U.S. patent application number 17/164875 was filed with the patent office on 2021-10-28 for asset integrity monitoring using cellular networks.
The applicant listed for this patent is SENSOR NETWORKS, INC.. Invention is credited to JAMES BARSHINGER, BRUCE A. PELLEGRINO.
Application Number | 20210333242 17/164875 |
Document ID | / |
Family ID | 1000005705255 |
Filed Date | 2021-10-28 |
United States Patent
Application |
20210333242 |
Kind Code |
A1 |
PELLEGRINO; BRUCE A. ; et
al. |
October 28, 2021 |
ASSET INTEGRITY MONITORING USING CELLULAR NETWORKS
Abstract
An ultrasound sensing system for monitoring the condition or
integrity of a structure, comprising: a plurality of ultrasound
sensors, each sensor being configured to receive at least one first
electrical signal, transmit an ultrasound signal in response to
said first electrical signal, receive at least one reflected
ultrasound signal, and transmit a second electrical signal in
response to said reflected ultrasound signal, said first and second
electrical signals being analog; and at least one digital sensor
interface (DSI) to which at least a portion of said sensors are
connectable, said DSI being configured to transmit said first
electrical signal and receive said second electrical signal, and to
generate at least an A-scan signal based on said first and second
electrical signals for each sensor, said DSI having a cellular
transceiver for transmitting a cellular signal based directly or
indirectly on at least said A-scan signal, said cellular signal
including an address corresponding to said at least one DSI.
Inventors: |
PELLEGRINO; BRUCE A.; (FAR
HILLS, NJ) ; BARSHINGER; JAMES; (STATE COLLEGE,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SENSOR NETWORKS, INC. |
Boalsburg |
PA |
US |
|
|
Family ID: |
1000005705255 |
Appl. No.: |
17/164875 |
Filed: |
February 2, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15169077 |
May 31, 2016 |
10908130 |
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17164875 |
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14839694 |
Aug 28, 2015 |
10247705 |
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15169077 |
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62168422 |
May 29, 2015 |
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62137532 |
Mar 24, 2015 |
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62058592 |
Oct 1, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01N 29/11 20130101;
H04W 72/082 20130101; G01N 2291/02854 20130101; G01N 29/44
20130101; G01N 29/043 20130101; G01N 2291/106 20130101; G01N
2291/044 20130101; G01B 2210/58 20130101; G01N 2291/0258 20130101;
G01B 17/02 20130101; H04W 4/70 20180201; G01N 29/2481 20130101 |
International
Class: |
G01N 29/24 20060101
G01N029/24; H04W 72/08 20060101 H04W072/08; G01B 17/02 20060101
G01B017/02; G01N 29/04 20060101 G01N029/04; H04W 4/70 20060101
H04W004/70; G01N 29/11 20060101 G01N029/11; G01N 29/44 20060101
G01N029/44 |
Claims
1. An ultrasound sensing system for monitoring the condition or
integrity of a structure, comprising: a plurality of ultrasound
sensors, each sensor being configured to receive at least one first
electrical signal, transmit an ultrasound signal in response to
said first electrical signal, receive at least one reflected
ultrasound signal, and transmit a second electrical signal in
response to said reflected ultrasound signal, said first and second
electrical signals being analog; and at least one digital sensor
interface (DSI) to which at least a portion of said sensors are
connectable, said DSI being configured to transmit said first
electrical signal and receive said second electrical signal, and to
generate at least an A-scan signal based on said first and second
electrical signals for each sensor, said DSI having a cellular
transceiver for transmitting a cellular signal based directly or
indirectly on at least said A-scan signal, said cellular signal
including an address corresponding to said at least one DSI.
2. The system of claim 1, wherein said cellular transceiver is
configured to communicate with a third-party cellular network.
3. The system of claim 2, further comprising: a user interface
connectable to said cellular network to receive said cellular
signal.
4. The system of claim 2, wherein said cellular transceiver is
configured to communicate with a cloud server via said third-party
cellular network.
5. The system of claim 4, further comprising: a user interface
configured to facilitate display information based on said A-scan
signal.
6. The system of claim 5, wherein said user interface runs a
standard browser.
7. The system of claim 6, wherein said user interface is a standard
browser-enabled device such as a laptop computer, tablet or smart
phone.
8. The system of claim 1, wherein said cellular transceiver is
configured to call out, and not to receive calls.
9. The system of claim 1, further comprising a battery to operate
said DSI.
10. The system of claim 9, wherein said DSI is configured to read
said sensors at a first frequency and to store readings from said
sensors in memory, and to upload via said cellular network said
readings stored in said memory at a second frequency, which is less
than said first frequency.
11. The system of claim 9, wherein said first frequency is daily
and said second frequency is weekly.
12. The system of claim 1, wherein said DSI is configured to upload
said readings to a cloud server.
13. The system of claim 12, further comprising said cloud
server.
