Installation guide - WT210 WiHART sensors This guide details installation process for WT210 WiHART sensors. It assumes the user is familiar with the operation of the IK200 installation kit. Refer to User guide – IK200 installation kit for more detailed usage instructions. Refer to Overview – WT210 WiHART system deployment for the full list of system documentation.
Table of contents Safety notices .......................................................................................................................................................................... 2 Compatibility .......................................................................................................................................................................... 2 Technical background............................................................................................................................................................ 2 Installation requirements ...................................................................................................................................................... 4 Task 1. Mounting the sensor ................................................................................................................................................ 5 Task 2. Mechanical installation and validation procedure ............................................................................................... 7 Task 3. Completing sensor installation .............................................................................................................................. 9 Re-installing a sensor (if required) .................................................................................................................................... 10 Re-provisioning a sensor (if required) .............................................................................................................................. 10
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Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922
Safety notices Installation of this sensor in an explosive environment must be in accordance with the standards and practices appropriate to the site. Review the Regulatory Compliance section in Datasheet – WT210 WiHART sensor for restrictions for safe installation. Only fit approved Permasense BP10E or BP20E battery packs. Ensure the device is installed with the antenna at least 20cm (8”) from all persons.
Compatibility Permasense WT210 WiHART sensors are only compatible with Emerson 1420 gateways with the EIMP order option. Permasense BP10 and BP20 battery packs can be used but note that they have a narrower ambient temperature range than the BP10E and BP20E. Antenna
Technical background Permasense systems are permanently installed ultrasonic corrosion monitoring solutions for use in oil and gas and other industrial facilities. At the heart of the systems are permanently attached dual-probe ultrasonic wall thickness measurement sensors that use breakthrough waveguide technology to enable them to operate in high-temperature environments. These unique waveguides provide separation between the sensor head, rated at -50°C to +75°C (-58°F to +167°F) and the potentially hot mounting location which can be up to 600°C (1112°F).
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Battery pack
Head (Contrining electronics)
Waveguides
Stabiliser
Foot Thermocouple
Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922
Each sensor is dry-coupled (meaning no couplant is required) to the surface of the pipe using a pressure contact, obtained with force applied from mounting the sensor on studs and securing with nuts. Note: Installing the sensor correctly, to ensure proper coupling between the sensor tip and the pipe surface, is key to ensuring correct functionality of each sensor. Once correctly installed, the ultrasonic signal produced by the sensor travels down one waveguide. Where the waveguide contacts the pipe, ultrasound waves travel across the outer surface which is seen in the received signal as a surface wave (S). Ultrasound waves also travel through and reverberate in the pipe wall which is seen in the received signal as multiple back wall reflections (B1, B2, etc). The thickness is calculated from these signals. Once a sensor is installed, it will communicate with the gateway specified during installation, and any other sensors already installed that are assigned to the same gateway. These sensors form a wireless mesh network. The gateway manages this mesh, selecting the best path to transmit data from each sensor to the gateway. The gateway then delivers this data to the Permasense database. Data from all sensors can be viewed by the end user via the Permasense Data Manager browser interface.
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Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922
Installation requirements Before sensor installation:
Emerson 1420 gateway must be installed.
Pairs of M8 (5/16") studs must be welded to the pipe work at the desired sensor locations. See Installation Guide – Stud welding.
Network ID and provisioning information (join keys) must be known. Access to the sensor locations must be in place. If lines are insulated, all insulation must be removed at sensor locations to allow suitable access for sensor installation.
Required hardware (supplied with Permasense WT210 sensors)
Permasense WT210 sensor Permasense BP10E or BP20E battery pack, 1 per sensor
Hey key, 2.5mm Telescopic inspection mirror
Consumables (supplied in Permasense IK200 Installation Kit)
Loctite 8009 anti-seize compound
M3 x 16mm stainless steel battery retaining bolts, 2 per sensor
Additional hardware required
Stainless steel circular heat shield, to protect sensor head from radiant heat (if required), 1 per sensor
M8 (compatible with 5/16" studs) Nord-Lock anti-vibration washers, 2 per sensor
Lanyard kit, comprising 2m 316 stainless steel lanyard with looped end, Gripple No.2, release key.
(not supplied by Permasense) Full plain nuts, to suit welded stud thread and metallurgy: Thread: M8 or 5/16" Material: Stainless steel, or suitable other corrosion resistant steel.
Socket for 5/16” nuts
Required tooling (supplied in Permasense IK200 Installation Kit)
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Rugged table PC, preloaded with Permasense installation software
CC21 USB powered commissioning communicator
Torque wrench, 3/8" sq. drive. 2 - 24Nm range, set to 8Nm
Deep socket, 6-point. 13mm, 3/8" drive 3/8" drive extension bar, 8"
Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922
Task 1. Mounting the sensor 1. On painted pipe-work, remove a circular patch of the coating about 25mm (1”) diameter mid way between the studs to allow waveguides to contact the pipe directly. 2. Ensure the studs are perpendicular to the sensor contact point.
3. Smear the threads with Loctite 8009 anti-seize compound. 4. Record the installation location, sensor ID, MAC address of the sensor, and battery serial number. Note: MAC address is a unique 16 digit hexadecimal (numbers 0-9 and letters A-F) number used to identify sensors. Sensor ID is an easy to work with 4 character Permasense unique ID used to identify the sensor in Data Manager. Each sensor shows its sensor ID and MAC address on a label on the sensor. 5. Examine the thermocouple and make sure it is protruding past the end of the waveguide by about 3mm (1/8”) so that it will press onto the pipe when the sensor is tightened.
