ClampO-PDF-10--ClampOn-Acoustic.pdf

ULTRASONIC INTELLIGENT SENSORS

ClampOn Acoustic Subsea

MonitoringHans A. Wagner


ClampOn Ultrasonic Intelligent SensorsDSP Particle MonitorDSP Pig DetectorDSP Leak MonitorDSP Corrosion -Erosion MonitorDSP Vibration MonitorVersions:

TopsideCompact Subsea (2500m)Deepwater (4500m)


• The ClampOn DSP Particle Monitor is designed to function as a first stage alarm system for sand production

• It provides immediate, accurate, reliable detection and notification to system operators and controls systems

ClampOn DSP Particle Monitor


DSP - (Digital Signal Processing)

Complete digitalization of the signalNo analogue filtersSignal range: 20 - 1 000 kHzMulti-drop of the signal - 16 SensorsFuture changes can be made by simple download of new software


Working Principle- Acoustic Detectors

By filtering the acoustic signal it is possible to remove most of the signal not being particles, and still keep an extremely high sensitivity to particles.

An acoustic sand detector measures the ultrasound generated by particles hitting the wall of a pipe, normally in a bend.

By accurate calibration of the detector it is possible to convert the measured ultrasound to a quantitative measurement of sand.


Working Principle- Acoustic Detectors


First Generation Detectors

Sensing element

AmplifierSignal

processingSignal

interface

Processed data

Weak signal

Weak signal

Field calibrations

Field calibrationsHigh noise

- Low sensitivity

High noise- Low

sensitivity


“The perfect detector”

•Extremely high sensitivity to the particle

frequencies

•Perfect filtration of unwanted signals

•Unaffected by electrical interference


Processed

data

ClampOn DSP-06 Detectors

SensorElement Amplifier

Signal processing

Signal interface

All processing done inside sensor:•No long cables between Sensor

element and amplifier•No electrical interference

•No field calibration required to have control of the sensor

•All sensor calibration can be done during production

•High sensitivity and high signal to noise ratio

All processing done inside sensor:•No long cables between Sensor

element and amplifier•No electrical interference

•No field calibration required to have control of the sensor

•All sensor calibration can be done during production

•High sensitivity and high signal to noise ratio


Challenges in Particle MonitoringFigure 1: Flow-sensitive system with background noise

Figure 2: ClampOn DSP Particle Monitor discriminates background noise


ClampOn DSP Particle MonitorSensitivity - Depending on flow velocity

Typical minimum traceable quantities of sand:2 m/s 0.083 g/s5 m/s 0.031 g/s

10 m/s 0.011 g/s15 m/s 0.005 g/s20 m/s 0.001 g/s

Particle size - range:Gas 15 µm up to 1500 µm / 1 PPMOil/Gas 25 µm up to 1500 µm / 1 PPM(Minimum detectable size: 9 µm in liquid)

Main “beam” is 100 - 250 µm


ClampOn Advantage

• Eliminated mechanical and structural noise by choosing a higher frequency band where they do not exist.

• Higher signal-to-noise ratio allows for improved quality measurements.

• Signal processing / filtering takes place within the monitor.


ClampOn DSP SpectrumSpectrum - Response from different media

0

10

20

30

40

50

60

70

80

90

100

Frequency

Pro

sent

age

%

Sand /Particle

Gas /Liquid

MechanicalWater / Liquid


ClampOn Advantage

• Sensors are calibrated during manufacturing for the same response to particles. No field calibrations required. Sand injections are optional - not required for sand measurement.

•Sensors can communicate directly with the SCADA system (no CIU required), or via ClampOn software.


ClampOn Sand Monitor 3.0 Software

Collects data from ClampOn sensors

Calculates sand rates and sand quantities for trending, monitoring, archiving and alarming

Provides access to data and configurations via TCP/IP based proprietary client-server interface

Interfaces with control system viaModbus, OPC, DDE, 4-20mA, Relay, etc.