14. The system of claim 13, wherein said cloud server is configured
to store said readings and execute post processing.
15. The system of claim 14, wherein said post processing includes
one or more of compensation for temperature drift or statistical
analysis of a corrosion rate.
16. The system of claim 14, wherein said cloud server is configured
to generate an alarm if a reading is above or below a preset.
17. The system of claim 13, wherein said cloud server is configured
to host a user interface that is accessible from a web browser to
allow users to view and interact with said readings.
18. The system of claim 1, wherein said sensor is a dual element
sensor.
19. The system of claim 1, wherein said DSI comprises encryption
functionality for encrypting said cellular signal.
20. The system of claim 1, wherein said DSI comprises functionality
to establish a VPN between said DSI and cloud data storage.
Description
REFERENCE TO APPLICATION
[0001] This application claims priority to U.S. Provisional
Application No. 62/168,422, filed May 19, 2015, and is a
continuation in part of U.S. patent application Ser. No.
14/839,694, filed Aug. 28, 2015, which claims priority to
Provisional Application No. 62/058,592 filed Oct. 1, 2014, and No.
62/137,532 filed Mar. 24, 2015, all of the above referenced
applications are hereby incorporated by reference.
FIELD OF INVENTION
[0002] This invention relates generally to a system for
ultrasonically monitoring the condition and integrity of pipes
and/or other structures or assets, such as those used in the oil
and gas and power generation industries using an improved wireless
monitoring scheme and business model.
BACKGROUND
[0003] Wall thickness and the presence of defects such as cracks
are important factors in determining the fitness-for-service of
structures such as above and below ground pipes and tanks,
including bulk material and weldments. When a pipe is in operation,
it can be subject to corrosion and/or erosion due to the content,
flow and/or environmental conditions inside or outside of the pipe.
Cracks can form and propagate due to the presence of manufacturing
defects, creep, thermal cycling, fatigue and environmental
conditions causing defects such as high temperature hydrogen attack
(HTHA), stress corrosion cracking, etc. Corrosion and/or erosion
results in the reduction in wall thickness, which can reach a point
at which operating conditions becomes unsafe, considering that the
pipe can be pressurized and may contain hazardous or flammable
materials. Likewise formation and propagation of cracks, in welds
for instance, can cause similar unsafe conditions. A failure may
cause catastrophic consequences such as loss of life and
environmental damage in addition to the loss of the use of the
asset, and any corresponding costs associated with repair, loss of
capacity and revenue loss.
[0004] Ultrasonic non-destructive evaluation techniques are
commonly used for evaluating the integrity of industrial
components. In the case of measuring wall thickness reduction due
to erosion/corrosion, the traditional process involves using a
portable handheld instrument and ultrasonic transducer (probe) to
measure the wall thickness. The instrument excites the probe via an
electrical pulse, and the probe, in turn, generates an ultrasonic
pulse which is transmitted through the structure. The probe also
receives an echo of the ultrasonic pulse from the structure, and
converts the pulse back into an electrical signal. The ultrasonic
pulses that are transmitted into and received from a structure are
used to determine the relative position of the surfaces (i.e.
thickness) of the structure wall. More specifically, by knowing the
travel time of the ultrasonic pulse from the outer wall to the
inner wall and back (.DELTA.T) and acoustic velocity (V) of the
ultrasonic pulse through the material of the structure (through
calibration or just initialization), a wall thickness (d) can be
calculated--i.e. d=.DELTA.T*V/2. In a similar fashion, ultrasound
can be used to detect the presence of defects such as cracks. Here,
the gauge is set up to look for the presence of ultrasonic echoes
returning from the defect. The absence of an echo would indicate a
part without a defect. There are many variants of these two basic
descriptions of ultrasonic thickness gauging and flaw detection
that are known to skilled practitioners of ultrasonic
nondestructive evaluation.
[0005] These approaches require an operator to manually position a
probe on the wall of the asset to take a reading. Not only does
this necessitate the operator manually taking each reading, but
also the measurement location must be accessible, which can be
challenging and costly. For example buried pipelines require
excavation to access, insulated pipe requires costly removal of the
insulation, offshore assets require helicopter or boat access, and
elevated vessels requiring scaffolding or crane access. While the
measurement is relatively simple, the cost of access (scaffolding,
excavation, insulation removal, etc) is often much higher than the
cost of measurement. Moreover, the operator is often subjected to a
hazardous conditions while taking the readings. Furthermore, to
obtain trending data with thickness resolution of 0.001'' or better
requires that the transducer be placed in the same exact location
for consistent readings at regular time intervals. This is
difficult and often impractical especially when the data-capture
rate needs to be frequent. Variations in operator and/or equipment
tends to skew the quality and integrity of the measurement
data.
[0006] One approach for avoiding some of the aforementioned
problems is to use installed sensors/systems for asset-condition or
-integrity measurement. The sensors are permanently or
semi-permanently installed on the asset and have features such as
wireless data transmission to avoid costly wiring installations.
