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Safety Enhancements Using Wireless Technology in Gas Plants

Najeeb S. Al-Hashim, Abdulrazaq H. Al-Deraa, Saudi Aramco

Copyright 2013, International Petroleum Technology Conference

This paper was prepared for presentation at the International Petroleum Technology Conference held in Beijing, China, 2628 March 2013.
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Abstract
The motive force behind this advanced concept in implementing Wireless Technology Using Solar Powered instruments is
to get hydrogen sulfide (H2S) and lower explosive level (LEL) signals from an unreachable location where hazardous waste is
being handled to a safe centralized control room. Implementing this would reduce the cable cost and the maintenance. This
solar power is eco-friendly. With wireless communication, allowing more sophisticated data to be transmitted to the
centralized control room; appropriate steps have been taken to install wireless devices in remote location. Such technology
plays a progressively essential role in up-to-date industries. The wireless solar powered sensors provide a cost-effective
alternative and are being used increasingly for equipment and other applications in a diversity of industrial processes. In
addition, its improved remote diagnostics makes plants and operations safer. In this paper, we will cover the benefits and
challenges we experienced at the Haradh gas plant while implementing wireless technology to prevent massive threats and
destruction to persons, property and equipment.
Keywords: DSSS, H2S, LEL, MESH, wireless, solar power, ISA100

Introduction
Wireless technology has been growing exponentially over the years. Consequently, wireless technology developments are
providing numerous advantages in gas plants and the operating plans for refineries. These developments are providing new
opportunities for enhancing plant performance, reliability and safety while reducing installation and maintenance/operating
costs. In Saudi Aramcos business, the safety of employees is at the top of its priorities. Since the lower explosive level (LEL)
gas or hydrogen sulfide (H2S) could be present in most of Saudi Aramcos operation facilities, it is mandatory to install
LEL/H2S sensors in every location where the hazardous gases are expected. For gas plants and refineries there are a lot of
challenges related to monitoring H2S and LEL gas releases. The biggest challenge for monitoring releases of gas in plants is to
cover isolated remote field locations such as the oily sumps area outside the plant fence. To overcome this challenge, a new
solution was designed to fit this application. This solution can be achieved by installing standalone wireless H2S and LEL
detectors powered by solar cells plus batteries, beacon and horn. The system consists of different equipment that is using Saudi
Aramco standards as well as international standards. The International Society of Automation (ISA) standard for wireless
systems Process Control and Related Applications is ISA 100.11a [3, 5].
This paper reviews the use of H2S and LEL solar powered wireless sensors for safe operation in gas plants and refineries. The
paper also addresses the system design and integration.

H2S and LEL Background and Risk

Safety is regarded as the most important thing in every organization. Safety is especially a big concern in industrial culture. As
a matter of fact, no organization wants to have a property loss; for instance, equipment damage, building damage or even plant

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damage on a big scale. Possible injury to personnel is another important consideration. Following this, lost time from not
following safety rules and regulations needs to be factored. For Saudi Aramco, safety is the companys top priority. One of the
main concerns in the industry is what is called the invisible killer: H2S. This gas is a highly toxic colorless transparent that is
gas heavier than air. H2S is an extremely poisonous or toxic gas. A single breath of highly concentrated H2S can damage the
human respiratory system and can kill a grown man. The danger is that H2S leaks may not be seen. High concentrations of H2S
gas in the air are extremely flammable and explosive. Moreover, H2S tends to sink into low-lying areas such as pipe trenches,
valve boxes, sumps and sewers, excavations and around rig platforms. In confined spaces, H2S settles to the bottom, forming a
deadly gas layer.
The LEL is the minimum concentration of a gas in a gas/air mixture at which the mixture will explode if exposed to an ignition
source. Therefore, monitoring both H2S and LEL is very essential in plants to ensure safe operation and a safe working
environment.

Monitoring Challenges
A challenge that can be encountered when monitoring gas releases in remote locations is the long distance between the sumps.
There is potential for gas releases at the nearest process interface building (PIB) where the control system cabinets are located.
The approximate distance between the mentioned locations is one kilometer. Another challenge is the hassle and difficulty in
using the conventional way of running signal and power cables, which includes excavation and road cutting and many other
obstacles. Moreover, the cost is another factor to be considered. Therefore, using conventional methods by running power
cables to the detectors is not feasible and efficient.

Application Solution
The newly proposed solution consists of two major parts; the first part is the use of wireless technology and the second part is
the use of solar power technology. Both components will be integrated to form the desired system in this application.
Figure 1 illustrates the solution schematics that shows each segment, component and the integrity between the different parts.

Figure 1: HdGP wireless sensors setup.

