Wireless Valve Monitoring System · 2018. 10. 1. · Severe Service Metallic Enclosure...
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Wireless Valve Monitoring System
Transcript of Wireless Valve Monitoring System · 2018. 10. 1. · Severe Service Metallic Enclosure...
Wireless Valve
Monitoring System
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Benefits• Reducedcosts(wires,conduits,cabletrays,cabinets,I/Os)• Easierengineeringandinstallation• Fastercommissioningandstartup• Solutionforspaceconstraints,smallerfootprint• Monitoringformanual,automated,rotaryorlinearvalves• Reducedunwarrantedfieldtripsandlaborcosts• Improvedoperationefficiencyandsafety
Features• Multipleenclosureoptions(resin,aluminum,316SST)• Highvisibilitybeaconandwirelessvalvemonitoring(0to100%)• 10-yearbatterylife• Intrinsicallysafeandexplosionproofoptions• Diagnosticsandvalvesignature• Directmounttovalvesandactuators• Easyintegrationwithcontrolsystems
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The Westlock solution to wireless valve monitoring
ThespeciallydesignedwirelessvalvepositionmonitoringsystemfromWestlockprovidesreal-timeinformationaboutavalve’sstatusdirectlyintothecontrolsystem,reducingfailureandriskwhileincreasingsafetyandyield.
The Westlock wireless valve monitoring system was specifically designed to work with both manual and automated on/off valves and to integrate directly with a wider plant control system. All field devices use a proven standard wireless protocol design to IEEE 802.15.4 -2006 at 2.4 GHz with built-in AES 128bit encryption security.
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The need to monitor plant for both operational and safety reasons has never been greater, however the potential cost involved in putting a monitoring system in place means that larger numbers of valves remain ‘un-monitored’.
The challenge of monitoring valves for operational and safety reasons
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Conventional wiringAmajorrestrictionwheninstallingautomationsystemsistheneedtousewirestoconnectsensorsandactuators.Wiringanautomationsysteminamodernplantisverytimeconsumingandcostly,takesaconsiderablefootprintandaddssignificantlytoweight.Researchsuggeststhatonly10%ofallpossiblemonitoringinstrumentationiscurrentlyinstalled.Wirelessautomationcouldincreasethisrateto30%ormore.
Mostplantoperatorshavetodealwithatleastoneeventperyearwhereamanualvalveisincorrectlyleftopen,closed,orpartiallyopen.Sincemostmanualvalvesarenotmonitored,thoseeventscangoundetectedforasignificanttimecausingconsiderableoperationallossesinadditiontoenvironmentalandsafetyrisks.
TypicallyhalfoftheI/Opointsonaplantcontrolsystemareusedforon/offvalves;howeverduetowiringcostconstraintsonlyonethirdoftheautomatedvalveshavelimitswitches(justthesolenoidiswired),leavingtwothirdsoftheseautomatedvalveswithoutanypositionfeedbackormonitoring.Moresignificantly,foreveryautomatedon/offvalvetherewillbeanother3to4manuallyoperatedvalvesontheplantleaving70to85%ofthevalveswithoutanymonitoring.
The main issue with using conventional wiring to monitor valves is the huge cost of cables, cable trays, cabinets, and the associated I/O points in the control system.
The wireless solutionThespeciallydesignedwirelessvalvepositionmonitoringsystemfromWestlockworkswithbothmanualandautomatedon/offvalvesandsmoothlyintegrateswithwiderplantcontrolsystems.Itprovidesreal-timeinformationaboutavalve’sstatusdirectlyintothecontrolsystem,reducingfailureandriskwhileincreasingsafetyandyield.
Withoutmonitoringitisimpossibletoassesstheefficiencyofanautomatedvalve.AWestlockwirelessdevicewillnotonlyprovideaccurateup-to-dateinformationonthevalve’sstatusatanypointintime,butcanalsoprovidethevalve’soperationalsignatureenablingcosteffectivepredictivemaintenance.
Monitoringmanualvalvescanbebothlaborintensiveandproblematicwithvalvesininaccessiblelocations;theWestlockwirelessdeviceprovidesaccurateinformationhelpingoperatorstoimprovesafetyandqualitywhilereducinginefficienciesandcosts.
DesignedwithinteroperabilityinmindusingbreakthroughwirelesstechnologytheWestlockwirelessvalvemonitoringsystemiscurrentlybasedonthestandardZigbeePro,withbuilt-inAES128bitencryptionsecuritybutwillalsobeavailableforWirelessHART®andISASP100inthenearfuture.