There are even automated systems that require no operator to be in
the vicinity of the asset, and that stream data to a control room
or to an operator's desk.
[0007] Current state of the art systems such as offered by
Permasense often utilize mesh networks, such as Zigby, Wireless
HART and/or ISA100 for data transmission. Mesh networks utilize a
scheme in which a wireless plant network is deployed using the
plant's wired Ethernet infrastructure and a Gateway that is
deployed on the plant's wired Ethernet. The gateway offers a
wireless connection to a set of wireless nodes (e.g., process
control or monitoring transmitters) that form a mesh network. In
the mesh network, devices can act as transmitters of data messages,
receivers of messages, and can relay messages from other devices.
These type of networks can have various topologies such as star,
mesh and point to point and are well known to those skilled in the
art.
[0008] This type of device implementation has several major
shortcomings. First, the installation cost of such a system is
initially driven by the cost of the gateway and gateway
installation. While a monitoring device or process controller might
cost $2-$4 k, it is useless without a gateway which might cost
upwards of $10-$20 k. An additional cost of $50 k or so may
incurred to install, power and deploy the gateway in the plant
network. Thus, the deployment of even a small monitoring network
can be extremely costly and will typically involve capital expense
budget sources. However, as funding for inspection and maintenance
is typically an operational expense, large capital expense budgets
are typically not available for such equipment.
[0009] Additionally, these devices must be proximate to the
wireless gateway due to the low power and relatively short wireless
range of the devices, and the devices must be proximate to each
other such that the devices are within range of each other and the
gateway. This is a barrier to deploying inspection points as
required by the maintenance or corrosion engineer because the
device location is not only defined by the desired locations that
are of interest for monitoring, but also by the design of the mesh
and the placement of the devices and the gateway. Thus, the
deployment of such solutions can be complicated and may require
more than one gateway to be deployed and/or extra nodes to "fill
in" the mesh, even though these extra nodes are possibly not
located in areas that are of interest for monitoring. Overall,
these factors increase the cost and complexity of deploying a
monitoring system using wireless mesh networks.
[0010] Furthermore, these mesh networks operate on the facility's
IT infrastructure. It is often extremely challenging to deploy new
equipment and software that operate on the IT infrastructure of
corporations due to concerns of security, data, compatibility and
network integrity, etc. Since mesh networks are deployed on a
facility's IT infrastructure, devices deployed via mesh networks
such as state of the art corrosion monitoring devices, require
analysis and approval by the facility's IT department. This offers
an additional barrier to the deployment of new monitoring
technologies.
[0011] Therefore, Applicants recognize a need for a wireless asset
integrity monitoring system that is simple and low cost to deploy
in facilities, and that is can operate apart from the plant IT
infrastructure if need be. The present invention fulfills this need
among others.
SUMMARY
[0012] The following presents a simplified summary of the invention
in order to provide a basic understanding of some aspects of the
invention. This summary is not an extensive overview of the
invention. It is not intended to identify key/critical elements of
the invention or to delineate the scope of the invention. Its sole
purpose is to present some concepts of the invention in a
simplified form as a prelude to the more detailed description that
is presented later.
[0013] In one embodiment, the invention relates to an ultrasound
sensing system for monitoring the condition or integrity of a
structure. In one embodiment, the system comprises: (a) a plurality
of ultrasound sensors, each sensor being configured to receive at
least one first electrical signal, transmit an ultrasound signal in
response to the first electrical signal, receive at least one
reflected ultrasound signal, and transmit a second electrical
signal in response to the reflected ultrasound signal, the first
and second electrical signals being analog; and (b) at least one
digital sensor interface (DSI) to which at least a portion of the
sensors are connectable, the DSI being configured to transmit the
first electrical signal and receive the second electrical signal,
and to generate at least an A-scan signal based on the first and
second electrical signals for each sensor, the DSI having a
cellular transceiver for transmitting a cellular signal based
directly or indirectly on at least the A-scan signal, the cellular
signal including an address corresponding to the at least one
DSI.
[0014] In one embodiment, the invention involves a battery powered,
cellular enabled ultrasonic digital sensor interface (DSI) that is
capable of interfacing with and operating ultrasonic transducers
for the purpose of inspecting and/or evaluating the condition of
industrial assets such as pipes, vessels and heat exchangers.
Because the instrument is capable of connecting to and using
available, a third party cellular network, it avoids the problems
associated with mesh network, gateways, and plant IT
infrastructure. This allows the deployment of even single
inspection points at low cost, without the expense of gateway
installation, and IT personnel evaluation.
[0015] In one embodiment, the DSI is connected via an available
cellular network to a cloud server(s) that is running an
application software that is designed to communicate with the DSI
for the purpose of collecting ultrasonic or other data associated
with the integrity of the asset being measured. In one embodiment,
the application software is also designed to store readings and has
a browser based user interface that allows for the display of data
and asset integrity information. In one embodiment, the application
can be viewed through standard browser enabled devices such as
laptop computers, tablets and smart phones.
