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SENS-IT. SENS-IT Small Electronic Network Sensor Integrity Tool. Development of a Low-Cost Permanently Installed Microelectronic Wireless Monitoring System for Process Plant 23 February 2005. Summary Project Details. Scope

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SENS-ITSmall Electronic Network Sensor Integrity Tool

Development of a Low-Cost Permanently Installed Microelectronic Wireless Monitoring System for Process Plant

23 February 2005

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Summary Project Details

  • Scope

    • Development of a Low-Cost Permanently Installed Microelectronic Wireless Monitoring System for Process Plant

  • Benefit

    • Improved monitoring techniques leading to lower operational costs, improved QHSE, more reliable information for increased integrity management, and zero loss of containment.

  • Duration: 34 months

  • Total Cost: €3.14m

  • EC Funding: €1.7m

  • Balance of Funding: Project Partners

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Progress to date

  • Oct 02 - Project Start

  • Mar 03 - Development of Functional Specification

  • Oct 03 - Detailed Operational and Interface Specification

  • Dec 03 - Paper design

  • Mar 04 - Project interim stage reached

    • Partners agree to continue project to conclusion

  • Apr 04 - Technology Demonstrator system designed and built

  • Apr 04 - Technology successfully demonstrated

  • Feb 05 - Prototype design on-going

    • Issues of intrinsic safety being addressed

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Areas of work

  • Sensor development

    • Piezo-composite sensors

    • Single and array

    • Specification, design, characterisation, test and evaluation

    • Sensor packaging

    • Manufacture

  • Microelectronic Interface design & manufacture

    • Design of drive electronics and pre-amp circuitry

    • Interface packaging

    • Miniaturisation

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Areas of work

  • RF interface

    • Network topology evaluation

    • Network interface specifications

    • Choice of communication technologies

    • Integration of RF

  • Data acquisition

    • Software and dataset specification

  • Power supply

    • Choice of battery technology

  • Software & Firmware

    • Software and dataset specification

    • Software utility for presentation of results

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Achievements: System

  • Demonstrator unit built

  • Integrated unit incorporating:

    • Sensor

    • Integrated electronic interfaces

    • Battery technology

    • Interim software package

      • (Main software now available)

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Achievements: Sensor

  • Twin crystal design to resolve 4mm wall thickness

  • Successful integration of probes to driver electronics and production of a signal suitable for wall thickness calculations Demonstration of probe arrays

  • Low power to comply with ATEX regulations

  • System can resolve wall thickness changes in a pit defect to within 0.2mm

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Achievements: Microelectronics

  • Miniaturized microelectronic unit consists of:

    • high speed analogue circuit

    • digital controller

    • 8 channel multiplexer / de-multiplexer

    • all have been fully assembled and tested

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Achievements: Miniaturisation

  • Credit card size micro-electronics interface achieved …

  • … and working!

  • Could be made smaller

    • This considered another development

    • Compromise on size and intrinsic safety issues

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Achievements: Power

  • Various battery solutions evaluated

  • Special battery pack

    • combination of primary / secondary cells implemented

    • provides high pulse currents throughout the target lifetime of two years

    • Probably 6 AA cells equivalent

    • (Due to IS requirements

  • Power profile reduced by 25% since mid-term position

  • On-going activity

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Achievements: Wireless

  • Wireless LAN 802.11b compatible (WiFi compliant)

  • Range: 500m (approx) range line-of-sight

  • Digital interface for connection to sensor unit

  • Star-shaped wireless network topologies with the use of central access points

  • FTP protocol allows communication with the sensor network via web gateway

  • Dimensions: 80x50x10mm (40cm3)

  • Temperature range: -20 to +85°C

  • Power consumption: 600mA at 3.3V (2W)

  • Solar cell (optional)

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Achievements: Software

  • An intuitive and simple user interface

  • A robust and effective interface to the communication units

  • Export/import solutions that will enable effective interface to end-users systems

  • Efficient and robust interpretation of the ultrasonic signals

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Achievements: Summary

  • Integrated design of a demonstrator unit

  • Signal output received

  • It works!

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Lessons Learnt … so far!

  • Issues of sensor characteristics and interfacing electronics

  • Issues of intrinsic safety

  • Issues of integration of RF for high speed, low power data links

  • Low noise, high speed circuit design

  • System Integration

  • Importance of working closely with partners

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Next Steps

  • Refine design for system integration and manufacture

  • Complete ATEX certification at component level

  • On-going ATEX certification for integrated system

  • Production and commissioning of prototype

  • Evaluation testing on site

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Programme to Completion

Anticipated time for on-site testing

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Thank you for listening

Any questions?