Gas Well Deliquification Workshop Sheraton Hotel, February 19 22, 2012 Wireless I/O, Connecting Remote Sensors in a Wide Range of Environments Glenn Longley, Sr. Product Manager FreeWave Technologies
Agenda Summary Applications, Installations Challenges Locations Conclusions 2
Summary Monitoring Remote Sensors presents a unique set of challenges to remain cost effective, safe and secure with installations in all different types of environments and distances. Wireless IO can bring back data from sensors that are anywhere from a few feet to 30+ miles away. These systems can connect to a PLC/RTU or go all the way back to a central SCADA system. We will review several example installations and provide an overview of the challenges that Wireless IO can help solve, whether installing in regular or hazardous location. This includes considerations necessary for Class 1 Division 2 and Class 1 Division 1 explosive gas locations that are common in Oil and Gas industry. 3
Why Use Wireless I/O? Saves time and money Improves performance and visibility of geographically dispersed assets Allows a more resource efficient process and better quality measurement Reduces the total cost of ownership for automated systems with distributed I/O Wireless is quick to install and easier to repair and move assets Virtually unlimited I/O points Free up I/O on master PLC/RTU Expansion provides simple future additions 4
Solutions: Benefits REMOTE 2014 Allows users to reach devices that would be too difficult with wired solutions IO System accuracy is not diminished by distances Error Free Communications Frequency Hopping - Communication and diagnostics between the IO Master and the IO Slaves. Affordable - Low installation and long-term maintenance costs. Low Latency - Less than one second signal delay No protocol support required (Wire Replacement) Complete electrical isolation between devices 5
What UL Class 1 Division 2 Means Class 1, Division 2 Locations: An area where flammable liquids and gases are handled, but not expected to be in explosive concentrations. However: 1)The possibility for these concentrations to exist might occur if there was an accidental rupture or other unexpected incident. 2)Area where ignitable gases or vapors are normally prevented from accumulating by positive mechanical ventilation, yet could exist in ignitable quantities if there was a failure in the ventilation systems. 3)Adjacent to Class I, Division 1 locations where it is possible for ignitable concentrations of gas/vapors to come into this area because there isn't proper ventilation. 6
What UL Class 1 Division 2 Means Class 1 Div 2 Product Standards: Hermetically Sealed Non-incendive Circuit Non-incendive Component Non-incendive Equipment Non-sparking apparatus 7
What UL Class 1 Division 1 Means Class 1, Division 1 Locations: 1)Expected to contain explosive mixtures of gases, vapors, or liquids during normal working operations. (Most common) 2)Ignitable concentrations frequently exist because of repair or maintenance operations. 3)Where there might be the release of ignitable concentrations of gases or vapors due to equipment breakdown, while at the same time causing electrical equipment failure. 8
What UL Class 1 Division 1 Means Class 1 Div 1 Product Standards: Intrinsically safe apparatus Intrinsically safe circuit Intrinsically safe system Explosion-proof apparatus Purged and pressurized 9
I/O: Applications Applications typically focus on one of these themes that decrease costs (time, labor) and increase revenue (volume, quality) or improve saftey 1. Process Automation 2. Process Optimization 3. Condition-Based Monitoring PRESSURE 4 to 20 ma valve SWITCH coil DIGITAL OUTPUT 0 to 10 V analog output ANALOG INPUT temperature MODBUS LATCH CONTROLLER Wire Replacement RTU Accuracy universal Signal Replication PLC transmitter transducer frequency hopping spread spectrum UL Class 1 Div 2 1 to 5 V SENSOR 10
I/O: Uses Tip: I/O is the interface between PHYSICAL ASSETS and CONTROLLERS PHYSICAL ASSETS are SENSORS and CONTROL ELEMENTS I/O inputs measures SENSOR output I/O outputs controls CONTROL ELEMENTS I/O interfaces communicate with CONTROLLERS 11
I/O: Uses Add Expandable I/O to a PLC or RTU Add Expandable I/O to Existing Wireless Networks Unlicensed Licensed Cellular Satellite Build SCADA Networks with Expandable I/O and Distributed Control Build Field Networks with Distributed, Expandable I/O 12
I/O: Uses 13
Applications: Wireless I/O in Oil and Gas 14
Applications: Wireless I/O in Oil and Gas 15
Applications: Wireless I/O in Oil and Gas Wellhead Monitoring and Control Pressures Artificial Lift Systems Plunger Lift Injection Pump Off Many More Valve Control Pipelines Pressures Temperatures Valve Control Pad Site & Facilities Tank Levels Liquid Meters Pumps Valves and Flow Lines Flare Stacks Dehydrator Temperature Separator Pressure Separator Temperature Emergency Shut Down (ESD) Any I/O without the need for immediate local decisions and control 16
