Wireless Valve Monitoring System

Westlock Controls

May 2012

Update Presentation Name or Confidentiality Status Under Footer Menu

May 17, 2012

Westlock Controls Confidential Not For Publication or Distribution

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.

Proprietary & Confidential

Westlock Controls

Conventional Automation System

Proprietary & Confidential

Westlock Controls

Process Plant Typical I/O Count Example

Analog I/O (4 to 20 mA)

Area 1 Area 2 Area 3 Area 4 Area 5

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

Description

AI

Instrumentation

373

Control Valves

82

82

On-Off Valves AO

Discrete I/O

Solenoid Valves (On-Off Valves)

Level Switches
Flow Switches
Weight Controllers
MCC 1
MCC 2
MCC 3
MCC 4
MCC 5
MCC 1
MCC 2
MCC 3
MCC 4

MCCs
Total

AO

DI

DO

Total

11

384

22%

164

9%

Area
3
Area 4
Area 5
0 574
287
861
49%
DO AO AI DI DO AO AI DI DO AO AI DI

108
7 228

Area 1
Area 2
AI DI DO AO AI DI
76 38
216
1
8
1
4
2 2 32
1 1 30
50 25
4
12

462

232 116
114
1

89 813 401
16
15
2
6

2
10

16
8
16
4

DO
50 25

356

20%

1765 100%
1
5

8
4
8
2

6
4

3
2

4
2
6
6

2
1
3
3

2
8
4

1
4
2

*I/O count may vary depending on process and application

Proprietary & Confidential

Westlock Controls

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

Proprietary & Confidential

Westlock Controls

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

Proprietary & Confidential

Westlock Controls

Valve Network: Strong Value Proposition

Proprietary & Confidential

Westlock Controls

Wireless Valve Network Even Better

Proprietary & Confidential

Westlock Controls

Typical Industrial Installation

85

85

No
Automation

Manual Valves
(No Automation)

*up to 95% of valves

are not monitored!

100
10
15

Automated Valves
Solenoid Only
(No Monitoring)

Automation

5
Automated Valves
(With Monitoring)

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
Proprietary & Confidential

Westlock Controls

Solution: Wireless Valve Monitoring System

Wireless
Gateway

DCS/PLC
Controllers

Wireless
Router

Wireless
Device

Manual Valve
(No Automation)

Proprietary & Confidential

Wireless
Device
Solenoid Wiring

Automated Valve
(Solenoid Only)

Westlock Controls

10

Single Wireless Module multiple enclosures

Proprietary & Confidential

Westlock Controls

11

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

Proprietary & Confidential

Westlock Controls

12

Wireless Valve Monitoring - System Architecture

System designed to IEEE 802.15.4 2006 at 2.4 GHz.

Proprietary & Confidential

Westlock Controls

13

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
Proprietary & Confidential

Westlock Controls

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Easy Integration
Open Protocol Integration
OPC, Modbus RTU/TCP, Profibus

Wireless
Gateway

Wireless
Device

DCS/PLC
Controllers

Wireless
Router
Wireless
Device

Wireless
Device
Wireless
Device

Proprietary & Confidential

Westlock Controls

15

Gateway Capacity using Routers

WD

Wireless
Router

Wireless
Gateway

100 Wireless Devices / Gateway

(using Routers)

Wireless
Router
WD

Wireless
Router

WD

WD

- 10,000 Wireless Devices (WDs) per WMS (Server Version)

- 100 Wireless Gateways (WGs) per WMS (Server Version)
Proprietary & Confidential

Westlock Controls

16

Gateway Capacity without Routers

WD

32 Wireless Devices / Gateway

(without Routers)

Wireless
Gateway

WD

WD

WD

- 10,000 Wireless Devices (WDs) per WMS (Server Version)

- 100 Wireless Gateways (WGs) per WMS (Server Version)
Proprietary & Confidential

Westlock Controls

17

Diagnostics for Automated Valves

Close Signature
Wireless Position
Monitoring

Wired Solenoid

Proprietary & Confidential

Alert

Valve
Signatures

Westlock Controls

Open Signature

18

10-year Battery life

Battery life monitoring and alarms (reported at each transmission)

2 hours operation without battery for field replacement

Proprietary & Confidential

Westlock Controls

19

Application Example: Auxiliary Inputs

HL

LL

Wireless
Valve Monitor
Auxiliary Inputs

Proprietary & Confidential

Westlock Controls

20

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

Proprietary & Confidential

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

Westlock Controls

21