Can be setup to run in background


Predicted Penetration Rate (standard elbow - 10,000 particles simulated)

MaximumErosion

Flow

Flow

15.6 mpy

0

7.80

10.4

13.0

5.20

2.60


FlowRate

No sanding

Sand-freelimit line

Massive sanding

Upper limit ofsafe operation

Productionenhancement

Sand Strength

Sand bursts

Operating Range concept


Optimum installation

Control Room

A, S & R

Flow input

Onshore login

ClampOn login


ClampOn DSP Particle Monitor, Deepwater

• 4500 meter water depth• Dual electronic• ROV Installable/Retrievable

sensor

• 3000 Meter Water Depth • Weight 8 kg• Retrofit, ROV

installable/retrievable

• Digital communication between field and computer• Built in health check, and the ability to check the

contact between sensor and pipe


Sensor with Flying Lead


ClampOn DSP Deepwater Particle Monitor Installation


ClampOn DSP Deepwater Particle Monitor Installation

Ease of installationNo cuttingNo weldingPre-clamped mounting bracket on the pipe, downstream of a 90°bendROV installable & retrievable sensor


ClampOn DSP Compact Retrofit Sensor


ClampOn DSP Vibration Monitor

Vibrations from 0.25Hz to 1024Hz will be quantified by an accelerometer. These vibrations will be measured in two orthogonal. The energy will be represented in g in the range of 0 – 5g

Vibrations or shear waves propagating in the metal itself will be picked up by an ultrasonic element. The bandwidth of these waves will span from 1024 Hz to 262 kHz.



• The system consist of 2 sensor types: - Accelerometer Sensor Measure X and Y – 2 axis- Acoustic Emission Sensor

• The ClampOn DSP Sensor picks up the vibration and shear waves that are transported in the metal structure that it is clamped on to.

• The ClampOn DSP Sensor processes all data digitally within the sensor itself (patented technology) to achieve the optimum signal-to-noise ratio without influence from other noise sources.

• The sensor measures in real time, and transmits the signals to the PC / DCS. The computer /control system presents the measurements asquantity levels below 1024 Hz.

• Transmits data once every 6 minutes (vibration)

• Can only measure one task; e.g. Vibration or Particle. Operator would need to select time criteria or pull on command.


DSP Vibration

• Customers have requested to keep the data frame rate low – therefore selected bins

• Data available every 6th minute – due to the low frequency it cannot be “pulled”more often

• Consist of 2 elements(Piezo element & a 2 axis accelerometer)



• In-house calibration: All sensors are calibrated to give the same response as our Master Sensor.

• All sensors have been calibrated and verified on a certified vibration bench.

How do we achieve good calibration


• Measure G-force0,25 – 1024 Hz3 axis X –Y – Z

• Measure Acoustic Noise

1 – 262 kHz

• Can be combined with Particle & PIG

Monitor –REAL TIME

New hardware ClampOn DSP Vibration Monitor


ClampOn DSP SpecificationsRetrofit Sensor: Acoustic, passive and intelligent

• Sensor electronics: Intelligent with digital output• Enclosure: Titanium 300 BarA• Weight: 6,0 kg • Operating temperature: -40oC to 225oC (-40oF - 437oF) • Frequency range: 0,25 – 1024 Hz Vibration 10mv• Installation: Clamps on to the pipe downstream of a bend• Power consumption: 0,8 Watt per detector• Max distance from SCM system: 2000 m / 6500 ft• Signal transmission: Twisted pair• Repeatability: 1%• The new hardware will monitor Vibration in 3-axis X-Y-Z

simultaneously with the Particle Monitor


ClampOn – The Leader

www.clampon.com

60 employees with sole focus on acoustic

measurement based on “cutting edge”

Ultrasonic Technology


Thank you!

Questions?

ClampO-PDF-10--ClampOn-Acoustic.pdf

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