manufacturability plan - proteus-sensor.eu · manufacturability plan d1.3 1 introduction the...

This project has received funding from the European Union’s H2020 Programme for research, technological development and demonstration under grant agreement No 644852

Manufac turability Plan

D1.3

Authors : B. Vergne ; F. Bellouard September, 28th 2015

www.proteus-sensor.eu

Ref. Ares(2015)4284488 - 14/10/2015

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MANUFACTURABILITY PLAN D1.3

Editor: Aqualabo (Ponsel Mesure)

Deliverable nature: R - Report

Dissemination level: PU - Public

Contractual/actual delivery date:

M03 M09

Suggested readers: Water Sensors developers, integrators, utilities

Version: V1.0

Keywords: Manufacturability, business

Abstract:

The Smart Water Market requires new technologies for Smart multi-parameter probes.

Several solutions are already deployed on water networks. Nevertheless there is no real consensus on parameters to follow and the range of measurements. Each manufacturer has its own analysis of the Smart Water requirements and its cost objectives. The cost of installation is an important part of the global cost of a system and build up to 30 % to 50% of the global cost.

There are a wide range of solutions depending on the history of the network. Standards remain difficult to define. But newly deployed smart systems on the market are still required to be compatible withpreexisting systems, especially SCADA and PLC systems. Henceforth, despite the need of high level ofintegration to reduce the cost, size and the price, the market also requires a strong flexibility to penetratethe maximum of water networks.

The manufacturing of such innovative sensors requires new methodologies, compatible with productionsteps in controlled atmosphere rooms. Also the factory calibration of such multiparameter probes requirescostly manpower or the development of validation tools, which must be accounted for in the manufacturing strategy.

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Disclaimer

This document contains material, which is the copyright of certain PROTEUS consortium parties, and may not be reproduced or copied without permission.

All PROTEUS consortium parties have agreed to full publication of this document.

Neither the PROTEUS consortium as a whole, nor a certain part of the PROTEUS consortium, warrant that the information contained in this document is capable of use, nor that use of the information is free from risk, accepting no liability for loss or damage suffered by any person using this information.

This project has received funding from the European Union’s Horizon 2020 Programme for research, technological development and demonstration under grant agreement n° 644852.

Copyright notice

� 2015 Participants in project PROTEUS

This work is licensed under the Creative Commons Attribution 4.0 International (CC BY 4.0) License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/legalcode

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Revision History

Revision Date Description Author (Organisation)

V0.0 06/05/2015 Creation of document F Bellouard, C Maigret, B Vergne, (Ponsel Mesure-Groupe Aqualabo)

V0.1 08/09/15 Production steps draft F. Bellouard

V0.2 08/09/15 Business part draft B. Vergne

V0.3 18/09/15 Minor additions F. Bellouard

V0.4 22/09/15 Tarik corrections B. Vergne

V0.41 24/09/15 IFSTTAR, EGM, NIPS corrections F. Bellouard

V0.42 28/09/15 Minor additions F. Bellouard

V0.43 30/09/2015 UNPARALLEL corrections Bruno Almeida (UI)

V0.44 01/10/15 Minor additions Paulo Nico, Carlos Sousa (SMAS)

V0.6 05/10/15 NIPS, SMAS, UNINOVA, IFSTTAR corrections F. Bellouard

NIPS, SMAS, UNINOVA, IFSTTAR

V1.0 14/10/15 Summary ; Inclusion of final comments ; Review overall edition

B.Vergne; F. Bellouard (PONSEL), B. Lebental,(IFSTTAR) F. Le Gall (EGM)

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Tab le o f c ontents Table of contents ..................................................................................................................................... 5

Table of Figures ....................................................................................................................................... 7

Executive summary ................................................................................................................................. 9

1 Introduction ..................................................................................................................................... 10

2 BUSINESS – MARKET .................................................................................................................. 11

2.1 Introduction ............................................................................................................................ 11

2.2 Market .................................................................................................................................... 11

2.2.1 The Smart Water Grid ....................................................................................................... 11

2.2.2 Market organization ........................................................................................................... 13

2.2.3 Market penetration: a French example .............................................................................. 14

2.3 Technologies on the market .................................................................................................. 14

2.3.1 Single parameter Probes ................................................................................................... 14

2.3.2 Multi-parameter probes ..................................................................................................... 16

2.3.3 RTU/PLCs – GSM/GPRS Data logger – Radio systems................................................... 25

2.3.4 SCADA Solutions on the market ....................................................................................... 26

2.4 Business Specifications: ........................................................................................................ 29

2.4.1 Standards methods for water and wastewater quality....................................................... 29

2.4.2 Health conformity for drinking water .................................................................................. 29

2.4.3 ATEX directive ................................................................................................................... 30

2.4.4 Measurement range .......................................................................................................... 30

2.4.5 Installation .......................................................................................................................... 31

3 MANUFACTURING ........................................................................................................................ 34

3.1 Main production steps ........................................................................................................... 34

3.2 Cost ....................................................................................................................................... 36

3.3 Required Data for industrial transfer ..................................................................................... 37

3.4 Equipments for productions ................................................................................................... 38

3.4.1 MEMS sensors .................................................................................................................. 38

3.4.2 Carbon nanotubes sensors ............................................................................................... 38

3.4.3 CMOS chip ........................................................................................................................ 39

3.4.4 Electronic circuits/Printed circuit board ............................................................................. 39

3.4.5 Mechanical parts................................................................................................................ 39

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3.4.6 Energy harvesting system ................................................................................................. 39

