Wireless Solutions for the Oil & Gas Industry
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 file 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 defines how network endpoints behave during the loss of communications. The network identifies when the communications link is lost and sets relevant outputs to user-defined 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 Difficulty 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 traffic and aging / deterioration
Reliable
Secure
Flexible
Industrial
FHSS Communication Frequency Hopping
Proprietary Protocol FHSS and TDMA (time-slotted) technology
Configurable & Mapped I/O
Multiple Signals, Digital and Analogue
Built-in Signal Strength
Link Loss Output Built-in network health capability
Power Possibilities
Cable Replacement
Instrumentation Interface Pressure Transducer (4-20 mA / 1-5 V) • Tubing & casing pressure at the wellhead • Low power consumption results in long battery life (> 3 years)
Pulsed Radar • Non-contact technology • Detects liquid or bulk solids
• I.S. sensors can be used in Class I, Div 1 / Zone 0 • Sampling as fast as once/second
• Various manufacturers • Sampling times as fast as every 5 minutes
Dual Float Sensor • Allows detection of oil-water interface with different density floats
Guided Wave Radar • Detects level in liquids, including crude oil and water • Various manufacturers • Cable/weight can be terminated in the field to suit different tank sizes • Sampling times as fast as every 5 minutes
• 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)
• DX99 provides loop power to instruments via internal battery (field replaceable) • Sensor scan time and RF report rate is user-defined • All parameters are configurable via DIP switches or free PC software
Flow Meter • Various technologies • Various manufacturers • 4-20 mA output proportional to flow rate
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Network Topology Star topology, time-slotted architecture
• RF network health capability • Proprietary protocol ensures network security
Up to 3 km
• Built in signal strength (RSSI) • Gateway communications protocols: Modbus RTU/TCP, Ethernet/IP, ProfiNet
DX80 C Gateway communicates with up to 47 remote Nodes (DX99 or DX80C) giving RTU / controller access to 500+ I/O points
Hazardous Area Classification 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
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Up to 3 km
SureCross Wireless I/O Unique hazardous area RF nodes combine radio, I.S. barriers and power supply into a single compact & rugged package! Global RF certification 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
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
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 userdefined intervals (configured via DIP switches or software) Eliminate switching amplifiers / Zener diode barriers and remain hazardous area compliant
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Drilling Drilling rig • Wireless node with integral inclinometer sensor and selfcontained 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
Ship to Platform Communications • Operational data exchange between shipboard and rigbased 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
Top drive • DX99 node constantly monitors RPM and direction of the drill shaft on the top drive • Defines drilling depth • Can notify operators when any drilling-related parameters are out of specification
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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 fluids 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 fluid 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 timeconsuming conduit and wire • Measurement technologies: floats, capacitive, guided wave, or pulsed radar • Crude oil, salt water disposal, or bulk sand storage tanks
Flare stack • Monitor temperature of flare and detect presence/absence of flame 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
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Production Artificial 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 flow • Complete flow 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 configurable boosted excitation voltage install directly in the classified 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
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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 reconfiguration is needed or when the well is shut in • Additional discrete inputs allow for addition of float switch high – high alarming
Production pipeline • Monitor liquid flow rates for custody transfer • Endpoint RF devices can accept analog or pulse signals from flow meters • Deployment using flexible 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 overfill prevention using SureCross DX99 nodes with level sensors • Ensure audit trail records for operational management of liquids deployment
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Sensors • 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, Ultrasonic & Magnetic Technology)
Vision • 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
Lighting & Indicators
Wireless I/O • 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
Machine Safety
• Bin & Part Picking • Error/Mistake Proofing • Pick-to-Light & Put-toLight • 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's Worldwide Presence 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
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
China
Japan
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
Taiwan
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
India
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
Mexico
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
Turkey
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
SENSORS
VISION
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
WIRELESS I/O
LIGHTING & INDICATORS
SAFETY
Banner offers a full range of sensing solutions www.bannerengineering.com/eu co om EN F179 – SEP 2012