Contributors: Mareca Hatler, Darryl Gurganious, and Charlie Chi Ph.D

Pages: 152 (143 figures, 54 tables)

Table of Contents

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Synopsis:

An erratic global economy did not prevent the industrial Wireless Sensor Network (WSN) market from doubling over the past two years.

Early adopters have demonstrated that WSN is secure, reliable and can be targeted at new monitoring and control solutions that were previously deemed too expensive or located in prohibitively difficult environments.

Networks are expanding with several current deployments that have over 3,000 WSN nodes.

For this report, ON World collaborated with the International Society of Automation (ISA), HART Communication Foundation (HCF) and the Wireless Industrial Networking Alliance (WINA) to conduct a survey on WSN with 216 industrial automation professionals.

ON World's study found that 70% of the surveyed end users are planning WSN or additional WSN deployments within the next 18 months.

The migration to standards has been rapid with approximately an equal number of respondents preferring WirelessHART or a hybrid strategy that includes WirelessHART and ISA100.11a.

Report Overview:

This report covers the global market for Wireless Sensor Networking (WSN) in industrial automation including the following:

Target Markets & Solutions: Identification of the largest and fastest growing WSN markets in three landscapes: process, vertical and discrete/factory automation. Analysis of the drivers/forces and adoption trends in more than 60 target markets/applications.

Forecasts: Five year market size forecasts by product segment (e.g. wireless field devices, gateways), revenues (e.g. WSN equipment and services), application, target market, technology/topology (by chipset), power source, new versus displaced applications, and by geography.

Survey Results: Key findings with 216 industrial automation professionals on the current adoption trends, applications, needs, wants and preferences, supported standards, satisfaction level with current WSN systems and future plans.

Technology Dynamics: Comprehensive technology evaluation on the standards situation, potentially disruptive technologies, and technology requirements for WSN technologies such as 802.15.4, WirelessHART, ISA100.11a, ZigBee, WiFi, Bluetooth/802.15.1 and other point-to-point/point-to-multipoint wireless technologies.

Competitive Landscape: Segmentation, disruption and sustainability analysis, profiles on 85 companies including platform providers and software developers, WSN systems manufacturers, component suppliers and energy harvesting startups.

Patent Evaluation: 300 awarded/filed patents in four product segments.

ON World has conducted research on industrial Wireless Sensor Networking since 2002 and has published dozens of reports on this and related areas.

Primary Research:

270+ phone and online surveys with 150+ organizations

End Users
120+ industrial end users and systems integrators

Vendors/Experts
150+ industrial automation professionals

Executive Summary:
Send us an email with
"industrial WSN"
in the subject.

Executive Summary
The Opportunity
Market Landscape
Accelerating Wireless Adoption
Standards Migration
End User Satisfaction with Current WSN Systems
Methodology/Scope

Industrial Wireless Sensor Networks
Trends & Developments
Wireless Impact on Industrial Field Devices
Migration to Standards
Wireless Mesh Systems Becoming Widespread
Increasing Demand for Energy Harvesting
Market Segmentation
WSN Solutions & Applications
Wireless Impact on Sensors
Most Likely Wireless Sensors & Applications
Production
Asset Management
Machine Health Condition Based Monitoring
Corrosion & Structural Integrity Monitoring
Energy Management
Health, Safety & Environmental Monitoring
Emissions Monitoring
Perimeter Security & Intrusion Detection

End User Viewpoints
Satisfaction with Current WSN Systems
Equipment Costs
Planned WSN
Planned WSN Applications
Drivers & Inhibitors
Innovations

Technology Dynamics
Trends & Developments
Standards Migration
Wireless Mesh Sensor Networking
IP Sensor Networking
Energy Harvesting
Mobility & RTLS
On-Node Intelligence
Technology Requirements
Industrial WSN Technologies
Sub 1GHz & Long Range Wireless
IEEE 802.15.4
ZigBee
WIA-PA
IEEE 802.15.4e
Non-Mesh 802.15.4
Other 802.15.4 Developments
WiFi (802.11)
Bluetooth/IEEE 802.15.1 & Bluetooth Low Energy
Industrial WSN Standards & Alliances
WirelessHART
Wireless Industrial Technology Konsortium (WiTeck)
ISA100
ISA100.11a
ISA100.11 and WirelessHART Compared
ISA100.12 (WirelessHART Convergence)
The Heathrow Group
Users Evaluate WirelessHART vs ISA100.11a
Factory Automation Standards
ISA100 Working Group16 Factory Automation
Profibus Wireless Sensor and Actuator Networks (WSAN)
IETF Standards
6LoWPAN
ROLL/RPL
CoRE/CoAP
"Passive" Wireless Sensors

