Wireless Solutions
for the Oil & Gas
Wireless I/O FAQ
Cable
Replacement
How reliable is the communication?
Good signal strength assures uninterrupted communication. Before actual system installation, a SITE SURVEY should be conducted. With the proper selection of antennas (positioning and gain level), good signal strength can be achieved even over long distances. Frequency Hopping Spread Spectrum (FHSS) modulation ensures a very high tolerance for interference, while time-slotted architecture allows multiple RF nodes to coexist seamlessly on a large deterministic network.
How secure is my data?
SureCross wireless devices communicate with one another using a proprietary protocol which only carries I/O data, making it impossible for a malicious executable fi le to be transmitted. This protocol does not operate like an open protocol such as Wi-Fi (802.11b/g/n) and is not subject to the security risks of an open protocol. SureCross wireless protocol cannot be decoded by other manufacturers’ RF equipment. In fact, SureCross RF devices can be deployed successfully in close proximity to other wireless technologies with no adverse effects.
How far can the signal travel?
When using 1 W radios, the signal will travel up to six miles line of sight. When using 150 mW radios, the signal will travel up to three miles line of sight. All SureCross wireless devices offer an integrated Site Survey capability to evaluate radio signal strength in real-time to ensure your network will communicate reliably prior to installation – no software required.
What will happen if there is a communication failure?
The star topology DX80 architecture is a deterministic system which precisely defi nes how network endpoints behave during the loss of communications. The network identifi es when the communications link is lost and sets relevant outputs to user-defi ned conditions. Once the radio signal is re-established, the network returns to normal operation.
Why & where should I use a Wireless system?
• Wire damage due to articulating or rotating motion
• Excessive downtime of critical equipment due to cable replacement
• Heavy cost of material and manpower due to running of cables at long distances
• Diffi culty in installation of cables due to roads / bridges, property owned by another owner, or where burial of conduit is impractical and/or impossible
• Cable damage due to rodents, heavy vehicle traffi c and aging / deterioration
FHSS Communication Frequency Hopping Proprietary Protocol FHSS and TDMA (time-slotted) technology
Confi gurable & Mapped I/O
Multiple Signals, Digital and
Analogue
3
Instrumentation Interface
Pulsed Radar
• Non-contact technology • Detects liquid or bulk solids • Various manufacturers
• Sampling times as fast as every 5 minutes
Pressure Transducer
(4-20 mA / 1-5 V)
• Tubing & casing pressure at the wellhead
• Low power consumption results in long battery life (> 3 years)
• I.S. sensors can be used in Class I, Div 1 / Zone 0
• Sampling as fast as once/second
Guided Wave Radar
• Detects level in liquids, including crude oil and water
• Various manufacturers
• Cable/weight can be terminated in the fi eld to suit different tank sizes • Sampling times as fast as every
5 minutes
Dual Float Sensor
• Allows detection of oil-water interface with different density fl oats
• Not fooled by foam or gas in head space of tank
• RS-485 serial connection between Node and probe • Sampling times as fast as
once/16 seconds • Low power consumption
results in long battery life (> 2 years)
Flow Meter
• Various technologies • Various manufacturers • 4-20 mA output proportional to fl ow rate• DX99 provides loop power to instruments via internal battery (fi eld replaceable)
• Sensor scan time and RF report rate is user-defi ned • All parameters are confi gurable
via DIP switches or free PC software
Network Topology
• RF network health capability
• Proprietary protocol ensures network security
• Built in signal strength (RSSI)
• Gateway communications protocols: Modbus RTU/TCP, Ethernet/IP, Profi Net
Star topology, time-slotted architecture
CSA C/US
• Class I, Division 1, Groups A, B, C, D • Class I, Zone 0, Group IIC
• Class II, Division 1, Groups E, F, G • Class III, Division 1
LCIE/ATEX
• Group IIC, Zone 0 • Dust, Zone 20
DX80 C Gateway communicates with up to 47 remote Nodes (DX99 or DX80C) giving RTU / controller access to 500+ I/O points
Hazardous Area Classifi cation
5
5
SureCross Wireless I/O
Intrinsically Safe
Eliminates need for Ex d ratings and wiring Robust cast metal enclosure
IEC IP68 rated, -40 to +65°C operation Internal lithium D-cell battery
Multi-year life expectancy; no need to wire power Eliminate the need for bulky, expensive solar
Unique hazardous area RF nodes combine
radio, I.S. barriers and power supply into a
single compact & rugged package!
