Mesh wireless system monitors power station pumps

Emerson Smart Wireless solutions in a 12-transmitter mesh network, protect remote pumping facilities at Milford Power, after an easy installation that saved USD75,000 compared to conventional wiring

Emerson Process Management, a leader in the application of wireless solutions for process control automation, has successfully applied its wireless self-organizing field network to monitor remote system and equipment buildings operated by Milford Power, a 500 MW gas-fired turbine facility in Milford, Connecticut.

The Emerson Smart Wireless solution enabled the power company to avoid as much as USD75k in capital and installation costs while advancing the protection of water pumping and circulation equipment against freeze damage that could cost as much as USD20k to repair or replace.

Although the remote stations are heated during cold weather, executives of Milford Power wanted a way to continuously inform plant operators of severe temperature drops in case of a heater failure so that fast corrective action could be taken.

Since installing direct wiring between remote monitoring devices and the control room would have been very expensive, officials at Milford Power began looking for a reliable wireless system to satisfy their needs at a reasonable cost.

"We looked at various technologies and selected the Emerson wireless solutions with Rosemount wireless temperature transmitters because we liked the communications approach, plus battery life, and cost" commented Cliff Esmiol, maintenance supervisor for Milford Power: "Especially important was the easy, flexible self-organizing network that could be installed and operational in a very short time".

The Emerson wireless solution was commissioned by placing twelve devices at pump locations around the power plant.

The mesh network was communicating in only two hours.

The signals were easily transmitted around buildings and other obstructions, proving the capability and reliability of this concept at Milford Power.

After the initial evaluation was completed, another building was constructed that visually hid one transmitter completely from the others on the network.

It didn't make any difference; the wireless network signals were unaffected.

Data from the remote devices pass through a 1420 gateway connected to an existing PC in the control room, where the existing internet browser is used to display measurements and sound an alarm in case of a significant temperature drop.

The Emerson Smart Wireless solution is an extension of the PlantWeb digital plant architecture, combining highly reliable, smart monitoring devices with wireless transmitters and a Time Synchronised Mesh Protocol (TSMP) communications technology.

This innovative self-organizing mesh network, which automatically adapts as device points are added or removed, has been extensively tested in real-world environments.

According to maintenance supervisor Cliff Esmiol, "Without question, this is an excellent wireless solution that works well, is easy to install, and very easy to expand when necessary".

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