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Westlock Controls Confidential Not For Publication or Distribution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