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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 it small electronic network sensor integrity tool

SENS-ITSmall 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
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
progress to date
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
areas of work
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
areas of work6
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
achievements system
Achievements: System
  • Demonstrator unit built
  • Integrated unit incorporating:
    • Sensor
    • Integrated electronic interfaces
    • Battery technology
    • Interim software package
      • (Main software now available)
achievements sensor
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
achievements microelectronics
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
achievements miniaturisation
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
achievements power
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
achievements wireless
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)
achievements software
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
achievements summary
Achievements: Summary
  • Integrated design of a demonstrator unit
  • Signal output received
  • It works!
lessons learnt so far
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
next steps
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
programme to completion
Programme to Completion

Anticipated time for on-site testing