[0016] In one embodiment, the system facilitates enhanced business
models that are enabled by a low cost, easily deployable, cellular
enabled ultrasonic instrument. For example, one business model
involves a monthly subscription plan. In this model, the
aforementioned physical hardware (DSI, probes) is provided to the
customer free of charge for as long as the customer subscribes to a
monthly charge for access to the asset integrity data that is
collected from the physical hardware and stored on the cloud
server. The customer will be billed a monthly fee for each DSI
deployed. This model avoids capital expense budget approvals,
shifting the expense to operation expense. In this model, there may
be an installation service charge or alternatively, the charge may
be financed and amortized over a certain period of the
subscription, for example 6, 12, 18 or 24 months. In this model,
the product offering becomes the service of providing asset
integrity data, rather than the physical hardware itself.
[0017] In another business model, the physical hardware is provided
to the customer for a nominal fee. The remaining features of the
monthly charge and optional financing of installation remains the
same.
[0018] These business models can be deployed solely by the
manufacturer of the equipment or portions such as the hardware
installation can be subcontracted to a service company. In this
case, the product offering remains the offering of the cloud based
asset integrity model. Other embodiments will be known or obvious
to one of skill in the art in light of this disclosure.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 shows a schematic view of different embodiments of
the system of the present invention.
[0020] FIG. 2 shows a schematic view of a dual probe
multiplexer.
[0021] FIG. 3 shows a block diagram of one embodiment of a DSI unit
of the system of present invention.
[0022] FIG. 4 shows different sensor configurations.
DETAILED DESCRIPTION
[0023] Referring to FIG. 1, schematic views of different
embodiments of the ultrasound sensing system 100 of the present
invention are shown. In one embodiment, the system 100 functions to
determine wall thickness of a structure, and comprises a plurality
of ultrasound sensors 102. Each sensor 102 is configured to receive
a first electrical signal, transmit an ultrasound signal in
response to the first electrical signal, receive a reflected
ultrasound signal, and transmit a second electrical signal in
response to the reflected ultrasound signal. The first and second
electrical signals are analog. The system 100 also comprises at
least one digital sensor interface (DSI) 103, to which at least a
portion of the sensors 102, are connectable. The DSI is configured
to transmit the first electrical signal and receive the second
electrical signal, and to record and process a digital time-voltage
waveform commonly known as an A-scan based on the first and second
electrical signals for each sensor. The digital A-scan signal can
be evaluated to perform a wall thickness calculation within the DSI
or can be transmitted in whole or part for post analysis.
[0024] In this embodiment, the DSI has a cellular transceiver 101
for transmitting a digital signal based directly or indirectly on
at least the A-scan signal via a 3rd party wireless cellular
network 104. As is known, the cellular network can operate over
various frequencies, technologies and standards as is required by
the network design. Frequencies include, for example, 850, 900,
1800, 1900 MHz, and technologies/standards include, for example,
CDMA, GSM, 3G, 4G, LTE.
[0025] In one embodiment, the DSI communicates over the cellular
network with a data server(s) 111. The data server may be any known
data server, and include, for example, single or multiple
computational and data storage devices and can include both
discrete computational hardware as well as distributed
computational and storage architectures such as would be known as
the "cloud computing" and "cloud storage." In this embodiment, the
devices serve as the computational and data storage mechanism that
receives, processes and stores raw and processed data from the
described ultrasonic transducers and cellular enabled DSIs over the
cellular network. Associated with the data server is an application
software 112 that runs on the data server(s). In one embodiment,
the application software 112 is a web browser configured to manage
data storage, analytics, user management, and usage tracking.
[0026] These components are described in greater detail below.
[0027] Sensors
[0028] The sensors, 102, function to convert between electronic
signals and ultrasonic signals. (As used herein, the term "signal,"
unless otherwise indicated, may be electrical or ultrasonic, and
may be in the form of electrical energy, sound pulse and other
forms of electromagnetic or sound waves.) Such sensors are well
known and are also referred to as ultrasonic transducers. The
transducers and generated/received ultrasonic energy are configured
for the purpose of evaluating the integrity of the structure, 101,
such as by measuring the remaining wall thickness of the asset or
by assessing whether the structure, has flaws such as cracks.
[0029] Typically sensors comprise a piezo-electric material such as
lead zirconate titanate (PZT), but may also be magnetostrictive,
and/or Lorentz force based. The transducer(s) may be deployed in
various configurations based upon the nature of the structure and
desired test. Exemplary configurations include single element, dual
element, angle beam, dual angle beam, single element delay line and
may also be configured in such a manner as is required to generate
longitudinal waves, shear waves, combined longitudinal and shear
waves, surface waves and guided waves as is required by the
application of the waves to assess the integrity of an asset.
