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SENS-IT

 

Background
Requirements for improved safety and environmental aspects of plant operation have stimulated considerable research and development effort in NDT over the past 20 years. Improved NDT has been crucial to the maintenance of structural integrity throughout the processing industries' production chain. The use of permanently installed monitoring systems (PIMS) bring potential for real-time, on-line monitoring and assessment of large areas of plant, drastically reducing down-time associated with current inspection intervention methods. The ability to detect signs of damage and its progression will lead to much improved standards of safety and efficiency for international processing industries.
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Project Objectives
  • Assist industry eliminate loss of containment in a process plant
  • Drastically reduce downtime attributable to existing inspection and monitoring philosophies
  • Focus on non-intrusive, low-cost, global, and rapid screening techniques
  • Enable real-time, on-line monitoring and assessment of large areas of plant
  • Provide an ability to sense defects, process information, and transmit this data via wireless methods such that the operator can monitor and react to issues of plant integrity
  • Provide a system based on Permanently Installed Monitoring (PIM)
 
Project Co-ordinator:
Project Partners:
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Intelligent Decisions AS
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Northumbria University
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Tentaclion GmbH
Vibration Technology Limited
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SENS-IT Project
 

The Sens-IT (Small Electronic Network Sensor Integrity Tool) project is focused on non-intrusive, low-cost, global, and rapid screening techniques based on Permanently Installed Monitoring (PIM). The key issues surrounding the technology are the ability to sense defects, process information, and transmit this data via wireless methods to the plant operator, such that the operator can monitor and react to issues of plant integrity. Technology advances in new materials, new sensing techniques, microelectronics, data processing, and use of wireless communication methods is the basis of development.

The project is based on a concept of modular components that allow application specific system functionality. The electronic modules enable the use of a range of sensing options capable of meeting the needs of process plant industry. The project focuses on a limited number of key issues that aim to enable system functionality at a desired performance level. This dictates that the project addresses system components and system integration issues rather than fundamental science.  
SENS-IT image
SENS-IT image

Technology is developed for sensing techniques, electronics, data acquisition and wireless communication. The SENS-IT project focuses on the miniaturization, system integration, and optimising the sensor data analysis.  

The system brakes down into three main segments, each of which is addressed as sub-systems with their own modular components: Sensors and/or sensor interfaces; Micro electronics to drive sensors, acquire and process data; and Communication interface and network. Ultrasonic is the primary sensing technique that is used as the vehicle to prove the concept; Field Signature Method (FSM), and electro-magnetic are seen as future requirements. Secondary techniques (such as acoustics) are also considered where they are easily interfaced. State-of-the-art developments are included, with emphasis on developing electronic modules that support different and emerging techniques. The possibilities of generating more information from the sensor outputs via advanced signal processing are also investigated.  

On-site evaluation of the system is a crucial part of the development process.

 
ENERGIE
 

The project has gained funding of EUR1.7million from the European Commission Fifth Framework Programme, ENERGIE. This award is to a consortium of companies, led by iicorr, towards the EUR3.2million development project "Sens-IT" over a three year period. Sens-IT will develop a low-cost permanently installed microelectronic wireless monitoring system for process plant.

iicorr Ltd is the project co-ordinator for a group high technology European companies including: Intelligent Decisions AS (Oslo, Norway), University of Northumbria (Microelectronics Industrial Centre, Newcastle, UK), Vibration Technology Ltd (Glasgow, UK), and Tentaclion GmbH, (Germany).

 
Outline System Specification
 
Project Progress
 
The Sens-IT project has developed PIMS hardware, this produced an autonomous ultrasonic sensor array that utilises wireless communications to transfer the UT data back to a central computer for storage, processing and presentation. The autonomous device consists of 8 multiplexed UT probes driven by battery powered microelectronics. The microelectronics have been designed to take periodic measurements, generally once a day, then transmit this data via the onboard 802.11b transceiver.
 
Sensor Interface Type (Current) Compression Wave UT Array
Sensor Interface Type (Future Development) DCPD Array; TOFD Array; CHIME; Pulse Eddy Current; Lamb Wave
Sensor Support All Common
No of Channels 8 multiplexed
Battery Life Expectancy 2 years (under normal operation of one measurement per day)
RF Standard IEE 802.11b WLAN/WiFi
Encryption 128 bit
Physical data transmission rate 1MBit/s
Net data rate 400 kbit/s
No of data per measurement 1 - 64 kbyte
Transmission Range 300m (unobstructed line of sight)
Operating Temperature Range -18 degC to +85 degC
Survival Temperature Range -40 degC to +85degC
Humidity 0 - 100%
Operating Environment Ex Zone 1
Intrinsic Safety CENELEC certification code EEx ia IIB T3
Operating System Microsoft Windows XP
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