3.4.7 Sensor cap testing ............................................................................................................. 39

3.4.8 Node .................................................................................................................................. 41

3.4.9 Sensor Node ...................................................................................................................... 41

3.5 Outsourcing steps .................................................................................................................. 42

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Tab le o f Figures Figure 1- Water Balance Table (American Water Works Association, 2012) ....................................... 12

Figure 2-Smart water part of the market ............................................................................................... 12

Figure 3-Four levels of components of the Smart Water Grid ............................................................... 13

Figure 4-Current organization of the water market ............................................................................... 14

Figure 5-In pipe installation ................................................................................................................... 15

Figure 6-Panel installation ..................................................................................................................... 15

Figure 7-Intellisonde V2, Intellitec Water Company (UK) ...................................................................... 17

Figure 8-IntellisondeV2, focus on the sensing elements ....................................................................... 18

Figure 9-View of the probe in the field ................................................................................................... 19

Figure 10- Multiprobe+, NEROXIS (Switzerland) .................................................................................. 20

Figure 11-ENDETEC Kapta 3000 AC4 ................................................................................................. 21

Figure 12-KAPTA 3000 ; focus on the sensing caps ............................................................................ 22

Figure 13-SIX cens, Censar (USA) ....................................................................................................... 22

Figure 14-Six cense: focus on the sensing part .................................................................................... 23

Figure 15-Pipesonde Hach (USA) ......................................................................................................... 24

Figure 16-Traditional organization of the SCADA with well separated city networks ........................... 27

Figure 17-Well separated city SCADAs with joint exploitation of the data ............................................ 27

Figure 18-joint management of several networks by a single SCADA ................................................. 28

Figure 19-Smart operational center ....................................................................................................... 28

Figure 20-Example of accessories for measurements in tank .............................................................. 32

Figure 21- Scheme of a visit box and bypass ....................................................................................... 33

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Figure 22-Main elements of the PROTEUS product ............................................................................. 34

Figure 23-Strategy and steps of production .......................................................................................... 35

Figure 24-functionalities of the testbench for sensor cap testing .......................................................... 40

Figure 25-Strategy of production, integration and test of the node and sensor node ........................... 41

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Exec utive sum m ary

The Smart Water Market requires new technologies for Smart multi-parameter probes.

Several solutions are already deployed on water networks. Nevertheless there is no real consensus on parameters to follow and the range of measurements. Each manufacturer has its own analysis of the Smart Water requirements and its cost objectives. The cost of installation is an important part of the global cost of a system and build up to 30 % to 50% of the global cost.

There are a wide range of solutions depending on the history of the network. Standards remain difficult to define. But newly deployed smart systems on the market are still required to be compatible with preexisting systems, especially SCADA and PLC systems. Henceforth, despite the need of high level of integration to reduce the cost, size and the price, the market also requires a strong flexibility to penetrate the maximum of water networks.

The manufacturing of such innovative sensors requires new methodologies, compatible with production steps in controlled atmosphere rooms. Also the factory calibration of such multiparameter probes requires costly manpower or the development of validation tools, which must be accounted for in the manufacturing strategy.

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1 Introd uc tion The PROTEUS aim is to provide Smart systems for water quality with a market orientation.

This report provides details on the business requirements for these smart systems and on their manufacturability.

The system must have a high level of integration in order to reduce the cost of the system but, in the same time, be flexible enough in order to complete current networks already deployed.

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2 BUSINESS – MARKET

2.1 Introd uc tion In order to be well positioned on the markets of water quality monitoring, the PROTEUS system must:

- Meet the monitoring requirements of the end users in their diversities (in terms of parameters, range of measurements, repeatability, accuracy, installation and maintenance, standards compliance).

- Be competitive when compared with current solutions available on the market or under development.

- Be compatible with the already existing systems (PLC, RTU, SCADA, Big data systems).

2.2 Ma rke t

2.2.1 The Sm a rt Wa te r Grid The main objective of PROTEUS is to deliver an autonomous, highly multifunctional sensor node for cognitive drink and wastewater quality monitoring. PROTEUS solutions target the Smart Water Grid.

The Smart Water Grid , also called Smart Water Network, consists of a 2 way “real time” network that remotely and continously monitors and diagnoses problems in water networks. More precisely, it is a fully integrated set of products, solutions and systems that enable water utilities to:

� Remotely and continuously monitor and diagnose problems, pre-emptively prioritize and manage maintenance issues, and remotely control and optimize all aspects of the water distribution network using data-driven insights,

� Comply transparently and confidently with regulatory and policy requirements on water quality and conservation.

The main parameters to monitor are pressure flowrate, temperature, quality parameters (turbidity, Chlorine…) and global energy consumption of the water treatement.

According to US EPA, the main application of Smart Water Grid is the drinking water, which water balance is described in Figure 1. The aging infrastructure and leakage are the principal problems. It is estimated that 10 to 60% of water that pumped to consumers are lost by utilities.

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Figure 1- Water Balance Table (American Water Works Association, 2012)

This market will increase from 5,8B USD to 22,2B USD (from 2010 to 2020)

Figure 2-Smart water part of the market

The association of several technologies are needed to develop a smart water grid. Most of these technologies are already available on the market.

A complete smart system consists of 4 levels of components:

� Instrumentation: mono or multiparameter probes, analysers

� PLC or RTU systems

� Communication (Ethernet, optical fibers, radio, serial, 4G, GPRS, GSM Data, Sigfox…). Most likely, dial-up will be not used.