[0030] In one embodiment, the system of the present invention is
configured to interface with any known or commercially-available
ultrasonic sensor, thus avoiding the need for proprietary sensors
and their inherent expense and limited availability. For example,
referring to FIG. 4, a variety of sensors are shown for determining
wall thickness and detecting cracks. The single-element sensor 501
both transmits and receives ultrasonic signals from the same
element 501a. Such a sensor is relatively inexpensive and allows
one sensor to operate on just one channel. In one embodiment, a
single-element sensor 502 is combined with a solid spacer (delay
line) 502b such that the spacer/delay line is disposed between the
sensor element 502a and the asset 550. The spacer/delay-line
functions to extend the travel time for an ultrasonic signal,
thereby increasing the time between the transmit and receive
signals, which improves the near surface resolution and also
measurement accuracy of single element sensors.
[0031] Another approach to improve measurement resolution is to use
a dual-element sensor 503, which transmits an ultrasonic signal
from one element 503a, and receives the reflected ultrasonic signal
with a second element 503b. Although application needs may vary,
generally a dual-element sensor can be advantageous for measuring
heavily corroded surfaces as the electrical separation between
transmit and receive channels allows for the use of increased
signal amplification without the deleterious effect of amplifier
saturation and recovery due to the transmission pulse.
[0032] To measure cracks, voids, welds, or other anomalies that are
not parallel to the mounting surface 551 of the asset 550, but
generally more perpendicular to the mounting surface, an angle-beam
L longitudinal wave sensor 504 or shear wave sensor 504 may be
used. In one embodiment, the angle-beam sensor 504 is configured
with an angled spacer (wedge) 504a to angle the sensor such that it
transmits refracts a signal into the asset that is angled relative
to the rear surface 552 of the asset. When the signal impinges on
the rear surface 552, it is reflected at the same angle (angle of
refraction) and continues to propagate in the asset wall 550. As
shown, if the signal encounters a crack 553 or similar anomaly, the
signal is reflected such that it reflects off of the rear wall back
to the sensor 504. Alternatively, rather than reflecting off the
rear wall, an additional angle beam sensor 505 may be configured to
receive the signal from the transmitting transducer. A defect in
the path of the signal will block the transmission to the receiver,
indicating the presence of a defect. The choice of the angle-beam L
or shear wave sensor depends on the application. The single,
delayed, dual element, angle-beam L and shear wave sensors are well
known in the art. Examples of commercially-available sensors are
available from manufacturers such as Olympus NDT, Imasonic, GE and
Blatek.
[0033] Referring back to FIG. 1, in one embodiment, groups of
sensors are arranged in arrays such as a two dimensional array 105
or a linear array 106, and the arrays interfaced with DSIs as
described below. In one embodiment, the array of sensors is fixed
semi-permanently to the asset, thus facilitating a wall thickness
measurement at the location of each sensor. The sensor array may be
implemented in various embodiments. For example, referring to FIG.
1, a medusa configuration 107 is shown in which the sensors consist
of individual probes and are cabled to the DSI via relatively short
(e.g., <Eft) cables 108. In another embodiment, the sensor array
and DSI are implemented in the same physical package 109, 110 as
shown in FIG. 1. In one embodiment, the array sensor is fabricated
such that it is flexible and can conform to the curved surface of a
pipe, pipe elbow or vessel.
[0034] As mentioned below in connection with the DSI, each sensor's
unique location, both relative to the other sensors in the array
and their absolute location as installed on the industrial asset,
can be permanently encoded, via a unique serial number or GPS
location into the monitoring system for accurate tracking of all
future measurements.
[0035] In another embodiment, provisions for temperature
measurement are included in the system with associated sensors such
as thermocouples and thermistors, and associated circuitry and
software within the DSI. In one embodiment, there is at least one
temperature measuring device per ultrasonic probe. For example, the
temperature monitoring devices may be attached to or embedded into
the ultrasonic transducers or attached directly to the asset
adjacent to the transducers. In another embodiment, one temperature
measuring device is used per several ultrasonic sensors.
Temperature measurements are taken adjacent in time (just before,
during, or after) an ultrasonic measurement and are used to adjust
the ultrasonic measurement for changes in ultrasonic (acoustic)
velocity due to temperature change. This is required to make more
accurate (precise) ultrasonic thickness measurements for example. A
software algorithm embedded in the thickness measurement (d=v/2*T)
can automatically correct "v" for its predicated change in acoustic
velocity as a function of asset temperature changes. Sensors for
temperature measurement are well known and include, for example,
Resistance temperature detector (RTDs) or thermocouples.