Conventional Wireless
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One wireless module fits multiple enclosures
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ThewirelessmodulefitsinmultipleWestlockenclosures
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The Westlock wireless valve monitoring system was specifically designed to work with both manual and automated on/off valves and to integrate directly with a wider plant control system. Based around the very flexible valve monitoring wireless device (WD) the system also includes the wireless router (WR), gateway (WG), handheld (WH) and the Wireless Management System (WMS) software.
Valve Monitoring Wireless Device (WD)Thevalvemonitoringwirelessdeviceisabatterypoweredwirelesspositiontransmitter(0to100%)withintegratedlimitswitchesandauxiliaryinputs.Theultracompactdesigncanbeintegratedwithanyvalve,manualoractuatedusingamechanicalattachmenttothevalveoractuatorshaft.
TheunitissuitableformountingtoanyISO/DIS5211.2F03manualvalveusingourcustomdesignedhardwareandtoactuatorsusingtheNAMURinterface;onothervalvesoractuatorsamechanicalbracketisused.
ThewirelessdeviceisfittedinachoiceofstandardWestlockenclosurestosuitarangeofplantconditions. Thedeviceissuitableforbothrotaryandlinearmonitoringandhastheoptionofinternalorexternalantenna (engineeredresinenclosures).
AvailabletoanumberofspecificationsthedevicecanbesuppliedintrinsicallysafeandsuitableforFM/IEC/ATEXZONE0andCLASS1DIVISION1.Thedevicehasa10yearbatterylifeandcanbeinstalledonexistingequipmentwithminimumdisruptionorspecifiedonnewvalve/actuatorpackages.Theunitsareeasilycommissionedandcalibratedusingthewirelesshandheld.
Thewirelessdevicereportsthevalvepositionevery15minutes(configurable)or,inamatterofseconds,aftereveryvalvemovementofatleast1.5°,enablingvalvesignaturestobecreatedforallautomatedvalves.
It also monitors temperature, battery status and alarms; all messages are transmitted with a real time stamp.
A wireless position monitor to put you in control throughout the plant
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Valve Monitoring Wireless Device (WD) The valve monitoring wireless device is suitable for both rotary and linear monitoring and has the option of internal or external antenna, and auxiliary inputs. Available to a number of specifications the device can be supplied intrinsically safe and suitable for FM/IEC/ATEX ZONE 0 and CLASS 1 DIVISION 1.
Ultra Compact Engineered Resin Enclosure IntrinsicallySafe/Weathertight Thisultra-compactwirelesspositionmonitorhasanenclosurewithBeaconvisualindicator,whichisinstalledonthetopofavalveoractuatorandcoupleddirectlytothevalveoractuatorshaft.
Lightweight Engineered Resin Enclosure IntrinsicallySafe/Weathertight Thesemid-sizehousingsareconstructedwithpremiumengineeringresintoprovidearobustlightweightalternativetometalenclosureswithextremechemicalandimpactresistance.Itcanbesuppliedwithaclearcoverandadditionalentriesforauxiliaryinputs.
Compact Metallic Enclosure IntrinsicallySafe/Weathertight Thesepositionmonitorsprovideacompactweathertightmetalsolutionfornon-hazardousorintrinsicallysafeapplicationswheremorerobustmaterialisrequiredlikecausticswashdowns,chlorideatmospheresorsaltwaterenvironments.
Severe Service Metallic Enclosure IntrinsicallySafe/ExplosionProof Thispositionmonitordesignmeetsexplosionproofareaclassificationandsatisfiesawiderangeofrequirementsincluding;robustmechanicalprotection,Beaconvisualindication,andadditionalentriesforauxiliaryinputs.
Severe Service Metallic Enclosure IntrinsicallySafe/ExplosionProof Explosionproofrangeofpositionmonitorsdesignedtoprovideflexibilityallowingpre-wiredcomponentstobefittedinacompactintegratedunitreadytobemounteddirectlytoavalveoractuatorhousing.
Features• Internalantennaoption• IP66engineeredresinenclosureensuresbothstrengthandcorrosionresistance
• Compactandlightweightdesign,perfectsizeformanualvalvemonitoring
• NamurVDI/VDEstandardmountingarrangement
Features• Beaconoffers360degreeinstantvisualrecognitionofvalvepositionfromupto150feetaway
• Internalantennaoption• Excellentchemical,UVandimpactresistance• NAMURshaftoptioncomplianttoVDI/VDE3845available
Features• Beaconoffers360degreeinstantvisualrecognitionofvalvepositionfromupto150feetaway
• Aluminumand316stainlesssteeloptions• Compactdesigntomountonsmalleractuatorsormanualvalvemonitoring
• NAMURshaftoutputcomplianttoVDI/VDE3845available
Features• Aluminumand316stainlesssteeloptions• Robustdesignforsuperiormechanicalprotection• StandardboltpatternformountingtoNAMURactuatorswithcommonbracketkits
• Globalcertificationsavailable
Features• Beaconoffers360degreeinstantvisualrecognitionofvalvepositionfromupto150feetaway
• Aluminumand316stainlesssteeloptions• Terminalstripsarepre-wiredandnumberedwithgenerousworkingspaceforeaseofuse
• Allunitsarestandardwithanadditionalconduitforeasyfieldwiringandmountingaccessories
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In addition to the Valve Monitoring Wireless Device (WD) the system includes all the components necessary to install operate and integrate with your existing plant operating system.