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� SCADA Host

Figure 3-Four levels of components of the Smart Water Grid

Drinking and wastewater networks are already using equipment on these networks in order to save money (optimize energy consumption, reduce leakage) and now to increase water quality (mainly through monitoring of free chlorine and other water quality parameters such as nitrates, conductivity, pH and chloride).

Lifetime of the equipment range from 5 to more than 20 years (ex: Eau de Paris). The customers should not have to to replace the full system (the four levels of components: sensors, PLC…) at the same time, so interoperable equipment is required.

Hence, even if the complete PROTEUS system (from probe to SCADA) must be competitive in its own right with a high level of integration, each sub-systems of PROTEUS project must also be open to interfacing with other solutions already deployed on the market.

2.2.2 Ma rke t o rg a niza tio n The PROTEUS market is organized along the following four levels:

� Municipalities:

The municipality is in all case the final customer of the system.

� Water companies:

Water management is delegated to a water company. Such company can be public or private. The delegation can be full (with obligations in terms of results) or only for services.

� Engineering companies:

Engineering companies provide global solutions to water companies.

� Equipment providers:

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Companies dedicated to the manufacturing and distribution of monitoring equipment.

In Figure 4 is represented the relation between the 4 levels. In this figure is presented the corresponding level of some of the most relevant companies as example.

Figure 4-Current organization of the water market

2.2.3 Ma rke t p ene tra tio n: a Frenc h e xa m p le A French law (Decret of the 27 January 2012) requires that cities have a complete knowledge of their networks by the 1st of January, 2014. It also requires that if the leakage is more than 15%, the city prepares an action plan. Most of these plans now integrate smart sensors.

For example, in the city of Rennes, for only 23 km of drinking network, there are 3 DMA (District Metering Area), 1 Chlorine injection point, 2 Chlorine analysers, 4 flowmeters, 7 Kapta multiparameter probes, 15 leak detectors, 2 water monitoring stations and 2 200 water-meters.

2.3 Tec hno log ies on the m a rke t The market features single, bi and multi-parameters probes to monitor water quality in drinking water, wastewater and rain water networks. Either a multi-parameter probe or an association of single probes may be used in order to provide a multi-parameter solution.

2.3.1 Sing le p a ra m e te r Prob e s We can consider 2 types of sensors according the application.

� Sensors for drinking water

� Sensors for wastewater application

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In addition, we have 2 types of installation:

� In pipe installation (Figure 5)

� Panel installation (Figure 6)

Figure 5-In pipe installation

Figure 6-Panel installation

There are 2 major suppliers on the market and several SMEs.

� Hach Lange (drinking water & wastewater)

� Endress & Hauser (drinking water & wastewater)

� Aqualabo (wastewater & drinking water)

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� Swann (drinking water)

To achieve measurement of several parameters with single parameter probes accounting for the size, the cost and the power consumption; the panel solution (association of several single parameter probes) is preferred.

The public price of a panel solution is between 500 EUR by sensors for classical sensor (pH, Oxidation-Reduction Potential (ORP), Chlorine…) to 1 000 EUR per sensor for sensors requiring optical technology (Turbidity, Dissolved oxygen, etc.). This cost does not include the transmitter, and the panel itself.

2.3.2 Multi- p a ra m e te r p rob e s Table 1 summarizes the different options for multi-parameter probes.

Table 1-Different market options for multiparameter probes

Solution Kapta 3000 InPipesonde Multiprobe+ Intellisondeversion2

Six Cense

Manufacturer ENDETEC (VEOLIA)

HACH (USA)

EFS (SUEZ?)

INTELLITECT (UK)

CENSAR (UK)

Price (EUR) 1 500 9 000 9 000 6 000 9 000 Drinking water 1 1 1 1 1 Wastewater 0 0 0 1 0 Diameter 35 mm 43 mm 38mm 36 mm 37 mm Autonomy 2 years - - 6 months - Temperature 1 1 1 1 1 Chlorine 1 1 (or DO) 1 1 1 MonoChloramine 0 0 0 1 1 Conductivity 1 1 1 1 1 pH 0 1 1 1 1 ORP 0 1 1 1 1 DO 0 1 1 1 1 Pressure 1 1 1 1 (option) 0 Flow 0 0 1 0 0 Turbidity 0 1 1 1 0 Color 0 0 0 1 0

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2.3.2.1 INTELLISONDE ve rsio n2

Figure 7-Intellisonde V2, Intellitec Water Company (UK)

The Intellisonde version 2 is the latest version from Intellitec Water Company (UK). This probe can monitor 12 parameters simultaneously. It is based on co-integration of several sensors, some of them being in the chip format.

This probe can be installed in pipe or on a panel thanks to accessories.

� Parameters:

Parameters Range

Temperature -5°C to +50°C

Flow 0 to 2 m/s

Free Chlorine 0 to 5 mg/L

Mono-Chloramine 0 to 5 mg/L

Dissolved Oxygen 0 to 100% SAT

pH 2 to 12

ORP -1000 to +1000 mV

Conductivity 20 to 10 000 µS/cm

Colour 0 to 50 Hazen

Turbidity 0 to 50 NTU

Pressure

External sensor

0 to 10 bars

ISE 0,1 to 20 mg/L

Conditions:

0 to 50°C

pH : 5 to 8

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� Communication:

o Ethernet Modbus TCP/IP

o RS232/RS485 Modbus RTU

o GPRS

Figure 8-IntellisondeV2, focus on the sensing elements

This sensor integrates a Chlorine sensor based on a Voltametric technology. It uses a proton generator to measure chlorine and monochloramine, independently from flowrate and pH. A proton generator produces an acid pH in the direct vicinity of the sensor. The pH level being thus maintained acid, the chlorine measurement is independent of pH (free chlorine is measured).