[0036] Digital Sensor Interface (DSI)
[0037] The DSI functions to interface with the sensors 102, and
generate a digital signal related to the physical characteristics
of a particular structure 101, including, for example, wall
thickness, anomalies/cracks in welds for instance. In one
embodiment, the DSI interfaces with the sensors by transmitting and
receiving the first and second electrical analog signals, as
described above, and generating an A-scan signal from which the
wall thickness of the structure can be derived. A-scan signals are
well known and relate generally to a data presentation by which
measureable ultrasonic signals from an object location are
displayed. As generally applied to pulse-echo ultrasonics, the
horizontal and vertical sweeps are proportional to time or distance
and amplitude or magnitude respectively. Thus the location and
magnitude of acoustical interfaces are indicated as to depth below
the sensor. It should be understood, however, that the A-scan
signal may be presented in different forms after processing within
the DSI.
[0038] Additionally, in one embodiment, the DSI functions to
generate a digital signal for output via a cellular network. The
digital signal may be based directly or indirectly on the A-scan
signal. More specially, in one embodiment, the A-scan signal is
merely converted to a digital signal, which is then transmitted via
cellular transmission. Alternatively, the digital signal may be
indirectly based on the A-scan scan. That is, the A-scan signal may
be converted to thickness data as described above, and then the
thickness data may be transmitted via cellular. Whether the signal
is directly related to the A-scan signal or indirectly related to
the A-scan signal is not critical to the claimed invention provided
that the output of the DSI is a digital signal comporting with
known protocols over wireless cellular. Other embodiments will be
known or obvious to one of skill in the art in light of this
disclosure.
[0039] In one embodiment, the DSI can be configured to store data
related to the inspection, including the ultrasonic parameters,
such as instrumentation gain, gate positions, and calibration data,
as well as contextual data such as GPS coordinates for the DSI and
TMLs, asset information, tag numbers, etc. This data may accompany
or be integrated with the digital signal transmitted on the digital
bus by the DSI, thereby providing the user with critical
information related to the specific DSIs, sensors and contextual
information of the readings without user intervention. In one
exemplary embodiment, the A-scan data, and related ultrasonic
parameters and contextual information are formatted into a file
type structure and transmitted via wireless cellular. The file
architecture can be ASCII text, Comma Separated Values (CSV), XML
and binary for example.
[0040] The DSI may be configured to interface with any known
sensor. For example, in one embodiment, the DSI is a dual-channel
ultrasonic device, meaning that it has two independent, analog,
transmit and receive channels. These channels can be used
independently, each with an ultrasonic sensor individually or
together with a dual element ultrasonic sensor. In one embodiment,
the DSI acts as a single-channel ultrasonic device, meaning that it
can be configured to transmit and receive on a single channel. In
an additional embodiment, each ultrasonic channel is multiplexed
using an array of switches to increase the number of measurement
points. For example, if each channel of the DSI is multiplexed to
16 outputs, then each channel can be connected to 16 ultrasonic
sensors for a total of 16 measurement points. Alternatively, the
channels may be configured in pairs with dual-element sensors for a
total of 8 measurement points.
[0041] In one embodiment, the DSI is configured to collect and
upload asset integrity data according to a schedule for the purpose
of battery management. In one embodiment, the DSI is intended to
operate on batteries (such as two C cells) for several years--for
instance between 3 and 15 years. One way to accomplish this is to
manage the time that the cellular radio is powered as the cellular
radio and data transmission requires relatively high amounts of
power. Additionally, the UT block tends to be relatively high
power, therefore it is also advantageous to keep the UT Block in an
unpowered state when the DSI is not making UT measurements.
Therefore, in one embodiment, only the microcontroller is powered
when the DSI is at rest, and, furthermore, the microcontroller is
configured to rest in a low power state and have a real time clock
that can wake up the microcontroller and areas of the circuit, such
as the UT Block and Cellular Radio, only when those circuits are
desired to perform a function, such as take a measurement for the
UT Block or transmit a measurement for a cellular radio. In one
embodiment, a real time clock is designed into the DSI either as a
discrete circuit or as part of the microcontroller to manage the
scheduling of various tasks and thus manage the power consumption
of the device.
[0042] An exemplary measurement schedule to manage and extend
battery life might be as follows: (1) wake the UT block up
periodically (e.g., two times per day) to make a measurement of
asset integrity and store this data in memory; and (2) wake up the
cellular radio less frequently than the UT block (e.g., once per
week) to upload all of the readings that were collected in the past
week. In this fashion and based upon knowledge of the power draw of
various parts of the circuit, a measurement and upload schedule can
be designed to achieve measurement goals and extend battery life as
long as possible.
[0043] Referring to FIG. 3, a block diagram of the architecture 300
of a specific embodiment of the DSI is considered in detail. In one
embodiment, the DSI comprises a UT Block 301. An example of a UT
block 200 is illustrated schematically in FIG. 2. Referring to FIG.