Global Total Market Size Forecasts
Methodology
Total Potential Market Size
Total Potential Industrial WSN Units
Global Wireless Field Device Shipments Scenario
Global Total Units
Global Total Revenues
Global Total Units by Product Segment
Global Total Revenues by Product Segment
Global Total Units by Landscape
Global Total Revenues by Landscape
Global Total Units by Solution
Global Total Revenues by Solution
Global Total Revenues by Geography
Global Total Units by New vs Displaced Applications
Global Total Units by Power Source
Global Total Units by Technology
Global Total Units by Topology
Average Sale Prices
Node Hardware Cost by Component

Target Markets

Traditional Process Markets
Survey Key Findings

Petroleum Refining & Petrochemicals
Market Forces & Drivers
WSN Applications

Chemicals, Plastics & Textile Mills
Market Forces & Drivers
WSN Applications

Oil & Gas Exploration, Production & Pipelines
Market Forces & Drivers
WSN Applications

Electric Power
Market Forces & Drivers
WSN Applications

Metals, Minerals & Mining
Market Forces & Drivers
WSN Applications

Pulp & Paper
Market Forces & Drivers
WSN Applications

Water & Wastewater
Market Forces & Drivers
WSN Applications

Market Size Forecasts
Units by Market
Revenues by Market
Units by Solution
Revenues by Solution
Revenues by Product Segment
Revenues by Geography
New vs Displaced Applications
Energy Harvesting
Units by Technology
Units by Topology

Vertical Markets
Survey Key Findings

Pharma, Biotech & Medical Devices
Market Forces & Drivers
WSN Applications

Food, Beverage & Tobacco
Market Forces & Drivers
WSN Applications

Electronics
Market Forces & Drivers
WSN Applications

Market Size Forecasts
Units by Market
Revenues by Market
Units by Solution
Revenues by Solution
Revenues by Product Segment
Revenues by Geography
New vs Displaced Applications
Energy Harvesting
Units by Technology
Units by Topology

Discrete/Factory Automation
Survey Key Findings

Automotive/Transportation
Market Forces & Drivers
WSN Applications

Machinery & Electrical
Market Forces & Drivers
WSN Applications

Other Discrete
Market Forces & Drivers
WSN Applications

Market Size Forecasts
Units by Market
Revenues by Market
Units by Solution
Revenues by Solution
Revenues by Product Segment
Revenues by Geography
New vs Displaced Applications
Energy Harvesting
Units by Technology
Units by Topology

Competitive Landscape

Communications Components
Disruption & Sustainability
Market Leaders
Innovators & New Entrants
Intellectual Property
Profiles

Thin Film Batteries & Energy Harvesting
Market Leaders & Innovators
Intellectual Property
Profiles

WSN Systems
Disruption & Sustainability
Market Leaders
Innovators & New Entrants
Intellectual Property
Profiles

Software/Hosted Services
Disruption & Sustainability
Profiles

Automation/IT Platforms
Disruption & Sustainability
Market Leaders
Innovators & New Entrants
Intellectual Property
Profiles

Awarded Patents/Filed Applications
Components
WSN Systems
Software
Automation/IT Platforms