Dissolved Oxygen Measurement principle is the Voltametric technique, using the same basic technology as the chlorine sensor, but with different operating parameters.

ORP is measured with a small platinum wire which is included in the pH sensor body. The voltage that this wire maintains in the water is measured by the same circuit as the pH sensor. The resulting voltage is then reported with no further processing.

For the temperature a thick film printed Pt1000 temperature-sensitive resistor is used. It is housed behind stainless steel housing in close contact with the water. Measurements are achieved with a constant current.

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The sensor integrates a platinum printed 4-electrodes conductivity sensor. Measurement is done by a constant alternative voltage.

Turbidity is measured with a single source (a LED emitting at 860nm as required by the standard, ISO 7027) and a 90° detector measuring the light scattered from particulates in the water in front of the LED. The detector faces upstream, maximising the flow against the sapphire windows of the probe to minimize fouling. Closed-loop control of LED brightness and phase sensitive detection of the scattered light is used to maximize stability and sensitivity.

A single LED light source (emitting 410 nm) and in-line detector are used to measure apparent colour of the water. Absorbance is a measure of the light that has been lost in transmission which is proportional to colour.

Figure 9-View of the probe in the field

We have no information on the pressure sensor (external sensor) and flow rate sensor.

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2.3.2.2 MULTIPROBE+

Figure 10- Multiprobe+, NEROXIS (Switzerland)

NEROXIS (Ex: Silsens) is a part of ENDETEC (VEOLIA). It is located near the CSEM (Neuchatel – Switzerland). The company provides a multi-parameter probe for drinking water.

This probe can be installed in pipe or on a panel thanks to accessories.

� Parameters:

Parameters Range


Active Chlorine 0 – 2 ppm

ORP -1000 to +1000 mV

Conductivity 0 to 2000 µS/cm

Flow 0 – 2 m/s

60m3/h (DN100, 500m3/h (DN300)

Pressure 0-20 bars

pH 2 -12 pH

Turbidity 0 -100 NTU

� Communication:

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o TTL, RS232, RS485, Ethernet/Modbus TCP/IP, GPRS, WIFI

� Power supply/Autonomy:

o 9 -30 V

� Installation:

o Penetration: 1/8 of the diameter of the pipe

Remarks:

� the flowmeter technology integrates a low power ultrasonic technology (µW)

and there is no pH and flow dependence of the Chlorine sensor

2.3.2.3 ENDETEC KA PTA 3000 AC4

Figure 11-ENDETEC Kapta 3000 AC4

This probe can be installed in-pipe or on a panel using some accessories.

� Parameters:

Parameters Range


Active Chlorine 0 – 2,5 ppm

ORP -1000 to +1000 mV

Conductivity 50 to 1000 µS/cm

� Communication:

o RS232 (Not Open) only for Veolia devices (e.g. Homerider)

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Figure 12-KAPTA 3000 ; focus on the sensing caps

The chlorine concentration is measured with a 3-electrode amperometric sensor. The working and the counter electrodes are platinum-thin-film layers manufactured on Si-wafers. Furthermore, the reference electrode is manufactured as a thin layer of Ag/AgCl, using a similar process. Organic membranes are photo polymerized on the top of the working electrode surface to achieve reproducible diffusion conditions. The selectivity is increased by the photo polymerized membrane.

2.3.2.4 SIX CENSE

Figure 13-SIX cens, Censar (USA)

Censar (Chemical ENvironmental Sensing Array) Technologies was founded in the year 2002 (US) in order to acquire key technologies from the company Water Security and Technology, which itself owns a former division of Siemens - Siemens Environmental Systems Labs (SESL).

The Six Cense version2 is a multi-parameter probe for drinking water only. This probe can monitor 7 parameters simultaneously.

This probe can be installed in-pipe or on a panel thanks to accessories.

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� Parameters:

Parameters Range


Free Chlorine 0 to 5 mg/L



pH 2 to 12

ORP -1400 to +1400 mV

Conductivity 20 to 10 000 µS/cm

� Communication:

o RS232

Figure 14-Six cense: focus on the sensing part

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2.3.2.5 PIPESONDE

Figure 15-Pipesonde Hach (USA)

The Pipesonde is a multiparameter probe from the company Hach. This probe is currently only available on the US market.

� Parameters:

Parameters Range


Flowrate 0 to 2 m/s

Chlorine 0 to 4 mg/L



pH 0 to 14

ORP -999 to + 999 mV

Conductivity 0 to 100 mS/cm

Turbidity 0 to 100 NTU

Pressure 0 to 20 bars

� Communication:

o SDI-12

o RS232/RS485 Modbus RTU

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2.3.2.6 Pric ing o f m ult ip a ra m e te r se nso rs

The definition of a public price of a sensor is the following:

Base price min

Base Price max

Price for end user 300 EUR 400 EUR Price for distributor : Distributor margin: 33% (25% to 35%)

200 EUR 250 EUR

Factory cost : Manufacturer margin: 50% (50 - 60%)

100 EUR 100 EUR

The prices of probes on the market are between 450 EUR (KAPTA 2000 - single MEMs Chlorine sensor to 9 000 EUR and more (Multiparameter probes)

The main competitor on the market will be the Kapta 3000 ACS (1500 EUR, VEOLIA). Nevertheless, the business model of VEOLIA is based on services and not on products so the equipment is included in the offer.