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Wireless System
Wireless sensors have broken down barriers for monitoring H2S and LEL gas releases in plant sump areas to ensure safe
operation and a safe working environment. This is due to the high cost of traditional hard wired sensors that are difficult and
time consuming to implement. H2S and LEL sensors and transmitters are installed in the remote area (sump area) with no
access to power (Fig. 1). The signal will be sent from the sensor to the repeaters and then to the gateway wirelessly. The
gateway is located inside the fence very close to the system cabinets. The connection between the gateway and distributed
control system (DCS) is through a hardwire (serial or Ethernet).
The wireless transmitters operate at 2.4 GHz, per the industrial, scientific and medical (ISM) nonlicensed radio frequency
practice around the world [4]. Wireless network integrity and security is obtained by employing direct sequence spread
spectrum (DSSS) wireless mesh technology. In addition, specific network ID and Modbus addresses are assigned for each
device in the system [1].
The spread spectrum technique is achieved when the transmitted signal takes up a larger bandwidth than the minimum
bandwidth required, sending the information signal [1] (Fig. 2). One of the main modulation types of SS is DSSS, in which a
high-rate separating waveform multiplies the data signal to spread the spectrum. Due to the low power of the speared
spectrum, it is often named a nose-like signal.
In the mesh network, each field device can function as a repeater for every other device in the network, which is useful in
difficult environments such as a plant full of piping and obstacles. This solution is useful for overcoming challenges for
sending signals from the sump area to the gateway in the process interface building and for controlling routes around line-ofsight obstacles.
ISA 100.11a is a wireless system standard for industrial automation that was developed by ISA to support and benefit the
process automation industry. The ISA Committee has established the ISA100.11a standard to achieve reliable wireless
communication systems that can be used in many industrial applications to have long-distance wireless communication and to
overcome interference from electromagnetic waves, and to allow the coexistence of Wi-Fi signals in a plant. As a result, the
consistent wireless system based on the ISA100.11a standard has dramatically enhanced the plants monitoring instruments [3,
5].

Figure 2: Direct sequence spread spectrum system signals are spread across a wide bandwidth [2].

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Solar Power System

Over long distances, the extension and maintenance of transmission lines is expensive, especially if the loads are relatively
small. This is true where generators in remote areas require regular fuel supplies and have high maintenance costs. The cost of
providing power to remote locations such as the sump area is high. Onsite solar power solutions become the best alternative.
Nowadays, solar technology has the potential to be a major valuable energy source for refineries and plants, particularly for
remote locations where the energy is needed. When there is sufficient sunlight, photovoltaic cells (PVs) utilize solar cells to
convert solar energy into electricity [2]. Solar power is used to maintain full battery charge levels for almost any application in
remote areas. For instance, it can be used as a source of power for remote sensing devices.
A typical block diagram for the PV generation system components is shown below (Fig. 3).

Figure 3: PV system structure.

Photovoltaic Panels
Photovoltaic solar panels need only the sunlight to generate electricity. They consist of several layers of materials that are
capable of producing electricity after being exposed to the sunlight. Solar power does not emit any greenhouse gases because
of the utilization of the renewable energy source from sunlight [2]. Therefore, utilizing solar panels have countless benefits in
many areas. Benefits include environmental safety, lack of energy costs, ease of deployment to any location; as well as the
collateral benefits of a system that operates when the power supply has failed.
Solar charging panel are also used to extend operating time and to maintain full battery charge levels for any application.
Therefore, the solar energy is practical in remote fields devices such as wireless sensors for gas sensing.
Energy Storage
In the absence of solar power, the battery is used to ensure continuous power supply. Therefore, the size of the battery and the
battery type, such as sealed lead acid or lithium ion, are the most critical when choosing a battery. The main purpose of battery
is to maintain a 24-hour energy supply to the H2S and LEL sensors in the field.
Power converter and controller
The system consists of power electronic converters to control battery charging/discharging and to convert the DC power to
60Hz AC in order to service the local power demand.

Solution Advantages over Conventional Methods

There are a variety of benefits from using wireless technology for operating sensors and other equipment in remote locations
compared to conventional ways or methods (Table 1).

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Table1: Comparison of wireless and conventional technology

Wireless technology needs less maintenance whereas the conventional methods require more maintenance. The conventional
methods consume more energy compared to what is possible with wireless technology. Wireless technology is very easy and
flexible for relocations and expansions compared to the conventional technologies due to elimination of the need to excavate
and lay cables. Although the initial equipment costs for wireless technologies are higher than for conventional technologies, in
the long run these new technologies are less expensive because conventional technologies are more expensive to install and
have higher maintenance costs.
Conclusion
In this paper we have explored numerous challenges related to the implementation of new wireless technologies in remote
locations. Wireless networks with solar technology in the plants and refineries have a promising future. For instance, by
utilizing solar powered wireless transmitters, sump areas can easily be monitored remotely. H2S and LEL sensors will
continuously monitor for gas releases and communicate wirelessly with an access point (gateway), which is connected to the
control station through Modbus. Since the wireless system operates in the 2.4 GHz band, it is vital that the ISA100.11a
standard equipment employs DSSS and mesh topology to survive coexistence and interference issues.
Power consumption is considered to be the major performance restraining factor and the leading concern for the wireless
signals in remote locations. To extend the lifetime of the wireless sensors, solar power technology is employed in addition to
the use of battery power.
Due to the cost savings that the wireless technology introduces, the wireless technology shows an increase in operating
efficiency by limiting human errors and monitoring of the plant in real time to enhance plant safety. Much more than that,
wireless technology helps to overcome physical problems encountered with wiring; it cuts the installation costs and can be
deployed easy.

References:
[1] Al-Hashim, N.S. 2009. Performance of Disparate-Bandwidth DS-SS Systems in Spectral Overlay Ad Hoc Networks,
M.S. thesis, School of Elect. Eng. and Computer Science, Ohio Univ., Athens, Ohio.
[2] JianHua, L., Jin, W., Zhi, T., Ying M., and XiaPing, X. 2001. The analysis and application of solar energy PV power,
2011. The International Conference on Advanced Power Automation and Protection, Beijing, China. 1696-1700.
[3] International Society of Automation, "ISA100 Wireless Systems for Automation" [www.isa.org]
[4] International Telecommunication Union [www.itu.int]
[5] ISA100 committee, 2009. ISA-100.11a-2009 Wireless systems for industrial automation: Process control and related
applications, ISA