Feature Wireless technology Break free from the restrictions of wire
Marcelo Dultra, global product manager, Westlock Controls, explains the importance of having a valve monitoring system in place, and shows how Westlock’s wireless monitoring system achieves greater visibility of valve equipment, overcoming the space and cost issues associated with wire
he need to monitor plant equip- ment has never been greater. However, the investment needed to introduce conventional wired systems means some valves remain unmonitored, therefore many plant operators are unable to maximise oper- ational efficiency and safety. Conventional wiring to connect valves and actuators with a plant con- trol system is costly and requires a considerable footprint. With only around 10% of all potential monitor- ing instrumentation currently installed, plants are at risk of incurring loses or running environmental and safety risks when a manual valve is incorrectly left open, closed or par- tially open and remains undetected for a period of time.
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In order to overcome the capital investment and space obstacles to installing a valve monitoring infra- structure, Westlock Controls has launched a wireless valve monitoring system. Specifically designed for both manual and automated valves, the system integrates directly with a plant control system using wireless technology to achieve greater moni- toring visibility of valve equipment, improving efficiency and safety in plant operations. The Westlock solution is as an inte- grated unit with direct mounting to valves or actuators and uses the com- pany’s distinctive beacon visual indi- cator. There are a range of size and material options, as well as intrinsi-
cally safe devices for hazardous appli- cations (FM/IEC/ATEX Zone 1). Typically half of the input/output points in a plant control system are used for on/off valves. However, due to wiring cost constraints only one third of these automated valves have position feedback or monitoring. More signifi- cantly, for every automated on/off valve there will be another three to four man- ually operated valves on the plant. This leaves a large proportion, anywhere
Improved accessi- bility to plant equipment is important in the process industry
The system is easily integrated with the plant control systems through standard communi- cation protocols
between 40 to 95%, of the valves with- out any monitoring. By eliminating the need for wires, conduits and associated hardware, plant operators could use wireless monitoring to increase this percentage without the high cost of installation and additional hardware of traditional wired
systems.The Westlock system also overcomes accessibility issues when valves are in hazardous or difficult to access locations. Without monitoring it is impossible to assess the efficiency of a valve, but by using the real-time information supplied by the wireless system, these inefficiencies can be reduced. The system can work with both manual and automated valves and integrates directly with a wider plant control system. Based around the valve monitoring wireless device (WD) the system also includes the wireless router (WR), gateway (WG), handheld (WH) and the Wireless Management System (WMS) software. AES 128bit encryption security is built into the wireless communication to provide a reliable and robust solution. The system is suitable for both rotary and linear monitoring and has the option of an internal or external antenna. The device has a 10 year bat- tery life, and the units are easily com- missioned and calibrated using the wireless handheld. Low power con- sumption and immunity from back- ground interference means the unit offers reliable readings and transmits messages in real time. The wireless device reports the valve position enabling valve signatures to be created for all automated valves. It also moni- tors temperature, battery status and alarms.
Westlock Controls
www.breakfreefromwires.com Enter 232
Remote interrogation where access is an issue
afarge Plasterboard can now monitor critical field instruments remotely from the plant control room following the introduction of FieldKey wireless adapters from ABB. “We would previously have had to physically go to each instrument and pull off the information onto a laptop,” said electrical technician Matthew Pepper. “Now we can interrogate instruments remotely, which is especially helpful where access is an issue.” Lafarge’s Bristol factory took part in a successful trial of prototype wireless adapters from ABB early last year, and has now followed up with the installation of several commercial FieldKey units. These are used to check the performance of critical instruments, and are moved around the site to monitor any instruments that engineers sus- pect may be experiencing a problem. “We’re using the adapters to check that there are no system faults on the instruments, check calibrations and make fine-tuning adjustments,” said Pepper. “We’re not currently looking to use them for process control on our existing production operations but we’ll be considering them in any new installations in future.” FieldKey adapters are quick and easy to fit to any instruments equipped with 4-20mA HART communications. On the Lafarge site they are used with equipment from at least
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three different manufacturers. The small adapters have a rotating antenna, enabling them to be fitted into tight spaces if necessary. They also use energy harvesting, taking power from the 4-20mA loop, so they don’t need batteries. With no need for hardwiring to the network, each FieldKey can be installed in under three minutes, eliminating the need for a plant shutdown The FieldKeys transmit the data from the instruments to a Wireless gateway which has an Ethernet port. In the case of Lafarge, the FieldKey adapters are integrated with the company’s existing PACTware asset management system. ABB
T: 0870 600 6122 26 E:
moreinstrumentation@gb.abb.com ref. ‘FieldKey’ Enter 233 JULY 2012 Process & Control
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