SENS-IT

SENS-ITSENS-ITSmall Electronic Network Small Electronic Network

Sensor Integrity ToolSensor Integrity Tool

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

23 February 200523 February 2005

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Summary Project DetailsSummary Project Details

ScopeScope Development of a Low-Cost Permanently Installed Development of a Low-Cost Permanently Installed

Microelectronic Wireless Monitoring System for Process PlantMicroelectronic Wireless Monitoring System for Process Plant

BenefitBenefit Improved monitoring techniques leading to lower operational Improved monitoring techniques leading to lower operational

costs, improved QHSE, more reliable information for increased costs, improved QHSE, more reliable information for increased integrity management, and zero loss of containment.integrity management, and zero loss of containment.

Duration: Duration: 34 months34 monthsTotal Cost:Total Cost: €3.14m €3.14m EC Funding: EC Funding: €1.7m€1.7mBalance of Funding:Balance of Funding: Project PartnersProject Partners

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Project PartnersProject Partners

Project Co-ordinationProject Co-ordination iicorr Ltdiicorr Ltd

System

System

Sen

sor

Sen

sor

Electro

nic

Electro

nic

Interface

Interface

Wireless

Wireless

So

ftware

So

ftware

Dem

oD

emo

iicorr - UKiicorr - UK

InDec - NorwayInDec - Norway

UNN - UKUNN - UK

Vibtech - UKVibtech - UK

Tentaclion - GermanyTentaclion - Germany

HOIS2000 (End-User)HOIS2000 (End-User)

WP LeaderWP Leader WP SupporterWP Supporter Project End User/SupporterProject End User/Supporter

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Progress to dateProgress to date

Oct 02 - Project StartOct 02 - Project Start

Mar 03 - Development of Functional SpecificationMar 03 - Development of Functional Specification

Oct 03 - Detailed Operational and Interface SpecificationOct 03 - Detailed Operational and Interface Specification

Dec 03 - Paper design Dec 03 - Paper design

Mar 04 - Project interim stage reachedMar 04 - Project interim stage reached Partners agree to continue project to conclusionPartners agree to continue project to conclusion

Apr 04 - Technology Demonstrator system designed and Apr 04 - Technology Demonstrator system designed and built built

Apr 04 - Technology successfully demonstrated Apr 04 - Technology successfully demonstrated

Feb 05 - Prototype design on-goingFeb 05 - Prototype design on-going Issues of intrinsic safety being addressedIssues of intrinsic safety being addressed

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Areas of workAreas of work

Sensor developmentSensor development Piezo-composite sensorsPiezo-composite sensors Single and arraySingle and array Specification, design, characterisation, test and evaluationSpecification, design, characterisation, test and evaluation Sensor packagingSensor packaging ManufactureManufacture

Microelectronic Interface design & manufactureMicroelectronic Interface design & manufacture Design of drive electronics and pre-amp circuitryDesign of drive electronics and pre-amp circuitry Interface packagingInterface packaging MiniaturisationMiniaturisation

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Areas of workAreas of work

RF interfaceRF interface Network topology evaluationNetwork topology evaluation Network interface specificationsNetwork interface specifications Choice of communication technologiesChoice of communication technologies Integration of RFIntegration of RF

Data acquisitionData acquisition Software and dataset specificationSoftware and dataset specification

Power supplyPower supply Choice of battery technologyChoice of battery technology

Software & FirmwareSoftware & Firmware Software and dataset specificationSoftware and dataset specification Software utility for presentation of resultsSoftware utility for presentation of results

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Achievements: SystemAchievements: System

Demonstrator unit builtDemonstrator unit built

Integrated unit Integrated unit incorporating: incorporating:

SensorSensor Integrated electronic Integrated electronic

interfacesinterfaces Battery technologyBattery technology Interim software packageInterim software package

(Main software now available)(Main software now available)

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Achievements: SensorAchievements: Sensor

Twin crystal design to resolve Twin crystal design to resolve 4mm wall thickness4mm wall thickness

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

Low power to comply with Low power to comply with ATEX regulationsATEX regulations

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

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Achievements: MicroelectronicsAchievements: Microelectronics

Miniaturized Miniaturized microelectronic unit microelectronic unit consists of:consists of:

high speed analogue circuithigh speed analogue circuit digital controllerdigital controller 8 channel multiplexer / de-8 channel multiplexer / de-

multiplexer multiplexer all have been fully assembled all have been fully assembled

and testedand tested

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Achievements: MiniaturisationAchievements: Miniaturisation

Credit card size micro-Credit card size micro-electronics interface electronics interface achieved …achieved …

… … and working!and working!

Could be made smallerCould be made smaller This considered another This considered another

developmentdevelopment Compromise on size and Compromise on size and

intrinsic safety issuesintrinsic safety issues

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Achievements: PowerAchievements: Power

Various battery solutions Various battery solutions evaluatedevaluated

Special battery pack Special battery pack combination of primary / combination of primary /

secondary cells implementedsecondary cells implemented provides high pulse currents provides high pulse currents

throughout the target lifetime of throughout the target lifetime of two yearstwo years

Probably 6 AA cells equivalentProbably 6 AA cells equivalent (Due to IS requirements(Due to IS requirements

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

On-going activityOn-going activity

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Achievements: WirelessAchievements: Wireless

Wireless LAN 802.11b compatible (WiFi compliant)Wireless LAN 802.11b compatible (WiFi compliant)Range: 500m (approx) range line-of-sight Range: 500m (approx) range line-of-sight Digital interface for connection to sensor unitDigital interface for connection to sensor unitStar-shaped wireless network topologies with the use of central access pointsStar-shaped wireless network topologies with the use of central access pointsFTP protocol allows communication with the sensor network via web gatewayFTP protocol allows communication with the sensor network via web gatewayDimensions: 80x50x10mm (40cm3)Dimensions: 80x50x10mm (40cm3)Temperature range: -20 to +85°CTemperature range: -20 to +85°CPower consumption: 600mA at 3.3V (2W)Power consumption: 600mA at 3.3V (2W)Solar cell (optional)Solar cell (optional)

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Achievements: SoftwareAchievements: Software

An intuitive and simple An intuitive and simple user interfaceuser interfaceA robust and effective A robust and effective interface to the interface to the communication unitscommunication unitsExport/import solutions Export/import solutions that will enable effective that will enable effective interface to end-users interface to end-users systemssystemsEfficient and robust Efficient and robust interpretation of the interpretation of the ultrasonic signalsultrasonic signals

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Achievements: SoftwareAchievements: Software

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Achievements: SoftwareAchievements: Software

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Achievements: SummaryAchievements: Summary

Integrated design of a Integrated design of a demonstrator unitdemonstrator unit

Signal output receivedSignal output received

It works!It works!

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Lessons Learnt … so far!Lessons Learnt … so far!

Issues of sensor characteristics and interfacing Issues of sensor characteristics and interfacing electronics electronics

Issues of intrinsic safetyIssues of intrinsic safety

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

Low noise, high speed circuit designLow noise, high speed circuit design

System Integration System Integration

Importance of working closely with partners Importance of working closely with partners

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Next StepsNext Steps

Refine design for system integration and Refine design for system integration and manufacture manufacture

Complete ATEX certification at component level Complete ATEX certification at component level

On-going ATEX certification for integrated On-going ATEX certification for integrated systemsystem

Production and commissioning of prototypeProduction and commissioning of prototype

Evaluation testing on siteEvaluation testing on site

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Programme to CompletionProgramme to Completion

Anticipated time for on-site testing

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Thank you for listeningThank you for listening

Any questions?Any questions?