2, a "pulser" circuit 201 that is designed to produce a voltage
waveform to excite the transducers. The waveform can be a simple
"spike" pulse, a square wave (e.g. at least 1 or more half cycles),
a sine wave, a sawtooth wave, a chirp or other type as appropriate
for the type of transducer and ultrasonic application. A receiver
circuit 302, contains one or more stages of amplification and
attenuation to appropriately size the incoming voltage waveform
prior to digitization. The receiver section may also contain analog
filters to condition the signal and may implement highpass, low
pass or band pass filters. Between the pulser/receiver and the
transducers is a switch or set of switches 203, 304 to multiplex
the P/R channel selectively to multiple transducers. In one
embodiment a 1X16 or 1X32 multiplexer is used. Additionally, the
P/R circuits may be separated along with the multiplexer switches
as appropriate for dual element transducers, for example having a
1X8 multiplexer on the pulser circuit and a 1X8 multiplexer on the
receiver to address 8 dual element transducers.
[0044] A common control (microcontroller or similar) 205 may be
used to ensure the settings of each individual switch are set such
that the TX and RX elements in the probe are connected to the
pulser and receiver channels at the same time. In one embodiment,
separate switches are used for TX and RX channels. This separation
allows for maximum electrical isolation between the TX and RX sides
of the probe, thus reducing electrical crosstalk and thus
maximizing measurement performance. Optionally, a switch 206 can be
placed between the pulser and receiver channels to automatically
switch the circuit between single element mode and dual element
mode. In an exemplary configuration, this switch is a relay or
physical jumper in order to achieve the high level of isolation
between the transmitter and receiver that is usually required in
dual element mode. Other embodiments will be known or obvious to
one of skill in the art in light of this disclosure.
[0045] Referring back to FIG. 3, the analog signal from the UT
block 301 feeds into a digitizer 302 to convert the analog voltage
waveform to a digital signal. The digitizer is then connected to an
FPGA 303, for additional processing and temporary storage of the
digital data. The FPGA may implement additional signal
conditioning, such as filters, and may measure the signal in
amplitude and/or time, including optionally performing a thickness
measurement or flaw detection algorithm within the FPGA. Other
embodiments will be known or obvious to one of skill in the art in
light of this disclosure.
[0046] The raw data as well as other outputs and/or results are
then sent to an attached microcontroller 304. The microcontroller
serves to manage operation of the DSI including power management
through activating the various blocks of the circuit when
needed.
[0047] The embodiment of the DSI disclosed here also comprises a
cellular interfance or transceiver 309 for transmitting and
receiving data over a cellular network. Such cellular transceivers
are well known and commercially available. Although a cellular
transceiver is disclosed herein, it should be understood that, in
other embodiments, the cellular interface may be a discrete
transmitter and/or receiver.
[0048] In one embodiment, the DSI 300 also comprises battery 310 to
eliminate the need for wired power to generate the various DC
voltages required by the circuit and cellular radio, 309, for
transmitting and receiving information, data and/or signals over a
cellular network. Suitable batteries are well known and include
those used for voice/cell phone communications. It should be
understood, that if an alternative power source is available then
the DSI need not comprise a battery.
[0049] Additionally, in one embodiment the DSI also comprises
various peripheral components to the microprocessor, including, for
example, a Real Time Clock 306, temperature sensor interface 307,
and serial EEPROM memory 308.
[0050] Cellular Network
[0051] Cellular networks are well known. Typically, a cellular
network is a radio network distributed over land through cells
where each cell includes a fixed location transceiver known as base
station. These cells together provide radio coverage over larger
geographical areas. User equipment (UE), such as mobile phones, is
therefore able to communicate even if the equipment is moving
through cells during transmission. Cellular networks give
subscribers advanced features over alternative solutions, including
increased capacity, small battery power usage, a larger
geographical coverage area and reduced interference from other
signals. Popular cellular technologies include the Global System
for Mobile Communication, general packet radio service, 3GSM and
code division multiple access. Generally, the cellular network can
operate over various frequencies, technologies and standards as is
required by the network design. Frequencies include for example
850, 900, 1800, 1900 MHz. Technologies/standards include, CDMA,
GSM, 3G, 4G, LTE, for example. In one embodiment, the cellular
radio in the DSI is implemented on a radio module such that the an
appropriate radio module can be inserted to operate with the
available cellular network.
[0052] Cloud Storage and Processing
[0053] In one embodiment, the DSI collects and processes the data
and formats the data into a file to then push to cloud storage 111,
for easy access by inspection personnel or asset owners. As used
herein, the term cloud-based storage is a model of data storage
where the digital data is stored in logical pools, the physical
storage spans multiple servers (and often locations), and the
physical environment is typically owned and managed by a hosting
company. Cloud storage services may be accessed through a
co-located cloud compute service, a web service application
programming interface (API) or by applications that utilize the
API, such as cloud desktop storage, a cloud storage gateway or
Web-based content management systems. Thus, cloud-based storage for
the ultrasonic measurements and related installation parameters
enables the use of web-based data access, 112, from any fixed or
mobile device having Internet connectivity and advantageously
offers a relatively low cost solution for implementation of asset
integrity monitoring devices as now software or hardware must be
deployed on a customer's IT infrastructure. Data access is then
accomplished through any "connected" mobile or computational device
with an internet browser.