List of Figures

Figure 1: Global Installed Industrial Wireless Sensing Points (2011-2016)
Figure 2: All Respondents - WSN Adoption Stage
Figure 3: All Respondents w/ >100 Wireless Field Devices (Single site)
Figure 4: All Respondents - Preferred Standards Approach
Figure 5: End Users – Most Important WSN Features Ranked by Satisfaction
Figure 6: Global Industrial WSN Revenues by Landscape (2011-2016)
Figure 7: End User WSN Adoption Stage
Figure 8: End Users with > 100 Wireless Field Devices (All Locations)
Figure 9: Largest Wireless Field Device Deployment per Site
Figure 10: Global Industrial Field Instrument Shipments, Wired & Wireless (2011-2016)
Figure 11: End User WirelessHART Adoption in 2012 vs 2010
Figure 12: WSN Adopters by Network Protocol Used
Figure 13: Preferred Standards Approach by Respondent Type
Figure 14: WSN Adopters - Most Likely Standards Approach by Type
Figure 15: WSN Adopters – Percent of Wireless Mesh Field Devices
Figure 16: WSN Adopters – Wireless Field Devices Powered by Energy Harvesting
Figure 17: Five Major Industrial WSN Market Landscapes
Figure 18: Target Markets by Reported WSN Application
Figure 19: Industrial WSN Applications
Figure 20: Global Wireless Sensing Point by Type (2011-2016)
Figure 21: Current WSN Applications by Benefit
Figure 22: Wireless Sensors in Use by Sensed Parameter
Figure 23: Most Likely Wireless Sensors
Figure 24: End Users – Most Likely Wireless Sensors Ranked
Figure 25: WSN Adopters – Most Common WSN Applications
Figure 26: All Respondents – Planned WSN Applications
Figure 27: WSN Applications Mentioned In Case Studies
Figure 28: Industrial Corrosion Costs by Segment
Figure 29: Energy Intensity by Sector
Figure 30: All Respondents – Most Important WSN Features
Figure 31: All Respondents – Satisfaction with Current WSN Systems
Figure 32: WSN Adopters – Satisfaction with Current WSN Systems
Figure 33: End Users – Satisfaction Ranked by Feature
Figure 34: Impact from 10X Lower Equipment Costs
Figure 35: Planned WSN
Figure 36: End Users - Most Likely Sensors to be Wireless
Figure 37: End Users - Planned WSN Applications
Figure 38: End Users – WSN Inhibitors Ranked
Figure 39: Open-Ended Comments on Adoption Drivers
Figure 40: Most Needed WSN Innovations
Figure 41: End Users – Most Needed WSN Innovations Ranked
Figure 42: WSN Network Protocols Currently In Use
Figure 43: End Users - WSN Standards Approach
Figure 44: End Users – Percent of Wireless Mesh Field Devices
Figure 45: Importance of IP Sensor Networking Ranked by Respondent Type
Figure 46: WSN Adopters - Level of Satisfaction with Battery Lifetime
Figure 47: End Users – Most Needed Innovations Ranked
Figure 48: Most Important WSN Technology Requirements
Figure 49: Satisfaction with Today's Industrial WSN Systems
Figure 50: Sub 1GHz/Long Range Wireless Summary
Figure 51: IEEE802.15.4 Mesh Summary
Figure 52: ZigBee Summary
Figure 53: WiFi Summary
Figure 54: Satisfaction with WirelessHART vs ISA100 by Feature
Figure 55: Data Reliability Ranked by Technology
Figure 56: Wireless Devices with WSAN Technologies in a Production Cell
Figure 57: SENSeOR Wireless Passive Sensor System
Figure 58: Total Potential Industrial Sensing Points by Market
Figure 59: Global Industrial Wireless Field Devices by Scenario (2011-2016)
Figure 60: Global Industrial WSN Unit Shipments (2011-2016)
Figure 61: Global Total Industrial WSN Revenues (2011-2016)
Figure 62: Global Industrial WSN Unit Shipments by Product Segment (2011-2016)
Figure 63: Global Industrial WSN Revenues by Product Segment (2011-2016)
Figure 64: Global Industrial WSN Unit Shipments by Landscape (2011-2016)
Figure 65: Global Industrial WSN Revenues by Landscape (2011-2016)
Figure 66: Global Industrial WSN Units by Solution (2011-2016)
Figure 67: Global Industrial WSN Revenues by Solution (2011-2016)
Figure 68: Global Industrial WSN Revenues by Geography (2011-2016)
Figure 69: Global Industrial Wireless Field Devices, New vs Displaced (2011-2016)
Figure 70: Global Industrial Wireless Field Devices by Power Source (2011-2016)
Figure 71: Global Industrial WSN Chipsets by Technology (2011-2016)
Figure 72: Global Industrial WSN Chipsets by Topology (2011-2016)