2.3.3 RTU/ PLCs – GSM/ GPRS Da ta lo g g e r –

Ra d io syste m s

2.3.3.1 Co m m unic a tio n p ro to c o ls

The 2 main communication protocols of probes on the instrumentation market for water quality are:

� Modbus RS485 (Europe and Asia),

� 4-20 mA (USA)

� Modbus TCP-IP

Big companies (Hach, Endress) have their own closed protocols and it is not possible to add other sensors.

Other protocols such SDI-12, Profibus are seldom used.

2.3.3.2 Po w e r sup p ly

Most of sensors require 6 to 30 V power supply (12 – 24 V is very popular).

We did not identify any sensor technology operating either with battery or with energy harvesting

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2.3.3.3 Re m o te te le m e try un it Automation is typically achieved with either a Remote Telemetry Unit (RTU) or a Programmable Logic Controller (PLC). Both of these technologies utilize a small computerized “brain” (CPU) to process inputs and outputs from primary sensing devices and pumping equipment.

There are 2 types of manufacturers of RTU/PLCs for the water market:

� Multinational companies coming from the energy market (Siemens, Schneider)

� Companies entirely focusing on the water market (Lacroix-Sofrel, Perax-Aqualabo)

2.3.3.4 Da ta tra nsm issio n to the SCA DA

A wide range of protocols are available (WIFI, Bluetooth, Ethernet Modbus TCP-IP, Radio, GSM,/GPRS SIGFOX etc.) according to the equipment already installed, the type of installation and the coverage.

For a single water network several systems may be used jointly, for instance radio system in the city center and GPRS concentrators with GPRS dataloggers in the suburban area.

The prices of the transmission module for probes on the market are between 300 EUR (Radio without license) to 900/1000 EUR (GSM/GPRS Datalogger).

2.3.4 SCADA So lutions on the m a rke t The acronym SCADA means Supervisory Control And Data Acquisition. It is an informatics system which allows an optimum drive of the water process (treatment and distribution) and a better safety regarding the water distribution. In the same time, the SCADA will support the continuously improvement of the quality of services and process.

The SCADA systems assure the following functions:

� Acquisition of the data from transducers

� Pumps and Valve command (and regulation)

� Presenting the measures (general and sectors schemes synoptics, virtual instruments, diagrams

� Maintenance of a secure and complete database

� Elaboration of synthesis reports and bulletin

The lifetime of such systems is more than 30 years (with several updates) due the cost of a new installation (50 000 and 500 000 euros for a complete solution).

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For water monitoring, there is a large range of SCADA architecture available on the market. We encounter the 3 following types of installations:

Figure 16-Traditional organization of the SCADA with well separated city networks

Figure 17-Well separated city SCADAs with joint exploitation of the data

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Figure 18-joint management of several networks by a single SCADA

Example of type III SCADA solution: ONDEO SYSTEMS/SUEZ has launched in 2015 the Smart Operational Center. This European center manages more than 1 Billion data per months for more than 500 customers.

Figure 19-Smart operational center

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2.4 Business Sp ec ific a tions:

2.4.1 Sta nd a rd s m e thod s fo r wa te r a nd

wa stewa te r q ua lity The sensors/probes technology must be approved by the ISO standards in order to provide acceptable data (other standards might be used according to the country of deployment).

. The measurement of different parameters must comply with different standards, such as:

� ISO-7888: conductivity

� ISO-7393: Chlorine

� ISO-10523: pH

Current standards for electronics and housing are the followings:

� ETSI EN 301 489 – 7, ETSI EN 301511 and EN 60950-1 : EMC – ERM compatibility

� FCC Class B products (US Market)

� BS EN 60529, 1992: Specifications for degrees of protection (IP68)

2.4.2 Hea lth c onfo rm ity fo r d rink ing w a te r Several regulations are available in Europe. These regulations are specific to each country:

� ACS (Attestation de Conformité Sanitaire) in France which is one of the strictest worldwide.

� KTW (Kunstsoffe und Trinkwasser) in Germany: only with plastic materials.

� WRAS (Water Regulations Advisory Scheme) in UK.

� NSF/ANSI standard 61 in the USA

In 1998, the European Commission started to develop a European System for the acceptability of materials in contact with water (EAS (European Acceptance Scheme). Nevertheless, there is no agreement on the content so presently no common signed protocol.

Please note that these protocols target just the body of the probe and not the active sensing parts.

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2.4.3 ATEX d irec tive The ATEX standard is mandatory for neither drinking water network nor wastewater networks. Nevertheless this standard should be deployed rapidly for wastewater applications and we have already ATEX products (pumps, etc.…) for this application

2.4.4 Me a sure m e nt ra ng e

2.4.4.1 Drink ing w a te r Table 2: Monitoring parameters for drinking water from the sensor manufacturer point of view

Parameter Minimum Maximum Precision

Conductivity 100 µS/cm Standard : 1000 µS/cm

Observation : 3000 µS/cm

+/-10µS/cm

Chlorine 0,05 mg/L Standard : 1,25 mg/L

Observation : 5 mg/L

5%

pH 5,00 10,00 +/-0.1pH

Temperature1 Standard : 5ºC

Observation : -5°C

35ºC +/-0.30°C

Pressure 0 bar 16 bar +/-0.1 bar (0-2)

5%(2-16)

Flowrate 0 m/s

0 L/s

2 m/s

200 L/s

+/-0.05m/s

+/-0.2L/s (0-10)

2%(10-200)

