in the early phase of the project should
also be part of this appraisal.
3.1 Application
WirelessHART® can be applied to a wide variety of process applications in all process industries
spread over differing geographical terrain. Evaluate the following factors for potential
WirelessHART application:
Process monitoring and measurements which are remote and uneconomical to
consider for wired monitoring
Equipment health monitoring
Environmental monitoring, energy management, regulatory compliance
Extreme environmental conditions for wired installations (hot, wet and corrosive)
Moving rails and test skids
Rotating equipment
Appraise
7
Section 3: Appraise
February 2016
Asset management, diagnostics and predictive maintenance
Simple closed-loop control (when appropriate)
API seal flush plans
Secondary systems
3.2 Technology
Evaluate the following factors for benefit by application of WirelessHART technology:
Minimizing the cost
Ease of installation
Reduced time for installation and commissioning
Ease of maintenance
Ease of expansion for future I/O points (scalability)
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3.3 Operations
WirelessHART field networks can help optimize contiguous or remote process operations by
collecting data in organized manner and enabling operators, shift supervisors, production/field
management, and facilities engineers to collaborate. Delivery of the right information to the
plant operations team helps them make the right decisions to improve plant throughput.
Evaluate WirelessHART operations for benefits in each of the following:
Access to monitoring points which are normally unavailable to plant operators
Increased safety by minimizing plant operator rounds in hazardous locations
Better alarm handling and reporting
Better insight by use of wireless transmitters for trending rather than gauges and
switches
3.4 Maintenance
There are no special maintenance requirements for WirelessHART devices apart from changing
the batteries. Diagnostic information provided to the Asset Management System alert
technicians of the need for maintenance.
WirelessHART devices provide advantage for maintenance in hazardous areas. The batteries are
intrinsically safe and power-limited, so they can be changed with the device locally without risk
of causing a source of ignition.
3.5 Appraise phase documentation
The Appraise phase documentation presents conceptual design that is referenced to customer
and project requirements, supported by economic analysis, and satisfies project imperatives.
8
Appraise
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3.5.1 Reference documents
Customer requirement specification (customer statement of requirements)
Project constraints
3.5.2 Deliverables from the philosophy document
Conceptual design philosophy/architecture
Economic analysis of technology and solutions
Project imperatives
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February 2016
Appraise
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Appraise
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Section 4 Pre-FEED
Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
Cost benefit study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12
Preliminary design basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14
Project references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
Pre-FEED documentation and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
4.1 Section overview
In Pre-FEED, the requirements, philosophies and imperatives established in the Appraise phase
are further elaborated. Deployment of WirelessHART
explored and verified in further detail during this phase. Figure 4-1 shows the inputs and
outputs of the Pre-FEED phase.
Section 4: Pre-FEED
®
for identified applications can be
February 2016
Figure 4-1. Pre-FEED Phase
An integrated approach should be used for incorporating wireless into a project. Wireless should
be merged with wired technology in the project procedures. It is essential to use the right field
device technology for the right application. New end user communities may be added as the
cost advantages of wireless expand applications during the FEED process.
Pre-FEED
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4.1.1 WirelessHART for control and monitoring applications
WirelessHART is designed for both control and monitoring applications. Most current use cases
emphasize monitoring applications due to conservative adoption of new technology in the
process manufacturing industry. The use of wireless control applications is continuing to evolve
with the introduction of discrete output devices for performing simple control functions. The
Ta bl e 4 -1 provides a high level summary for selection of the right protocol when factoring in
loop criticality; cost to engineer and implement; and location of field devices relative to main
process areas and host systems.
Table 4-1. Selecting the Right Protocol
Safety
systems
Critical
control
On-off
control
In-plant
monitoring
Conventional
Fieldbus
WirelessHART
Legend Based on technical and/or cost considerations
Most appropriate solution
Appropriate in some cases
Lease effective solution
Ta bl e 4 -2 shows the available technology solution for different signal types.