Figure 73: Industrial Wireless Field Device Average Sale Price per Solution (2011-2016)
Figure 74: Industrial WSN Equipment Costs by Component (2011-2016)
Figure 75: Global In-Plant Process WSN Revenues (2011-2016)
Figure 76: Process Industries – Respondents by Target Market
Figure 77: Process Industries – WSN Adoption Stage
Figure 78: Process Industries - Largest WSN Deployment
Figure 79: Process Industries – Preferred Standards Approach
Figure 80: Process Industries – Planning WSN by Market
Figure 81: Process Industries – Planned WSN Applications
Figure 82: Global Oil & Gas WSN Revenues (2011-2016)
Figure 83: Global Electric Power Transmission WSN Revenues (2011-2016)
Figure 84: GridSense Wireless Monitoring Examples
Figure 85: Process – WSN Units by Market (2011-2016)
Figure 86: Process – WSN Revenues by Market (2011-2016)
Figure 87: Process – WSN Units by Solution (2011-2016)
Figure 88: Process – WSN Revenues by Solution (2011-2016)
Figure 89: Process – WSN Revenues by Product Segment (2011-2016)
Figure 90: Process – WSN Revenues by Geography (2011-2016)
Figure 91: Process – WSN Wireless Devices, New vs Displaced (2011-2016)
Figure 92: Process – Wireless Field Devices by Power Source (2011-2016)
Figure 93: Process – WSN Chipsets by Technology (2011-2016)
Figure 94: Process – WSN Chipsets by Topology (2011-2016)
Figure 95: Global Vertical Markets WSN Revenues (2011-2016)
Figure 96: Vertical Markets - Respondents by Target Market
Figure 97: Vertical Markets - WSN Adoption Stage
Figure 98: Vertical Markets - Largest WSN Deployment
Figure 99: Vertical Markets - Preferred Standards Approach
Figure 100: Vertical Markets - Planning WSN by Market
Figure 101: Vertical Markets - Planned WSN Applications
Figure 102: Food/Bev Market Forces
Figure 103: Pharma/Biotech Market Forces
Figure 104: Electronics Market Forces
Figure 105: Vertical – WSN Units by Market (2011-2016)
Figure 106: Vertical – Revenues by Market (2011-2016)
Figure 107: Vertical – WSN Units by Solution (2011-2016)
Figure 108: Vertical – WSN Revenues by Solution (2011-2016)
Figure 109: Vertical – WSN Revenues by Product Segment (2011-2016)
Figure 110: Vertical – WSN Revenues by Geography (2011-2016)
Figure 111: Vertical – Wireless Field Devices, New vs Displaced (2011-2016)
Figure 112: Vertical – Wireless Field Devices by Power Source (2011-2016)
Figure 113: Vertical – WSN Chipsets by Technology (2011-2016)
Figure 114: Vertical – WSN Chipsets by Topology (2011-2016)
Figure 115: Trad'l Factory Automation WSN Revenues (2011-2016)
Figure 116: Discrete Industries – Respondents by Target Market
Figure 117: Discrete Industries – WSN Adoption Stage
Figure 118: Discrete Industries - Largest WSN Deployment
Figure 119: Discrete Industries – Preferred Standards Approach
Figure 120: Discrete Industries – Planning WSN by Market
Figure 121: Discrete Industries – Planned WSN Applications
Figure 122: Automotive Mfg Market Forces
Figure 123: Machinery/Electrical Market Forces
Figure 124: Other Discrete Market Forces
Figure 125: Discrete – WSN Units by Market (2011-2016)
Figure 126: Discrete – WSN Revenues by Market (2011-2016)
Figure 127: Discrete – WSN Units by Solution (2011-2016)
Figure 128: Discrete – WSN Revenues by Solution (2011-2016)
Figure 129: Discrete – WSN Revenues by Product Segment (2011-2016)
Figure 130: Discrete – WSN Revenues by Geography (2011-2016)
Figure 131: Discrete – Wireless Field Devices, New vs Displaced (2011-2016)
Figure 132: Discrete – Wireless Field Devices by Power Source (2011-2016)
Figure 133: Discrete – WSN Chipsets by Technology (2011-2016)
Figure 134: Discrete – WSN Chipsets by Topology (2011-2016)
Figure 135: The Industrial WSN Value System
Figure 136: WSN Components- Disruption & Sustainability
Figure 137: WSN Components -Filed/Awarded Patents by Company
Figure 138: Energy Harvesting - Filed/Awarded Patents by Company
Figure 139: WSN Systems - Disruption & Sustainability
Figure 140: WSN Systems - Filed/Awarded Patents by Company
Figure 141: Software - Disruption & Sustainability
Figure 142: Automation/IT Platforms - Disruption & Sustainability
Figure 143: Automation/IT Platforms - Filed/Awarded Patents by Company