6. Locate and place the WT210 sensor over the studs, ensuring the waveguides are positioned centrally (±5mm, 0.2”) . 7. Place Nord-Lock washers over the studs.
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Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922
8. Thread nuts onto the studs, and run them down several threads. 9. Observe the sensor contact from the side. As shown in the following illustrations, check that:
Sensor feet are parallel to the pipe surface Studs are perpendicular to the pipe surface Sensor tip is in the middle of the two studs
10. Carefully secure the sensor in this position by finger tightening each nut.
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Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922
Task 2. Mechanical installation and validation procedure 1. Power up the rugged tablet PC and connect the CC21 to any of the USB ports. 2. Double-click the Permasense WT210 installation app desktop icon. Within ~10seconds, the Permasense installation tool software should open. 3. Attach the CC21 to the sensor. In the WT210 installation app software: 4. The sensor ID and MAC address of the sensor should be displayed at the top of the screen within 10 seconds. 5. Click on the Provision tab. Note. Provisioning information can be entered either manually (via the on-screen keyboard) or automatically (via a commissioning file produced by Gateway Manager). This guide shows manual entry of provisioning information to a gateway using a common join key. To use automatic data entry, or for more details about provisioning, refer to User guide – IK200 installation kit. 6. Enter the 5 digit network ID and the 32 hexidecimal (numbers 0-9 and letters A-F) join key 7. Click the Provision button. Confirmation is given when provisioning is complete. 8. Check in the Network Discovery panel to confirm that the sensor can hear a device with the network ID you wish the sensor to join. Note. All WiHART Sensors send Network Discovery information every 45 seconds. If no devices with a matching network ID appear in Network Discovery, the provisioning and sensor installation can
6) Enter network ID and Join Key
7) Click Provision
8) Check sensor can hear the network
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Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922
be completed, but the sensor is unlikely to join the network without additional sensors to extend the mesh. 9. Check that:
Torque wrench is set to a value of 8Nm (6 ft.lbs). Sensor alignment is correct. Note: The sensor foot must remain parallel to the pipe wall contact point - ensure nuts are ONLY tightened incrementally as described above.
10. Click the Installation tab 11. Click Start Observe the graphical information displayed in the install tool software:
As the sensor is tightened and becomes coupled to the pipe, the coupling amplitude will rise in line with each 1/4 turn tightening of the nuts.
At 10 seconds after the start button is pressed, an ultrasonic waveform will appear in the bottom window. This waveform is continuously updated every 10 seconds.
The ultrasonic waveform will comprise several peaks. It is important that the first TWO peaks are clean, and well defined, as in the example illustrated.
12. Continue to tighten each nut in 1/4 turn increments, alternating between nuts until torque is reached on each nut. Continue to monitor the install tool software during this process. Overtightening the nuts can damage the waveguides
11) Click Start
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Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922
Task 3. Completing sensor installation 13. Review the graphs following tightening and check these criteria are met:
The coupling amplitude history plot shows an increasing trend, in-line with nut tightening. The coupling amplitude is above 40. The last displayed ultrasonic waveform shows the first two peaks are clean and well defined. The measured thickness displayed in the bottom right of the window is comparable with expectations for the measurement location.
14. When all of the above criteria are satisfactorily met, press the Complete button. 15. Ensure all required sensor information is accurately logged (e.g. sensor ID and location). 16. Remove the CC21 and fit the battery pack. When the battery pack is fitted, the sensor will restart and try to join the WiHART gateway. In a large network of 100 sensors this can often take 2 hours, and sometimes 6 hours. Refer to Installation guide – BP series battery pack. Sensor installation is now complete. 17. To protect the sensor from high levels of radiated heat, install the circular stainless steel heat shield. At insulated locations the heat shield can be fixed to the insulation jacket. See the document Guidelines - Re-insulation of lines following sensor installation.Task 4. Fitting the lanyard Install the lanyard around the pipe and sensor to provide a fall protection restraint. 1. Wrap the lanyard around the circumference of the pipe. The 2m (7ft) length will accommodate a maximum diameter of 24”. 2. Thread the bare end of the wire through the loop in the lanyard to secure it to the pipe. 3. Feed the bare end of the lanyard into the ‘gripple’ and push the ‘gripple’ 15cm (6”) up from the bare end. 4. Feed the bare end between the waveguides near the sensor head, loop back around a waveguide without trapping the thermocouple. Feed into the return hole of the ‘gripple’. One of the waveguides should now be in the loop. Note. The wire can be released from the ‘gripple’ using the release key.
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Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922
Re-installing a sensor (if required) If a good ultrasonic signal is not being sent by the sensor, it can be reinstalled: 1. Attach the CC21 to the tablet PC and the sensor and run the WT210 installation app. 2. Loosen the M8 (or 5/16") sensor fixing nuts. 3. On the Installation tab, press the Reset uninstalled button. Note. The sensor will no longer join the network until the Complete button is pressed again. 4. Follow the instructions as for a new installation. The steps to provision the sensor can be skipped.
Re-provisioning a sensor (if required) A sensor can be re-provisioned, if required, without needing to reinstall the sensor: 1. Attach the CC21 to the tablet PC and the sensor and run the WT210 installation app. 2. On the Provision tab, enter the new provisioning information 3. Click the Provision button The Join Network button can be pressed to start the sensor join process and receive on-screen feedback about the join state of the sensor. Note. Although the join process often take just a few minutes, it can take several hours depending on the size and activity of the network. See User guide – IK200 installation kit for more details about using the status bar to identify the join state.
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Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK www.permasense.com
[email protected] +44 20 3002 0922 Revision 1, 20/05/2014 © Permasense Ltd. Permasense is a registered trademark of Permasense Ltd.