I/O: Uses Tip: I/O connects to different types of SENSORS, PROCESS ELEMENTS and CONTROLLERS ANALOG INPUT: Pressure transmitter, Temperature transmitter, Level sensor, Chemical concentration, Battery voltage DIGITAL INPUT: Level switch, Flow meter, Switch, Plunger arrival ANALOG OUTPUT: Variable position valve DIGITAL OUTPUT: Valve, Actuator, Latch, Pump, Alarm, Variable frequency drive PROCESS CONTROLLERS: RTU s and PLC s from Emerson, Siemens, Rockwell, ABB, etc 17
I/O: Applications Wireless I/O in Oil and Gas Physical Asset Wireless I/O Process Controller 18
Conclusions Wide range of Industries Wide range of Problems Short Range and Long Range Applications Extends existing capabilities Works in Challenging Locations 19
Questions REMOTE 2014 20
THANK YOU! Glenn Longley Sr. Product Manager FreeWave Technologies 5395 Pearl Parkway, Suite 100 Boulder, CO 80301 Office: (303) 381-9287 Cell: (971) 219-2970 Fax: (303) 407-5966 glongley@freewave.com www.fr eewave.com Feb. 17 20, 2013 21
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Backup Feb. 27 - Mar. 2, 2011 2011 Gas Well Deliquification Workshop 24
What UL Class 1 Division 2 Means Class 1, Division 2 Location: An area where flammable liquids and gases are handled, but not expected to be in explosive concentrations. However: 1.The possibility for these concentrations to exist might occur if there was an accidental rupture or other unexpected incident. 2.Area where ignitable gases or vapors are normally prevented from accumulating by positive mechanical ventilation, yet could exist in ignitable quantities if there was a failure in the ventilation systems. 3.Adjacent to Class I, Division 1 locations where it is possible for ignitable concentrations of gas/vapors to come into this area because there isn't proper ventilation. 25
What UL Class 1 Division 2 Means Class 1 Div 2 Product Standards: Hermetically Sealed: Equipment is sealed against the entrance of an external atmosphere where the seal is made by fusion, for example, soldering, brazing, welding, or the fusion of glass to metal. Nonincendive Circuit: A circuit, other than field wiring, in which any arc or thermal effect produced under intended operating conditions of the equipment is not capable, under specified test conditions, of igniting the flammable gas, vapor, or airborne dust Nonincendive Component: A component having contacts for making or breaking an incendive circuit and the contacting mechanism is constructed so that the component is incapable of igniting the specified flammable gas, vapor, or airborne dust. The housing of a nonincendive component is not intended to exclude the flammable atmosphere or contain an explosion. Nonincendive Equipment: Equipment having electrical/electronic circuitry that is incapable, under normal operating conditions, of causing ignition of a flammable gas, vapor, or airborne dust due to arcing or thermal means. Non-sparking apparatus: Apparatus that has no normally arcing parts or thermal effects capable of ignition. 26
What UL Class 1 Division 1 Means Class 1, Division 1 Location: 1.When the atmosphere of an area or location is expected to contain explosive mixtures of gases, vapors, or liquids during normal working operations. (Most common) 2.Where ignitable concentrations frequently exist because of repair or maintenance operations. 3.Where there might be the release of ignitable concentrations of gases or vapors due to equipment breakdown, while at the same time causing electrical equipment failure. 27
What UL Class 1 Division 1 Means Class 1 Div 1 Product Standards: Intrinsically safe apparatus - The apparatus must be intrinsically safe, meaning that the device must be secure enough in hazardous environments that it will not contribute to the ignition of a hazardous atmosphere. Intrinsically safe circuit - All circuits should be deemed incapable of becoming ignited by any spark or thermal effect under specific testing conditions. Intrinsically safe system - Each piece of a system and interconnecting cables used in hazardous (classified) locations must be intrinsically safe. Explosion-proof apparatus - The apparatus is enclosed in a case that will uphold in the explosion of a specified gas or vapor that may occur and, likewise, will prevent the ignition of a specified gas or vapor surrounding the enclosure by sparks, flashes, or explosion of the gas or vapor within. It must operate at a temperature that will not cause the surrounding flammable atmosphere to ignite. Purged and pressurized - The process of (1) purging - supplying an enclosure with a protective gas at a sufficient flow and positive pressure to reduce the concentration of any flammable gas or vapor initially present to an acceptable level; and (2) pressurization, supplying an enclosure with a protective gas with or without continuous flow at sufficient pressure to prevent the entrance of a flammable gas or vapor, a combustible dust, or an ignitable fiber. 28