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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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 -50C to +75C
(-58F to +167F) and the potentially hot mounting
location which can be up to 600C (1112F).

Battery pack

Head
(Contrining
electronics)

Waveguides

Stabiliser

Foot
Thermocouple

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support@permasense.com
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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.

Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK
www.permasense.com
support@permasense.com
+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)

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
support@permasense.com
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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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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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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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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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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.

Permasense Ltd, Century House, 100 Station Road, Horsham, RH13 5UZ, UK
www.permasense.com
support@permasense.com
+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.

10

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www.permasense.com
support@permasense.com
+44 20 3002 0922
Revision 1, 20/05/2014 Permasense Ltd. Permasense is a registered trademark of Permasense Ltd.