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In oil and gas operations, especially in critical areas like vapor recovery units and flare knock-out drums, early detection of H₂S and combustible gas leaks is essential for maintaining site safety, compliance, and operational uptime. However, expanding traditional gas detection systems into these areas—especially around emergency flare stacks—can be complex and cost-intensive due to infrastructure limitations.
🔍 The Challenge: Limited I/O and Expensive Wiring Requirements
A major refinery was tasked with expanding gas detection coverage around two emergency flare lines. While power was available nearby, the site lacked sufficient I/O infrastructure to support a wired detection system. The flare lines were located at significant distances from the plant network, and the cost of extensive cabling and network expansion made a conventional approach impractical.
An initial pilot deployment used a combination of Vanguard WirelessHART gas detectors and a single field gateway. However, the layout posed significant challenges:
- The network connection point was located at the farthest end of the monitoring zone
- Long distances between devices increased the number of data “hops”, raising concerns about signal loss and latency
- To compensate, the team installed a 350-meter antenna cable and two wireless repeaters—an effort that improved performance, but also introduced additional complexity and installation cost
✅ The Solution: Intrepid Gateway with Industrial Wi-Fi Mesh+
To simplify the system and improve performance, the refinery implemented the Intrepid™ WirelessHART Field Gateway from United Electric Controls (UE). Unlike traditional gateways, the Intrepid solution incorporates Industrial Wi-Fi Mesh+ technology, allowing it to operate seamlessly without repeaters or long homerun cabling.
By creating dedicated mesh networks around each flare line, the gateway significantly improved:
- Network reliability and data integrity, by reducing hops and latency
- Scalability, enabling the addition of the Vanguard WirelessHART gas detectors and even Wi-Fi enabled safety tools such as infrared cameras
- Infrastructure simplicity, eliminating the need for repeaters and long antenna runs
This streamlined design makes the system easier to maintain and more flexible for future expansions across complex sites.
📡 UE Wireless Safety Solutions: Extend, Enhance, and Support Your Safety Network
While wired gas detection remains the standard in many industrial settings, UE’s WirelessHART® portfolio offers a flexible and cost-effective way to monitor hard-to-reach areas, expand existing coverage, or provide redundant backup in safety-critical environments.
Wireless is not about replacing wired systems—it’s about enhancing safety coverage where traditional infrastructure can’t go.
UE’s WirelessHART Ecosystem Includes:
- Vanguard WirelessHART® Gas Detector
Detects toxic or combustible gases and communicates directly to the WirelessHART Gateway
5-year battery life for long-term deployments - Intrepid WirelessHART® Gateway
Collects data from field devices and connects to your PLC, SCADA, DCS, or RTU over Ethernet or RS-485 - WirelessHART® Bullet
Makes any 4–20 mA device WirelessHART-compatible; supports up to 8 HART devices - WirelessHART® Repeater
Battery-powered repeaters that extend network range and reliability in complex layouts
Whether you’re integrating into an existing industrial control system or creating a mesh network in the field, the UE WirelessHART architecture scales to your operation—and improves it.
🔧 Results at a Glance
- Simplified infrastructure—no more repeaters or long cable runs
- Improved wireless network reliability
- Enhanced scalability for future safety technologies
- Reduced installation time and long-term maintenance costs
🇨🇦 Available in Western Canada Through Westech Industrial
Westech Industrial is proud to be the exclusive Western Canadian distributor for United Electric Controls, offering advanced safety solutions like the Intrepid™ WirelessHART Gateway and Vanguard Gas Detectors.
If you’re facing challenges in extending gas detection coverage across large or remote sites—Westech can help design a reliable, cost-effective wireless solution tailored to your facility.
👉 Learn more about UE Intrepid and Vanguard WirelessHART solutions
📞 Call us at 1-800-912-9262
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