Table 4-2. Selecting Signal Types with the Right Protocol
Analog inputs Analog output Digital inputs Digital outputs
Conventional
Fieldbus
WirelessHART
N/A
Remote
monitoring
4.2 Cost benefit study
WirelessHART and wired solutions need to be evaluated during the Pre-FEED phase for
comparison from a cost and time perspective. Furthermore, assessments on the benefits to
schedule improvement (by phase) and of change management should be an input to this cost
benefit study.
The following factors can be considered for this comparison:
Main junction box requirements
Secondary junction box requirements
Main cable tray requirements
Secondary cable tray requirements
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Multi-core cable requirements
Mechanical and civil work for cable routing
Power supply in system cabinets
System cabinet requirements
Marshalling cabinets
3D modeling review for cable tray routing, cable tray engineering, and location of
Cost of change request management
Time and efforts for installing cable trays and cables
Power consumption requirement
Space requirements
Material weight reduction
System design time requirements
Material consideration based on area classification and protection concept
Section 4: Pre-FEED
February 2016
junction box
In addition to the above criteria, accommodating changes is cheaper and more efficient with
WirelessHART during any project phase. Typical case studies for cost, time, power, space and
weight savings are shown in Figure 4-2 and Figure 4-3. These case studies should consider the
criteria listed above.
Figure 4-2. Case Study for Cost and Time Savings
Pre-FEED
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Figure 4-3. Case Study for Power, Space, and Weight Savings
Section 4: Pre-FEED
February 2016
4.3 Preliminary design basis
Determine a preliminary design basis using the Customer Requirement Specification updated in
the Appraise phase along with the preliminary conceptual design documents available from
Appraise like site plan/layout, P&IDs, instrument index etc. This includes the quantity of
WirelessHART instruments, Gateways and repeaters needed to create a pervasive sensing
network. Assumptions on the basis of experience for similar plants/units can be made in
absence of requisite inputs.
Considering requirements of WirelessHART for indoor, outdoor and remote locations, develop a
preliminary network topology for the Wireless Field Network.
Develop a suitable interface solution for connection of the multiple Wireless Field Networks to
the host system and asset management system.
Verify spectrum approvals for the end-user and any intermediary locations. Refer to Appendix A:
Example ISA Specifications for more details.
Pre-FEED
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4.4 Project references
Previous projects operating with WirelessHART are a rich source of information and reference for
new planned WirelessHART implementation. Look towards these references as the first line of
help to overcome specific issues encountered in new installations.
4.5 Pre-FEED documentation and tools
Documentation from the Pre-FEED phase records use of conceptual design reference inputs to
develop high level functional design deliverables.
4.5.1 Reference documents
Initial plot plan
Initial 3D layout drawings
Initial P&ID
Instrument index
Customer specification documents
Section 4: Pre-FEED
February 2016
Proposal documents for cost estimates
4.5.2 Deliverables
Initial wireless field network system architecture
Measurement signal types
Bill of quantity
Pre-FEED
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Section 5: Front End Engineering Design
February 2016
Section 5 Front End Engineering Design
Section overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
Scope definition of engineering execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
WirelessHART functional design requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
WirelessHART infrastructure requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
Operational requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20
Design inputs documents review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20
Development of basis for design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 20
Initial design review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 22
5.1 Section overview
Front End Engineering Design (FEED) is an important stage where key deliverables exist for
wireless including cost estimation, design guidelines, and specifications. Collaborative efforts
put in by all stakeholders during FEED, will help in capturing all project specific requirements and
avoiding significant changes during the Execution phase.
The following factors can be evaluated during the FEED phase for WirelessHART
®
deployment in
the project.
Environmental considerations
WirelessHART functional design requirements
Scope definition of engineering execution
WirelessHART infrastructure requirements
Operational requirements
Design inputs documents review
Development of basis for design
Risk assessment and initial design philosophy review
Figure 5-1 shows the inputs and outputs of the FEED phase.
