wireless monitoring network upgrade for instrument air compressors
METALS | NSW, AUSTRALIA
Our team completed the commissioning of a wireless monitoring network upgrade. More specifically, an ISA100 Field Wireless Device Network on three large Air Compressors, two Instrument Air Dryers, and also an A & B Instrument Air Flow Transmitters. As such, activities included preliminary investigation, recommendations, design, procurement, installation, and also configuration activities.
The project involved upgrading traditional pressure and temperature gauges, plus switches used to monitor process variables daily. To explain, as the operators ‘completed the rounds’ each day, they would write the measurement data on a paper log sheet. Consequently, this manual reporting provided little history and could not easily view equipment integrity relating to operation over time. Additionally, it took the operators away from other tasks, which were more vital to the overall plant operation.
Due to both reliability and ease of configuration, the upgrade included seven multivariable transmitters and two single EJX DP transmitters with ISA100 Field Wireless devices. In addition, installation can occur where extra racking, cable support systems, and also long cable runs would otherwise be required. Also, several of the devices are battery-powered and provide a five to seven-year lifetime at polling rates of sixty seconds.
The success of this project has led to further work. For instance, this included integrating thirty-six Bentley Nevada conditioning monitoring devices, including bearing vibration and temperature, into the ISA100 Field Wireless Device Network to monitor the long-term condition of onsite fans.
Scope
- Develop electrical design and software functionality to meet customer requirements.
- Design control and instrumentation systems to meet site conditions.
- Develop, supply, and also install a wireless communication network and configure ISA100 gateway, Access Point, and Field Wireless Devices.
- Rewire and retrofit existing panels with the equipment required.
- Remove all existing pressure and temperature gauges and switches.
- Supply and install new pressure transmitters, thermocouples, and converters.
- Supply and install converters to maintain the alarm and control interface with the existing Air Compressor PLC.
- Cutover each compressor in a 16-hour window – for remote operations at the plant control room.
- Integrate with existing HMI system on site.
- Perform system site acceptance testing with the customer, including trip signals.
Control systems
- Yokogawa CentumVP DCS communicating via Modbus to ISA100 Field Wireless Management Station.
- Wireless Network, including Yokogawa Field Wireless Management Station (YFGW410) and Yokogawa Field Wireless Access Point (YFGW510).
- Measurement Hardware, including seven Yokogawa Multi-Input Temperature Transmitters (YTMX580) and also two Wireless Differential Pressure Transmitters (EJX110B).
Deliverables
- New remote monitoring and controls for key process variables on each compressor, air dryer, and air main.
- Installation completed on time, within budget, and most importantly, without issue.
- Changeover of system and support provided during initial few weeks of operation.