[0054] In one embodiment, the DSI transmits the A-scan signal or
similar signal in essentially "raw" form for cloud-based computing.
Cloud computing relies on sharing of resources to achieve economies
of scale. Cloud computing focuses on maximizing the effectiveness
of the shared resources. With cloud computing, multiple users can
access a single server to retrieve and update their data without
purchasing licenses for different applications. Thus, in this
embodiment, cloud computing performs the calculations on the A-scan
signal to determine wall thickness or detect flaws. Generally,
determining when and where to calculate the thickness data from the
A-scan signal is a question of optimization. For example, it may be
preferable to convert the A-scan signal to thickness data in the
DSI to save on storage space because the A-scan signal data
consumes more space than the thickness data. On the other hand,
converting this signal to thickness data tends to require more
processing power, thus, more energy needs to be provided to the DSI
which may adversely affect battery life. Advanced processing of
data such as measurement trending and statistical analysis will
also rely on cloud computing.
[0055] An important aspect of operating over public networks is
security. Customers need to have their data secure from corruption,
theft, and hacking. The use of cellular networks offers an
important advantage because the measurement device is not connected
to the plant network, and, therefore, is not a door to be opened by
hackers. Rather, the data can be stored in a secure cloud
environment. However, cellular data networks by themselves are not
encrypted. To protect the client's data, some level of encryption
is generally preferred, although not required. In an embodiment,
the data to be transmitted to cloud storage is encrypted by the DSI
prior to transmission, transmitted to the cloud, and then decrypted
at the cloud server. The encryption can take several forms,
including, for example, an implementation of a proprietary
algorithm, or can be a standard method such as SSL/HTTPS. In an
additional embodiment, a virtual private network (VPN) is set up
between the DSI's and the cloud storage. Additional encryption may
also be desired at the cloud storage database.
[0056] Usage and Business Model
[0057] Yet another aspect of the invention is the method of use and
business model. A first exemplary use is the monitoring of
corrosion in O&G facilities. The DSI and probes are installed
in the facility and set up for use. The DSI is configured to
operate on an available cellular network. Configuration may involve
inserting a SIM card (for a GSM radio) or otherwise activating the
cellular radio such as providing an IMEI number to the cellular
provider. The DSI schedule is set for the measurement reading
frequency and upload frequency. After setup, the DSI automatically
wakes up on a predetermined reading schedule, for example once per
day and will take ultrasonic readings of the asset and any other
sensor readings for configured sensors such as temperature
measurement devices. The readings will be stored in the DSI memory
until they are uploaded. The DSI also automatically wakes up on a
predetermined upload schedule--for example once per week and
activates the cellular radio. Once activated, the cellular radio
connects to the appropriate cellular network and uploads the stored
result(s) file to the cloud server. The cloud server stores
readings and post processes the readings if desired--such as
compensation for temperature drift or statistical analysis of the
corrosion rate. In one embodiment, the cloud server also generates
alarms if the measured wall thickness is below preset thresholds or
the corrosion rate is above preset thresholds. Alarms can be simply
color coding of displayed readings in the UI or could involve the
generation of email or txt messages to appropriate personnel. In
one embodiment, the server also hosts a user interface that is
accessible from a web browser to allow users to view and interact
with the measured data.
[0058] Due to the novel aspects of this invention, the equipment
and software, including probes, DSI, cellular network, cloud
server/application are deployed externally to the customers IT
infrastructure. This allows new models of business for corrosion
monitoring as the equipment can be deployed in a low cost fashion.
For example, in one business model, the equipment is provided free
of charge to the customer. The customer pays a monthly contract
amount with a guaranteed performance period for the contract--for
instance 24 months. Hardware installation fees are paid upfront or
amortized over the contract period.
[0059] Another business model is similar to the first but the
customer purchases, leases, or rents the physical hardware. A
monthly contract amount is paid by the customer for access to the
data on the cloud server.
[0060] Yet another business model is that the customer purchases,
leases, or rents the physical hardware. The customer chooses not to
use the cloud service and rather the DSI emails the data directly
to a specified email address via an SMTP server.
[0061] Many other models will be obvious to those of skill in the
art in light of this disclosure.
[0062] Having thus described a few particular embodiments of the
invention, various alterations, modifications, and improvements
will readily occur to those skilled in the art. Such alterations,
modifications, and improvements as are made obvious by this
disclosure are intended to be part of this description though not
expressly stated herein, and are intended to be within the spirit
and scope of the invention. Accordingly, the foregoing description
is by way of example only, and not limiting. The invention is
limited only as defined in the following claims and equivalents
thereto.
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