Global RF certifi cation
900 MHz or 2.4 GHz ISM band Rugged 2 dBi dome antenna
Available internal antenna 150 mW radio power*
4.8 km (3 mile) distances possible Even-driven transmit rates
Response speeds up to 62 ms
Multiple input types supported
Analog (4-20 mA, 0-10 V, 1-5 V), discrete, counter, bridge & temp
Smart power for external devices up to 19 V Supply loop power to I.S. instrumentation at user-defi ned intervals (confi gured via DIP switches or software)
Eliminate switching amplifi ers / Zener diode barriers and remain hazardous area compliant
Drilling
Drilling rig
• Wireless node with integral inclinometer sensor and self-contained battery reports the platform’s inclination angle in real-time
• Used to precisely monitor alignment during drilling operation
• Report platform out-of-level, sinkage issues • Alarm on measurement values outside of normal
• Radios with analog inputs allow monitoring of swing arm angle of the bale on the trip side, ensuring expensive equipment damage does not occur
Top drive
• DX99 node constantly monitors RPM and direction of the drill shaft on the top drive
• Defi nes drilling depth
• Can notify operators when any drilling-related parameters are out of specifi cation
Ship to Platform Communications
• Operational data exchange between shipboard and rig-based PLC / instrumentation without need for hard-wired cabling
• SureCross radio technology handles both data and I/O values in both hazardous and non-hazardous environments
7
Production
Conventional pump jack
• Beam angle is measured currently with a wired inclinometer sensor
• Objective is to accurately determine the position of the sucker rod
• Position is important for the POC in order to optimise the extraction of fl uids from the well
• Optimization minimizes wear and tear on the electrical / mechanical components
• SureCross node with integral inclination sensor eliminates need for troublesome cables
Storage Tanks
• Manage fl uid volumes and insure against costly spills • Totally wireless tank level measurement in remote areas
without access to grid power • Class I, Division 1 / Zone 0 rated
• DX99 nodes can be paired with a variety of level instrument types where the node provides barrier-protected boost voltage to the loop-powered device
• Completely eliminates need for expensive and time-consuming conduit and wire
• Measurement technologies: fl oats, capacitive, guided wave, or pulsed radar
• Crude oil, salt water disposal, or bulk sand storage tanks
Flare stack
• Monitor temperature of fl are and detect presence/absence of fl ame using DX99 nodes with thermocouple or RTD input types
• Battery powered nodes can relay information thousands of feet to ensure compliance at unattended well pads
Production
Artifi cial lift production pumper
• Load cell measures force applied to the sucker rod • Festoon (cable) attaching the load cell to the POC can
suffer catastrophic damage when it gets caught in the mechanical workings in high winds
• DX99 bridge input node eliminates cabling by attaching a simple, battery-powered RF device to the load cell • Wireless eliminates expensive and failure-prone cables • Ensures maximum production uptime
Mobile asset monitoring
• SureCross wireless devices can monitor level, temperature, pressure, and fl ow
• Complete fl ow back management on site • Ensure materials management onboard trucks • Onsite potable water, propane, and sand
• Monitor service vehicles (blending, frac, cementing, and wireline)
Production rig
• Eliminate cabling coming from transmitters measuring tubing pressure and casing pressure at the wellhead • Nodes with analog inputs and confi gurable boosted excitation voltage install directly in the classifi ed area, require no DC power, and no intrinsically safe (I.S.) barriers • Many custom wireless solutions utilizing 3rd party I.S.
pressure transducers
• Signals can be reliably transmitted thousands of feet into the safe area and regenerated as 4-20 mA or 1-5 V analog outputs into the RTU or controller
9
Transportation
Tank Gauging
• Accurately monitor crude oil volumes in 400 bbl storage tanks for custody transfer
• DX99 nodes provide operational management of well pad inventory without the need for expensive, permanent wiring requiring trenching and conduit runs
• Wireless affords the ability to re-deploy the automation technology when tank reconfi guration is needed or when the well is shut in
• Additional discrete inputs allow for addition of fl oat switch high – high alarming
Production pipeline
• Monitor liquid fl ow rates for custody transfer
• Endpoint RF devices can accept analog or pulse signals from fl ow meters
• Deployment using fl exible and economical battery or solar technologies
• Network topology may be point-to-multipoint or mesh depending on pipeline layout and coverage needed
Terminal / Mobile Asset
• Monitor and automate terminal operations for truck, ship, railcar loading / off-loading
• Inventory management and overfi ll prevention using SureCross DX99 nodes with level sensors
• Ensure audit trail records for operational management of liquids deployment
Headquarters USA Banner Engineering 9714 10th Avenue North Minneapolis, Minnesota 55441 USA +1 763 544 3164 Fax: +1 763 544 3213 sensors@bannerengineering.com www.bannerengineering.com China
Banner Engineering Int'L inc. (China) Shanghai Rep.