Chloride 10 mg/L Cl 250 mg/L Cl 5%

Nitrates 2 mg/L NO3 Standard : 60 mg/L NO3

Observation : 100 mg/L

5%

2.4.4.2 Wa ste w a te r

Table 3: Monitoring parameters for waste water from the sensor manufacturer point of view

Parameter Minimum Maximum Precision

pH 3 10 +/-0.1pH

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Flowrate 0 L/s 300 L/s +/-0.2 L/s(0-2) 10%(2-300)

Total dissolved solids 0 Standard : 500 mg/L

Observation : 5 000 mg/L

+/-10mg/L(0-100)

10%(100-5000)

Temperature2 5ºC 35ºC +/-0.30°C

Pressure 0 bar 5 bar +/-0.1 bar (0-2)

5%(2-5)

Dissolved oxygen 0 12 mg/L O2 +/-0.2mg/L

Salinity 0 PSU 10 PSU +/-0.1 PSU(0-2)

5%(2-10)

Redox potential3 -200 mV 500 mV +/-10mV

Conductivity 100 µS/cm 10000 µS/cm +/-10µS/cm

(100-200)

5% (200-10000)

Nitrates 2 mg/L NO3 100 mg/L NO3 5%

Methane gas 4

Hydrogen sulphite gas 5

Oxygen 6

2.4.5 Insta lla tion Of course the system must be easy to install in order to limit cost.

PROTEUS nodes must be designed in a way that allows the easiest possible installation, having always in consideration the associated costs. Two types of installation are commonly used in the industry: the first consists in the installation in the main pipe, and the second in a bypass section.

4 This information need to be treated before, if it´s necessary. 5 This information need to be treated before, if it´s necessary. 6 This information need to be treated before, if it´s necessary.

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2.4.5.1 In m a in p ip e insta lla tio n

In drinking water network, a clamp is the standard to install instrument in pipe under pressure.

For the pipe, the Nominal Diameters are 40, 63, 100, and 300 mm maximum. The relation between the diameter of the pipe and the drag surface must be taken into account. The installation of two valves (before and after the installation) is recommended.

For maintenance, the instrument must be easy to withdraw from a pipe under pressure (extracting system and valve).

In wastewater networks, we currently use a perch where probes are fixed. This system maintains the sensor at a defined depth in a tank and protects the active part of the sensor against solid waste and debris ferried by the waters.

Figure 20-Example of accessories for measurements in tank

2.4.5.2 By p a ss Insta l la tio n

A Bypass installation should be another option where it is not possible to place the sensor inside the pipe directly or, if the clamp don´t work properly with the pressures above 3 bar.

The installation of two valves (before and after the installation) is recommended, so we can work properly (the only problem is the need to cut the water connection).

In the figure below, there is an example of box to install the bypass or the connector. The construction cost is about 4000€.

33


?? Ø??

2000

?? Ø ??

A

FFD DN50

170170

1000

1 12

3 34 45

Figure 21- Scheme of a visit box and bypass

To make a bypass facility, it will be necessary to have a room to work. So the box should be large enough.

The following accessories are necessary (approximate cost in Portuguese market):

- Two connection brackets or T connections (with the same diameter of the main pipe), 600€ each one

- One Sectioning valve (with the diameter of the main pipe), 260€

- Two water connection curves, 50€ each one

- Two Sectioning valves (with the diameter of the bypass), 100€ each one

- Pipe, 70€

- One device to install de sensor,

- Several pieces of pipe to make the connections

- Labor cost, one day for two workers.

The total material cost is estimated to be around 3660€.

The material of the sensor must resist to erosion by sand or other particles that goes with the water.

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3 MANUFACTURING

3.1 Ma in p rod uc tion step s The final product can be divided into three main elements regarding to manufacturing aspects:

Energy harvesting system

SENSOR NODE REMOTE SYSTEMOTHER ELEMENTS

SENSOR CAP(ACTIVE PART)

MONITORING / COMPUTING

UNIT

ELECTRONICSfor ENERGY

STORAGE and MONITORING

COMMUNICATION

MEMORY

ANTENNA

GATEWAY

SENSOR HOLDING DEVICES

ENERGY GENERATOR

ELECTRONIC BOARD

CABLE

MEMS

CMOS CHIP

CARBON-NANOTUBES

MATRIX

NODE DATA BASE

ALGORITHM

HOUSING

Figure 22-Main elements of the PROTEUS product

Concerning the node the main steps of production are described below in Figure 23.

35


TemperatureFlow rate Pressure

Conductivitymatrix of MEMS

(steps undefined yet)

MULTI FUNCTIONNAL SENSOR CHIP

SENSOR CAP

Cap housingMechanical integration

Potting/coating

Electronics board PCB 2 (node)

Components(µC, DC-DC converter, RS485 driver,

connectors, etc)

pick-and-place

EXTERNAL CONNECTORS(for power supply, to antenna,

for testing device (RS485))

NODE housing

CABLES

CONNECTORS to sensor cap

NODE

Mec

han

ical

inte

grat

ion

SENSOR NODE

PRODUCTION STEPS for SENSOR NODE

consumables

functional check

Factory calibration

functional check

Process check

Process check

Process check

consumables

Process check

Process check

Factory data base :

Firmwareloading

Testing device 2

Node serial numberFirmware versionResults of test for Energy monitoring, Memory access, communication...

