Westlock Wireless Valve Monitoring System Presentation
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Transcript of Westlock Wireless Valve Monitoring System Presentation
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Update Presentation Name or Confidentiality Status Under Footer Menu May 17, 2012
Westlock Controls Confidential Not For Publication or Distribution
Wireless Valve Monitoring System
Westlock Controls
May 2012
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WestlockTM Controls
Established in 1984 as a Limit Switch and Position Indicator Company.
WestlockTM Controls has a global reputation providing innovative
solutions for networking, monitoring, and controlling of process
valves.
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Conventional Automation System
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Process Plant Typical I/O Count Example
Analog I/O (4 to 20 mA)
AO AI AO AI AO AI AO AI AO AI
Control Valves 17 17 26 26 24 24 15 15
Temperature Transmitters 31 21 52 12
D.P. Flow Transmitters 12 7 4 5
Differential Pressure Transmitters 11
Magnectic Flowmeters 1 11 7
Pressure Transmitters 8 1 1 6
Densimeters 4 6 6
Rotameters 3 5
Vortex Flowmeters 4 2
D.P. Level Transmitters 1 8 5 14
D.P. Remote Seal Level Transmitters 7 4 16 4
Discrete I/O
AO AI DI DO AO AI DI DO AO AI DI DO AO AI DI DO AO AI DI DO
Solenoid Valves (On-Off Valves) 76 38 216 108 232 116 50 25
Level Switches 1 8
Flow Switches 1 1
Weight Controllers 4
MCC 1 2 2 32 16 6 3
MCC 2 1 1 30 15 2 1 4 2 4 2
MCC 3 50 25 4 2 10 5 2 1
MCC 4 12 6 2 1 2 2 6 3
MCC 5 6 3
MCC 1 16 8
MCC 2 8 4 2 1
MCC 3 16 8 8 4
MCC 4 1 1 4 2 1 1 4 2
Area 1 Area 2 Area 3 Area 4 Area 5
Area 1 Area 2 Area 3 Area 4 Area 5
Description AI AO DI DO Total %
Instrumentation 373 0 11 0 384 22%
Control Valves 82 82 0 0 164 9%
On-Off Valves 0 0 574 287 861 49%
MCCs 7 7 228 114 356 20%
Total 462 89 813 401 1765 100%
*I/O count may vary depending on process and application
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Typical Valve Automation
ON-OFF Valves
Minimum of 3 twisted pairs:
Limit Switch 1
Limit Switch 2
Solenoid
Long wire runs & full cable
trays
Full marshaling cabinets
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Additional Constraints
DCS/PLC I/O: Two (2) inputs and one
(1) output for each
automated valve
required
Engineering &
Installation Labor intensive layout
Difficult to maintain and
to make modifications
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Valve Network: Strong Value Proposition
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Wireless Valve Network Even Better
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Typical Industrial Installation
100
85
15
5
85
10
Manual Valves
(No Automation)
Automated Valves
Solenoid Only
(No Monitoring)
Automated Valves
(With Monitoring)
No
Automation
Automation
*up to 95% of valves
are not monitored!
Main reason is cost: data suggests $2K to $5K per valve
(Wires, Cable Trays, Cabinets, I/Os, Installation)
*Ratio may vary depending on process and application
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Solution: Wireless Valve Monitoring System
DCS/PLC
Controllers
Wireless
Device
Wireless
Router
Wireless
Gateway
Wireless
Device
Manual Valve
(No Automation) Automated Valve
(Solenoid Only)
Solenoid Wiring
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Single Wireless Module multiple enclosures
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Multiple Enclosure Options
Ultra Compact Engineered Resin Enclosure
Intrinsically Safe / Weathertight
Compact with integrated visual indicator
Ideal for hand valves
Lightweight Engineered Resin Enclosure
Intrinsically Safe / Weathertight
Extreme chemical and impact resistance
Additional entries for auxiliary inputs
Compact Metallic Enclosure
Intrinsically Safe / Weathertight
Aluminum and 316 SST
Compact design for smaller valves/actuators
Severe Service Metallic Enclosure
Intrinsically Safe / Explosion Proof
Robust design for superior mechanical protection
Aluminum and 316 SST
Severe Service Metallic Enclosure
Intrinsically Safe / Explosion Proof
High visibility Beacon
Aluminum and 3166 SST
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Wireless Valve Monitoring - System Architecture
System designed to IEEE 802.15.4 2006 at 2.4 GHz.
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Wireless Valve Monitoring Main Components
Wireless Hand Held (WH)
Local field interface
Configuration, calibration, and troubleshooting
Wireless Router (WR)
Redundancy with automatic routing & mesh topology
Extends wireless coverage
Wireless Gateway (WG)
Provides redundant connectivity to plant network
Manage data from wireless devices and routers
Wireless Management System Server
Data logging and information management
Allows multiple client connections
Wireless Management System Client
Provides GUI interface
Alarms/Alerts and valve diagnostics
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Easy Integration
Wireless
Device
Wireless
Device
Wireless
Router
Wireless
Gateway
DCS/PLC
Controllers
Wireless
Device
Wireless
Device
Open Protocol Integration
OPC, Modbus RTU/TCP, Profibus
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Gateway Capacity using Routers
Wireless
Router Wireless
Gateway
- 10,000 Wireless Devices (WDs) per WMS (Server Version)
- 100 Wireless Gateways (WGs) per WMS (Server Version)
WD Wireless
Router
Wireless
Router
WD
WD
WD 100 Wireless Devices / Gateway
(using Routers)
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Gateway Capacity without Routers
Wireless
Gateway
- 10,000 Wireless Devices (WDs) per WMS (Server Version)
- 100 Wireless Gateways (WGs) per WMS (Server Version)
WD
WD
WD
WD
32 Wireless Devices / Gateway
(without Routers)
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Diagnostics for Automated Valves
Wired Solenoid
Wireless Position
Monitoring
Valve
Signatures
Close Signature
Open Signature
Alert
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10-year Battery life
Battery life monitoring and alarms (reported at each transmission)
2 hours operation without battery for field replacement
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Application Example: Auxiliary Inputs
Wireless
Valve Monitor
LL
HL
Auxiliary Inputs
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Wireless Valve Monitoring System
Benefits
Reduced costs (wires, cable trays,
cabinets, I/Os)
Easier engineering and installation
Faster commissioning and startup
Solution for space constraints,
smaller footprint
Monitoring for manual, automated,
rotary or linear valves
Reduced unwarranted field trips
and labor costs
Improved operation efficiency and
safety
Features
Multiple enclosure options (resin,
aluminum, 316 SST)
High visibility beacon and wireless
valve monitoring (0 to 100%)
10-year battery life
Intrinsically safe and explosion
proof options
Diagnostics and valve signature
Direct mount to valves and
actuators
Easy integration with control
systems