Xinlian Scientific Research Building: Level 12, Building 2, 1535 Hongmei Road, Shanghai 200233
+86 21 33 98 68 88
sensors@bannerengineering.com.cn www.bannerengineering.com.cn
Japan
Banner Engineering Japan
Cent-Urban Building 305 3-23-15 Nishi-Nakajima Yodogawa-Ku, Osaka 532-0011 +81 6 6309 0411 mail@bannerengineering.co.jp www.bannerengineering.co.jp Taiwan
Banner Engineering Int’l Incorporated Taiwan Rep. Office
8F-2, No. 308, Sec. 1, Neihu Rd. Taipei 114 +886 2 8751 9966 #15
info@bannerengineering.com.tw www.bannerengineering.com.tw
EU, Middle East, Africa
Banner Engineering EMEA
Park Lane, Culliganlaan 2F 1831 Diegem | Belgium +32 (2) 456 07 80 Fax +32 (2) 456 07 89 mail@bannerengineering.com www.bannerengineering.com/eu India
Banner Engineering India – Pune (HQ)
Office No. 1001, 10th Floor Sai Capital, Opp. ICC
Senapati Bapat Road, Pune 411016 +91 20 66405624
salesindia@bannerengineering.com www.bannerengineering.co.in
Mexico
Banner Engineering de Mexico Edificio VAO
Av. David Alfaro Siqueiros No.103 Col. Valle Oriente C.P.66269 San Pedro Garza Garcia, Nuevo Leon 52-81-8363-2714
mexico@bannerengineering.com www.bannerengineering.com.mx
Turkey
Banner Engineering Elk. San. Ve Tic. Ltd. Sti.
Barbaros Mah. Uphill Court Towers A Blk D:49 34746 Atasehir Istanbul +90 216 688 8282
Fax: (+90) 216 688 8181
turkey@bannerengineering.com.tr www.bannerengineering.com.tr
Sensors
Vision
Wireless I/O
Lighting &
Indicators
Machine Safety
SENSORS VISION WIRELESS I/O LIGHTING &
INDICATORS SAFETY
Banner Engineering's Worldwide Presence
• Presence/Absence Detection • Foreground &
Background Suppression • GO/NO GO Inspection • Gating and Triggering • Parts Counting • Level and Distance
Measurement • Positioning
• Contrast and Colour Sensing
• Vehicle Detection (Radar, Ultra sonic & Magnetic Technology)
• Vision Sensors with Onboard User Interface • Pattern Recognition • Traceability (Barcode,
Datamatrix and Text Reading)
• OCR/OCV
• Complex Part Inspection • Part Orientation • Assembly Verification • Colour Inspections
• Slip Ring Replacement • Tank Farm Monitoring • Livestock Environmental
Monitoring
• Water and Wastewater Treatment
• HVAC Remote Monitoring • Traffic Monitoring &
Control
• Remote Sensing in Process Automation • Cable Replacement • ATEX Approved Solutions
• Bin & Part Picking • Error/Mistake Proofing • Pick-to-Light &
Put-to-Light
• Operator Guidance • Call for Parts • Incorrect Pick Signal • Remote Start/Stop
Indication
• Work Station Lighting • Mobile Equipment Work
Lights
• Production Machine and Cabinet Lighting
• Safety Light Screens • Ergonomic Two-Hand
Control Devices • Safety Modules • Emergency Stop Devices • Safety Interlocking • Laser Scanners for Safety
Applications
• Programmable Safety Controllers
• Enabling Devices
Banner Engineering India Pvt. Ltd. Office No. 1001, 10th Floor
Sai Capital, Opp. ICC Senapati Bapat Road
Pune 411016 +91 20 66405624 Fax +91 20 66405623