Factory data base : serial numbers of the two associated elements and the results of tests

Testing device 3

Factory data base :Sensor cap serial numberFactory calibration coefficients

Testing device 1

Selective pH NANOTUBES

Printing (5x)

Selective dissolved O2 NANOTUBES

Selective Nitrate NANO-TUBES

Selective HClO NANO-TUBES

Selective Chloride NANO-TUBES

consumablesSteps of Process in Controlled Atmosphere Chamber

consumables

SMD connector

PCB 1 (cap)Gold Wire bonding

CMOS

Gold Wirebonding

Wafer cutting

Pro

ce

ss

che

ck

Process check

Figure 23-Strategy and steps of production

36


The first purpose is to group all of the process steps that need to be carried out in controlled atmosphere, such as mems production, wire bonding on CMOS chip and PCB. CNT printing is preferably achieved under controlled atmosphere but can work also in regular environment.

In the diagram, we distinguish “process check”, “functional test” and “calibration” because the first ones should be done by the manufacturers whereas the others, more critical to the application, will be realized by PONSEL company with specific calibration benches.

Process check example: Test vectors can be prepared to validate the operation of the CMOS chip, in order to automatize the process.

A testing step for the energy part, including its management will be included in a process check after electronics board manufacturing.

The wireless communication, short range and/or long range, tests are included the “functional check”.

The other elements such as energy generator will also consume manpower for functional testing, configuration of the complete product.

This manufacturing strategy is defined based on the available data; it will evolve regularly during the project following the different steps of prototype development.

Production steps are detailed in Paragraph 3.4 “equipment for productions”.

3.2 Cost Costs of production identified by elements of the product are detailed in the table below.

Elements

types of cost MEMS CMOS chip CNT based

sensor sensor cap node sensor node Power source

communication system

Materials

raw materials for mems (silicon, platinum, gold pads and wire)

CMOS chip CNT and chemicals reagents

PCB, connector,

housing, resin

PCB, connector, housing, cable,

resin

Depending on the Energy Harvesting System including energy storage,

the materials include:

piezoelectric sheets, PV cells,

battery or supercapacitor;

cable

antenna ; cable ; modem

consumables for production

consumables for processing in

controlled atmosphere

chamber (gas, energy,

solvent…)

consumables for processing in

controlled atmosphere

chamber (gas, energy,

solvent…)

solvents, single-use withdrawal

and cleaning articles

single-use withdrawal

and cleaning articles

Rejects <3% <1% <3% <3% <1% ---- <1% <0.5%

other cost maintenance fee for equipments

maintenance fee for equipments

maintenance fee for inkjet

printer

maintenance fee for

calibration device

manpower for production

mems process gold wire bonding

Fabrication of CNT inks ;

printing assembly assembly

serialization coefficients

loading assembly

37


manpower for process checking

visual inspection,

electrical testing

visual inspection,

electrical testing

electrical testing

visual inspection, electrical testing

visual inspection, electrical testing

modem configuration

manpower for calibration

yes

consumables for calibration

gas, solvents, standard solutions

manpower for testing

communication

test, loading final functional

test electrical testing

communication

Royalties to be defined

(ESIEE)

to be defined (IFSTTAR)

to be defined (UNINOVA)

to be defined

(NIPS/UNIPG) to be defined

(UI)

The initial values of process yields (see table below) must increase in order to reach to low level of rejects and consequently decrease the cost of production. For defaulting elements, a recycling strategy must be defined. For example, non-functional CNT matrix could be erased from the chip and printed a second time.

Elements of the sensor node Process yield (initial value)

Four parameter matrix of MEMS-based ohmic physical sensors 75%

Matrix of carbon-nanotubes-based ohmic chemical sensors 80%

CMOS system on chip compatible with SiP integration >90%

Single chip 50%

3.3 Req uired Da ta fo r ind ustria l tra nsfe r In order to perform the industrial transfer from research laboratories to Aqualabo Company, it is necessary to collect data about the products at each steps of the process (from single components to each intermediate assembly). In the manufacturing process, steps of checking must be included. Then Aqualabo also needs data about testing devices. These data are required both from devices available on the market or developed in research laboratories.

Considering the families of items, the useful data are detailed below.

1. For components available on the market:

1 2 3 4 5 6 7 8 9 10 11

Item description

Specifications / data sheet

Manufacturer Manu. reference

distributor Distrid. reference

Unit cost Usual delay Technical obsolescence

Alternative distributor

Alt. Distrid. reference

38


2. For intermediate assemblies or manufactured components:

1 2 3 4 5 6 7 8 9 10 11 12

Item description

Drawing

reference

Assembly instruction sheet

manufacturer

Manu. reference

Unit cost Usual

delay

Testing

Device description

Testing instruction sheet

criteria for acceptance inspection

acceptance range

Recycling

instruction sheet

3. For consumables used for manufacturing:

1 2 3 4 5 6

Item description Specifications / data sheet Provider/distributor Distrid. reference Unit cost Usual delay

4. For testing device available on the market:

1 2 3 4 5 6 7

Item description Specifications distributor Distrid. reference Unit cost Usual delay User manual / instruction sheet for testing

5. For specific testing device:

1 2 3 4 5 6 7

Item description Drawing reference Assembly instruction sheet

Manufacturer Manu. reference Unit cost instruction sheet for testing

6. For consumables used for testing:

1 2 3 4 5 6

Item description Specifications / data sheet Provider/distributor Distrid. reference Unit cost Usual delay

7. For software / firmware in product and testing device:

1 2 3 4 5

Software description Type of file version functions User manual

3.4 Eq uip m ents fo r p rod uc tions

3.4.1 MEMS se nso rs For production of mems, many equipment used for treatment of raw silicon wafers, deposition of SiO2, Si3N4, platinum or gold, wire bonding, are gathered together in clean room facilities (controlled atmosphere chamber with specified amount of dust particles). In this case, in a first step, a partnership relationship with research institute is necessary to have access to this kind of means of production. In a second step, when the volume of products will increase, production in an industrial plan could be realized.

