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 SENS-IT

Summary Project Details Scope Development of a Low-Cost Permanently Installed Microelectronic Wireless Monitoring System for Process Plant Development of a Low-Cost Permanently Installed Microelectronic Wireless Monitoring System for Process PlantBenefit Improved monitoring techniques leading to lower operational costs, improved QHSE, more reliable information for increased integrity management, and zero loss of containment. 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

SENS-IT Project Partners Project Co-ordination iicorr Ltd SystemSensorElectronicInterfaceWirelessSoftwareDemo  iicorr - UK  InDec - Norway  UNN - UK  Vibtech - UK  Tentaclion - Germany HOIS2000 (End-User)  WP Leader  WP Supporter Project End User/Supporter

SENS-IT 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 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 Issues of intrinsic safety being addressed

SENS-IT Areas of work Sensor development Piezo-composite sensors Piezo-composite sensors Single and array Single and array Specification, design, characterisation, test and evaluation Specification, design, characterisation, test and evaluation Sensor packaging Sensor packaging Manufacture Manufacture Microelectronic Interface design & manufacture Design of drive electronics and pre-amp circuitry Design of drive electronics and pre-amp circuitry Interface packaging Interface packaging Miniaturisation Miniaturisation

SENS-IT Areas of work RF interface Network topology evaluation Network topology evaluation Network interface specifications Network interface specifications Choice of communication technologies Choice of communication technologies Integration of RF Integration of RF Data acquisition Software and dataset specification Software and dataset specification Power supply Choice of battery technology Choice of battery technology Software & Firmware Software and dataset specification Software and dataset specification Software utility for presentation of results Software utility for presentation of results

SENS-IT Achievements: System Demonstrator unit built Integrated unit incorporating: Sensor Sensor Integrated electronic interfaces Integrated electronic interfaces Battery technology Battery technology Interim software package Interim software package (Main software now available)

SENS-IT 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

SENS-IT Achievements: Microelectronics Miniaturized microelectronic unit consists of: high speed analogue circuit high speed analogue circuit digital controller digital controller 8 channel multiplexer / de- multiplexer 8 channel multiplexer / de- multiplexer all have been fully assembled and tested all have been fully assembled and tested

SENS-IT Achievements: Miniaturisation Credit card size micro- electronics interface achieved … … and working! Could be made smaller This considered another development This considered another development Compromise on size and intrinsic safety issues Compromise on size and intrinsic safety issues

SENS-IT Achievements: Power Various battery solutions evaluated Special battery pack combination of primary / secondary cells implemented combination of primary / secondary cells implemented provides high pulse currents throughout the target lifetime of two years provides high pulse currents throughout the target lifetime of two years Probably 6 AA cells equivalent Probably 6 AA cells equivalent (Due to IS requirements (Due to IS requirements Power profile reduced by 25% since mid-term position On-going activity

SENS-IT Achievements: Wireless Wireless LAN b 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)

SENS-IT 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

SENS-IT Achievements: Software

SENS-IT Achievements: Software

SENS-IT Achievements: Summary Integrated design of a demonstrator unit Signal output received It works!

SENS-IT 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

SENS-IT 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

SENS-IT Programme to Completion Anticipated time for on- site testing

SENS-IT Thank you for listening Any questions?