Westinghouse 7381A10G03 – High-Reliability AI Card for WDPF Fossil & Nuclear Plants

The Westinghouse 7381A10G03 is an 8-channel analog input (AI) module designed for the WDPF (Westinghouse Distributed Processing Family) distributed control system—a foundational DCS platform deployed globally in nuclear, fossil fuel, and industrial power generation facilities from the late 1970s through the 1990s. This module conditions and digitizes standard industrial analog signals (typically 4–20 mA or 1–5 V DC) from field transmitters such as pressure, temperature, flow, and level sensors, enabling the WDPF controller to monitor and regulate critical plant processes.

As many WDPF systems remain operational due to extended plant licenses and high migration costs, the 7381A10G03 continues to serve as a vital spare part—ensuring signal integrity in safety-related and regulatory-compliant control loops where failure is not an option.

Application Scenarios

At a U.S. coal-fired power plant operating under a 60-year life extension, a degraded 7381A10G03 module began reporting erratic feedwater flow readings—triggering nuisance alarms and threatening unit stability. With the original Westinghouse product long obsolete, the plant sourced a reconditioned 7381A10G03 that had been fully tested on a WDPF-compatible simulation rig. After installation and loop calibration, the module restored accurate flow measurement, avoiding a costly derate during peak winter demand. The success reinforced the plant’s strategy of maintaining a strategic spares inventory for legacy WDPF I/O like the 7381A10G03.

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Technical Principles and Industry Value

Precision Signal Conditioning

The 7381A10G03 uses precision resistors and isolation amplifiers to convert milliamp signals into digital values with minimal drift—critical for combustion control, turbine protection, and emissions monitoring.

Robust Design for Harsh Environments

Built with conformal-coated PCBs, gold-plated edge connectors, and industrial-grade components, it withstands decades of operation in high-EMI, high-vibration power plant environments.

Seamless WDPF Integration

The module communicates directly with WDPF DPUs (Distributed Processing Units) over the proprietary highway, requiring no external configuration—channel mapping is defined in the system database.

Bridge to Modernization

Many plants retain 7381A10G03 modules during phased migrations, using them to preserve existing field wiring while upgrading only operator interfaces or adding protocol gateways (e.g., Modbus TCP).

Related WDPF Components

7381A10G01 / G02: Alternate analog input variants (different calibration or signal ranges)

7381A20Gxx Series: Analog output (AO) modules—complement AI functions in control loops

9942A30G13: Digital I/O module—used alongside 7381A10G03 in mixed-signal cabinets

WDPF DPU (e.g., 1C31117H01): Central controller that processes data from 7381A10G03

WDPF OIS: Operator Interface Station—for configuration, trending, and diagnostics

Terminal Blocks (e.g., 7381-TB series): Field wiring interface compatible with this module

Sourcing, Testing, and Support

Since Westinghouse exited the DCS market (with WDPF assets eventually integrated into Emerson Ovation), the 7381A10G03 is no longer produced. However, certified suppliers offer:

New Old Stock (NOS): Unused original inventory—ideal for critical spares

Fully Reconditioned Units:

Visual inspection for capacitor leakage, PCB corrosion

Cleaning and re-conformal coating (if needed)

Functional test using WDPF-emulator or legacy test bench

Verification of 4–20 mA response, channel isolation, and DPU communication

As-Removed (Tested): Verified operational with full diagnostic report

We provide each 7381A10G03 with:

Detailed test report (per-channel input validation, LED check, backplane fit)

Compatibility confirmation with your WDPF revision

12-month warranty on reconditioned units

Our engineering team can also assist with:

Cross-referencing alternate part numbers

Loop calibration support

Obsolescence risk assessment for your WDPF I/O suite

Final Note

The Westinghouse 7381A10G03 may be a legacy component, but in thousands of power plants worldwide, it remains the quiet guardian of process integrity—converting physical reality into digital truth, one milliamp at a time. Proper management of such modules ensures safety, compliance, and decades of continued service.

Contact us for verified availability, technical consultation, or a customized WDPF support plan. Keep your legacy system precise, reliable, and ready.