3.4.2 Ca rb on na no tub es senso rs For carbon nanotubes based chemical sensors, chemicals reagents, solvents and laboratory equipment (vessels, stirrer, etc.) should be necessary in order to prepared printable inks with selective nanotubes (pH, Chlorine, dissolved oxygen, nitrate, and chloride). For deposition of all these materials on the silicon chips, an inkjet printer should be used. For this apparatus, the background of the research institute will be useful to produce first batches. For production steps using carbon nanotubes,

39


PONSEL will take care about operator’s conditions of work in order to eliminate risks to their health. Investments in devices like bench-mounted fume cupboard, gloves box and vacuum pumps should be planned.

3.4.3 CMOS c hip The production of the chip will be realized by silicon foundry specialized in standard CMOS technology.

3.4.4 Elec tro nic c irc uits/ Printe d c irc uit b o a rd The production of electronic boards for the sensor cap and the node will be subcontracted to a printed circuit board manufacturer who can provide PCB fabrication services for multi-layer PCBs in volume production amounts. It can provide PCB manufacturing and assembly services using a variety of inspection methodologies to ensure the functionality of the final product. These methodologies include visual inspection of all PCBs, electrical testing, X-ray Inspection if it is necessary.

3.4.5 Me c ha nic a l p a rts Housing for the sensor cap and the node will be realized by a mechanical manufacturer. Mechanical parts could be precision-machined for plastic parts or manufactured using plastic injection moulding.

3.4.6 Energ y ha rvesting syste m Depending on the sub-systems included in the hybrid energy harvesting system, the production requires assembly lines with mechanical and electrical manufacturing tools. The production process includes: plastic and mechanical parts with 3D printing and precision machining, soldering, electroactive material processing (e.g. piezoelectric sheets) and wire bonding for PCB electrical interface. The manufacture of the Energy Harvesting System could be subcontracted to specific industrial subcontractors for large volume.

3.4.7 Senso r c a p testing Sensor cap assembly must be batch-tested with a specific testbench in order to detect default and define sensor-to-sensor factory calibration coefficients. The elements of the testbench are the following:

� A tank or a flow cell containing standard solutions as pH buffers, Potassium chloride solution for conductivity, etc.

� Gas circuit (air / N2) for oxygen calibration

� refrigerated circulating bath to define several levels of temperature

� Valves and pump for flow rate monitoring,

40


� Reference sensors for temperature, pressure, flow measurements,

� Multi connection system,

� Power supply designed for sensor caps

� Computer and data base.

NOTE: A way to optimize CNT based sensor calibration could be found by using a “multi-parameter” standard solution like a pH buffer which conductivity and chloride concentration are known.

The features of the testbench are the followings:

� Connecting several sensor caps (one way by cap)

� Conditioning of each sensor (temperature, pressure, conductivity, pH CNT, etc.)

� Monitoring fluids in the tank,

� Collecting digital signals from each sensor cap,

� Collecting reference values from reference sensors (flowmeter, thermometer, manometer)

� Processing and recording the coefficients for each sensor cap.

sensors plugged

Factory calibration

SENSOR CAP

SENSOR CAP

SENSOR CAP

Factory data base

Signals ; reference values

testing device :Static or flow cell

Multi-sensors connection system

RS485/ethernetconverter

Monitoring

DC power supply

Sensor cap serial numberFactory calibration coefficients

Figure 24-functionalities of the testbench for sensor cap testing

41


3.4.8 Nod e Electronic board, connectors, cables and housing are the main elements of the node. The reliability of this assembly will verified with another testbench. In this case, while the circuit board have been checked by the manufacturer, the testbench should control the wire communication, the power consumption (standby mode) of the assembly, load the firmware and write the serial number in node's memory.

3.4.9 Senso r Nod e After connecting a sensor cap to a node, the resulting product is the sensor node. It will be functional only after the factory calibration coefficients of the specific sensor cap will have been loaded in the node memory. At this step, for each serialized sensor cap, the factory database will provide the corresponding coefficients to the node. In the same time, the database will store the correspondence between node and sensor cap using their individual serial numbers. Finally, the testbench will operate the sensor node to gather a few measurements. In the ambient air, measurements of temperature, oxygen level, pressure from the Sensor node, could be easily checked.

SENSOR CAP

NODE

SENSOR NODEFactory data base

Node serial number

Factory calibration coefficients

DC power supply

DC power supply

Testing device

Firmware ; node serial number

Test results (Consumption, etc)

Sensor cap serial number

Circuit boardStorage : Number of batch,

Test results (Consumption, etc)Connectors

Cablehousing

connection

Sensor nodeTest resultRS485/ethernet

converter

RS485/ethernetconverter

Figure 25-Strategy of production, integration and test of the node and sensor node

42


3.5 Outsourc ing step s As well as printed circuit board and mechanical parts, MEMS and CNT sensors could be produced by industrial partners when the process will have been fully optimized by respectively the ESIEE and IFSTTAR research team.

The strategy for the production of the CNT is not defined yet due to the information we have at this stage and first results in laboratory. This technology is very new for water applications and there is not real industrial production.

Two or three strategies will be defined before June 2016 (prototype) and the validation of the strategy before the end of 2016 (according first results in field conditions).

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