Wireless Valve Monitoring System - Components
Wireless Handheld (WH) TheWirelessHandheldallowslocalcommunicationwiththekeycomponentsofthesystem–wirelessdevice,routerandgateway.Intendedforuseatcloserangethewirelesshandheldisusedtocalibrateandsetupeachwirelessdevice,configureoperatorIDandpasswords,turnunitson/offandtoprompttransmissionconfirmingthevalve’sstatus.
Wireless Router (WR) TheWirelessRouterisusedtoextendtherangeandbufferthedatafromthewirelessdevicesandallowslocalmonitoringfromasinglepoint.Italsoconnectswithotherroutersandtransfersinformationusingaself-healingmeshtopologyprovidingalternateinformationrelaysintheeventofafailure.
Wireless Gateway (WG) TheWirelessGatewaymanagesthedatafromroutersanddevicescollectingdatafromupto32devicesusingastandardwirelessprotocolandthentransfersthistoaWMSstation(standaloneorserver)viaEthernetTCP/IP.Thegatewayalsooperatesaspartoftheself-healingmeshtopologyensuringfullredundancyandavoidingasinglepointoffailure.
WMS Client TheWirelessManagementSystemClientprovidestheGUIinterfacetotheplantcontrolsystemandimplementsconnectivitythroughstandardcommunicationprotocolslikeModbusRTU,ModbusTCP,andOPCDA.TheWMSClientalsomanagesafloatinglicensefromtheServer.
WMS Server TheWirelessManagementSystemServeristhegatewaytothemainplantcontrolsystemandcanmanagedatafromupto100Wirelessgateways.Thesystemrunsasanapplicationorasaservice,managesthelicenseandgeneratesalogofallactivity.ThemainfunctionoftheWMSserveristocollectdata,monitorthenetworkanddeliverinformationtouppertiermanagementsystems.
Features• Localfieldinterface• Configuration,calibration, andtroubleshooting
• InternaldatabasewithUSBportforeasydownloading
Features• Buffersdataforwirelessdevice• Redundantcommunicationpathwithautomaticroutingandmeshnetworktopology
• Extendswirelesscoverage
Features• Managesdatafromrouters anddevices
• Automaticredundancyto plantnetwork
• EthernetTCP/IPconnection toplantnetwork
Features• ProvidesGUIinterface• Viewandsetmaintenancelogsfor alldevices
• Standardcommunicationprotocolconnectivity
Features• Collectdataandnetworkmonitoring
• Dataloggingandinformationmanagement
• Supportsmultiple clientconnections
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System ArchitectureThe Westlock wireless valve monitoring system has been designed with simplicity and reliability in mind. All field devices use a proven standard protocol for communication.
Specificallydesignedforlowpowerconsumptionandimmunityfrombackgroundinterferencethisensuresreliablereadingsandlongbatterylifeforallthewirelessunits.Thefielddevicesarealsoconfiguredusingameshnetworktopology,whichensuresfullredundancyandavoidsanysinglepointoffailure.Thesystemiseasilyintegratedwiththeplantcontrolsystem(DCS,SCADA,orPLC)throughstandardcommunicationprotocols,likeOPCDAandMODBUSRTU/TCP.
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MaintenanceWMS Server
Operation WMS Client
Operation WMS Client
DCS/PLCControllers
Wireless Gateway
Wireless Gateway
Wireless Router
Wireless Router
WH WirelessHandheld
WD
WD
WD
WD
WD
WD
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Key Numbers
Limits•WirelessDevices(WD)perWirelessManagementServer(WMS) • 10,000usingWMSServer •120usingWMSStandAlone •WirelessDevices(WD)perWirelessGateway(WG) • 100usingWirelessRouters(WR) •32withoutWirelessRouters(WR)
Battery Life•WirelessDevice,nominalconfiguration:10years
Typical Distances•WirelessDevice(WD)toRouter(WR):25m(70m/openspace) •Router(WR)toRouter(WR)/Gateway(WG):100m(200m/openspace)
Typical Latencies •Hoptohop:10ms •WirelessDevice(WD)toWMS:1second
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WES
PBR-090
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www.westlockcontrols.com
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