List of Tables

Table 1: Global Industrial Field Instrument Shipments, Wired & Wireless (2011-2016)
Table 2: Global Wireless Sensing Point by Type (2011-2016)
Table 3: WirelessHART and ISA100.11a Features
Table 4: Global Industrial Wireless Field Devices by Scenario (2011-2016)
Table 5: Global Industrial WSN Unit Shipments (2011-2016)
Table 6: Global Total Industrial WSN Revenues (2011-2016)
Table 7: Global Industrial WSN Unit Shipments by Product Segment (2011-2016)
Table 8: Global Industrial WSN Revenues by Product Segment (2011-2016)
Table 9: Global Industrial WSN Unit Shipments by Landscape (2011-2016)
Table 10: Global Industrial WSN Revenues by Landscape (2011-2016)
Table 11: Global Industrial WSN Units by Solution (2011-2016)
Table 12: Global Industrial WSN Revenues by Solution (2011-2016)
Table 13: Global Industrial WSN Revenues by Geography (2011-2016)
Table 14: Global Industrial Wireless Field Devices, New vs Displaced (2011-2016)
Table 15: Global Industrial Wireless Field Devices by Power Source (2011-2016)
Table 16: Global Industrial WSN Chipsets by Technology (2011-2016)
Table 17: Global Industrial WSN Chipsets by Topology (2011-2016)
Table 18: Industrial Wireless Field Device Average Sale Prices (2011-2016)
Table 19: Industrial WSN Equipment Costs by Component (2011-2016)
Table 20: Process – WSN Units by Market (2011-2016)
Table 21: Process – WSN Revenues by Market (2011-2016)
Table 22: Process – WSN Units by Solution (2011-2016)
Table 23: Process – WSN Revenues by Solution (2011-2016)
Table 24: Process – WSN Revenues by Product Segment (2011-2016)
Table 25: Process – WSN Revenues by Geography (2011-2016)
Table 26: Process – WSN Wireless Devices, New vs Displaced (2011-2016)
Table 27: Process – Wireless Field Devices by Power Source (2011-2016)
Table 28: Process – WSN Chipsets by Technology (2011-2016)
Table 29: Process – WSN Chipsets by Topology (2011-2016)
Table 30: Vertical – WSN Units by Market (2011-2016)
Table 31: Vertical - Revenues by Market (2011-2016)
Table 32: Vertical – WSN Units by Solution (2011-2016)
Table 33: Vertical – WSN Revenues by Solution (2011-2016)
Table 34: Vertical – WSN Revenues by Product Segment (2011-2016)
Table 35: Vertical – WSN Revenues by Geography (2011-2016)
Table 36: Vertical – Wireless Field Devices, New vs Displaced (2011-2016)
Table 37: Vertical – Wireless Field Devices by Power Source (2011-2016)
Table 38: Vertical – WSN Chipsets by Technology (2011-2016)
Table 39: Vertical – WSN Chipsets by Topology (2011-2016)
Table 40: Discrete – WSN Units by Market (2011-2016)
Table 41: Discrete – WSN Revenues by Market (2011-2016)
Table 42: Discrete – WSN Units by Solution (2011-2016)
Table 43: Discrete – WSN Revenues by Solution (2011-2016)
Table 44: Discrete – WSN Revenues by Product Segment (2011-2016)
Table 45: Discrete – WSN Revenues by Geography (2011-2016)
Table 46: Discrete – Wireless Field Devices, New vs Displaced (2011-2016)
Table 47: Discrete – Wireless Field Devices by Power Source (2011-2016)
Table 48: Discrete – WSN Chipsets by Technology (2011-2016)
Table 49: Discrete – WSN Chipsets by Topology (2011-2016)
Table 50: WSN Components – Profiles
Table 51: Power Sources – Profiles
Table 52: WSN Systems – Profiles
Table 53: Software – Profiles
Table 54: Automation Platform – Profiles