Figure 5-1. FEED Phase
Front End Engineering Design
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5.2 Scope definition of engineering execution
Stakeholder meetings are important to ensure all disciplines understand the scope of wireless
applications. Agenda items should include the following:
Review potential benefits in key areas of the work structure
Put in place appropriate training and strategy to achieve potential benefits.
Clearly distribute project work to optimize dependencies within the project team so
that schedule efficiencies can be achieved.
Identify In-house wireless network requirements to define the scope of Integration of
WFN and WPN network.
Clearly define wireless communication network availability, redundancy, WirelessHART
equipment supply, installation, configuration and commissioning site work activities,
and spare requirements scope
Define and include in the scope: overall wireless network architecture design, wireless device
location, minimum distance and coverage between access points, network coverage and
performance requirements.
Identify and include in the scope: supplementary wireless network devices such as WirelessHART
handheld communicator, mobile worker supply.
Determine the field device types and WirelessHART signal types for project implementation,
including consideration of the following signal and device types (refer to Emerson
™
Process
Management literature for the most up to date measurement types and innovations).
Pressure
Tem p er at ur e
Flow
Level
Tuning fork level
Conductivity
pH
Corrosion
Tank gauging
Guided wave radar
Discrete position monitoring
Discrete inputs
Discrete outputs
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Acoustic (steam trap and PRV monitoring)
Vibration
Flame detection
Front End Engineering Design
Engineering Guidelines
00809-0100-6129, Rev AB
Section 5: Front End Engineering Design
February 2016
5.3 Environmental considerations
Check for compliance with hazardous area classification requirements, temperature class, and
ambient temperature of plant.
Ensure compliance with regional and country specific RF frequency usage norms.
5.4 WirelessHART functional design requirements
During the initial stage of FEED, translate owner-operator’s functional requirements into a
network infrastructure, device characteristics, host interfaces, and applications. Document
these in the design specification; also include boundary conditions (e.g. all monitoring points on
this project will be wireless) associated with WirelessHART applications.
5.4.1 WirelessHART functional requirements
Develop the WirelessHART design, including the following:
Network environment and area classification
WirelessHART system architecture
Operational requirements
Data requirements
Interfaces
Te st in g
Spares consideration
Documentation requirements
Training
WirelessHART network Security, reliability and interoperability requirements
5.5 WirelessHART infrastructure requirements
Conduct plot plan reviews and determine the infrastructure requirements for the following:
System architecture
Wireless
Field network design including IEC62591 WirelessHART Field Instruments
Automation
Host system interface
Process control network interface
Asset management system diagnostics including those for field device and the field
Front End Engineering Design
network configuration
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Section 5: Front End Engineering Design
February 2016
5.6 Operational requirements
Determine operational requirements for the following:
Process monitoring and signal types
Device diagnostics
Loop response time
DCS HMI
Redundancy
WirelessHART network components
Reduction in field inspections of physical wired infrastructure (IECC60079)
Elimination/reduction of operator rounds
5.7 Design inputs documents review
Collect initial design documents that describe project requirements including plot plans,
equipment layout plans, preliminary instrument index, and three-dimensional layout drawings.
Engineering Guidelines
00809-0100-6129, Rev AB
Project team shall make sure inputs are sufficient to define the project initial design philosophy.
If documentation is inadequate then project team needs to seek technical clarification from the
facility owner-operator.
5.8 Development of basis for design
5.8.1 Design guidelines for WirelessHART
During the FEED process, all project stakeholders should be made aware of the capability and
benefits of WirelessHART so that design engineers can identify potential application candidates.
The project team should develop a wireless design and circulate to all project stakeholders.
For example, the process design engineer can use a set of criteria as shown in Ta b le 5 - 1 to
identify wireless application candidates.
Table 5-1. Example Criteria of Wireless Application Candidates
Safety
systems
WirelessHART
Critical
control
On-off
control
In-plant
Monitoring
Remote
Monitoring
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Legend Based on technical and/or cost considerations
Most appropriate solution
Appropriate in some cases
Lease effective solution
Front End Engineering Design
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