IK Online Electronics ID5001P Manuel utilisateur

ONLINE ELECTRONICS LTD

ID5001P_5001_B00

Page 0 of 36

Online Electronics Ltd

Online House

Blackburn Business Park

Woodburn Road

, Blackburn

Aberdeen

AB21 0PS

+44 (0)1224 714 714

www.online

-electronics.com

sales@online

-electronics.com

NON-INTRUSIVE PASSIVE ULTRASONIC

TOPSIDE PIG SIGNALLER

OPERATING MANUAL

The ID5001P is a fully ATEX and IECEx certified, Exd flameproof,

non-intrusive pig signaller which detects, signals and logs the passage

of pigs at critical points along a pipeline both on land and offshore

Inline Services, LLC. 27731

Commercial Park Rd.

Tomball TX 77375

p.. 281.401.8142 | 888.973.0

e.. sales@inlineservices.com

w.. inlineservices.com

ONLINE ELECTRONICS LTD

ID5001P_5001_B00 Page 1 of 36

ID5001P_5001 MANUAL

Rev

Date

Summary of change

A00

02/05/19

CR00570: Initial release.

A01

23/05/19

CR00570: Section 2 & 9: Certificate numbers corrected.

B00

14/01/20

Various graphics updated throughout (IK Rebranding).

CR00264.

Section 2: Specifications added for high temperature pipelines.

Section 2: Specifications for battery options added.

Section 5.3 & 5.4: High temp pipeline mounting instructions added.

Section 4.3: Added instructions for latched detection operation.

Section 10: Notified Body number updated.

Added section to cover Config Software installation and operation.

COMMENTS:

ONLINE ELECTRONICS LTD

ID5001P_5001_B00 Page 2 of 36

CONTENTS Page

1. General Description ..............................................................................................3

2. Specifications ...................................................................................................... 4

3. Rules For Safe Operation .......................................................................................5

4. Operation............................................................................................................6

4.1. Turning On ......................................................................................................6

4.2. Listening .........................................................................................................7

4.3. Detection ........................................................................................................ 7

4.4. Detection Algorithm .......................................................................................... 8

4.5. Single Button Menu Interface ........................................................................... 10

4.5.1. Main Menu................................................................................................. 11

4.5.2. Events Menu .............................................................................................. 12

4.5.3. System Info Menu ...................................................................................... 13

4.5.4. Live Display Menu....................................................................................... 13

4.5.5. Output Config Menu .................................................................................... 14

4.5.6. Detect Config Menu..................................................................................... 15

4.6. RS485 Serial Interface .................................................................................... 16

4.6.1. MODBUS Register Map ................................................................................ 16

5. Installation ........................................................................................................ 18

5.1. Main Housing Mounting Plate............................................................................ 18

5.2. Main Housing Post Mounting............................................................................. 18

5.3. Main Housing Pipeline Mounting........................................................................ 19

5.4. Sensor Mounting ............................................................................................ 19

5.5. Sunshade Post Mounting.................................................................................. 20

5.6. Sunshade Pipeline Mounting............................................................................. 20

5.7. Opening The Housing ...................................................................................... 21

5.8. Closing The Housing ....................................................................................... 21

5.9. Battery Removal............................................................................................. 22

5.10. External Connections ...................................................................................... 23

5.10.1. Relay Output.............................................................................................. 23

5.10.2. EX Connections .......................................................................................... 24

5.10.3. RS485 Serial Interface ................................................................................ 24

5.10.4. 0V Connection............................................................................................ 24

5.10.5. Enclosure Connection .................................................................................. 24

5.10.6. Remote Switch Connection........................................................................... 24

5.10.7. Switch Connection ...................................................................................... 24

5.10.8. Current Loop Output ................................................................................... 25

5.10.9. VBAT Connection ........................................................................................ 25

5.10.10. External Power Connection ....................................................................... 25

6. ID5001P Config Software..................................................................................... 26

6.1. Software Installation ....................................................................................... 27

6.1.1. Microsoft .NET Framework Installation ........................................................... 27

6.1.2. ID5001P Config Software Installation ............................................................ 27

6.2. Using The Config Software ............................................................................... 28

6.2.1. Setup Tab.................................................................................................. 28

6.2.2. Read/Write Tab .......................................................................................... 29

6.2.3. Read Only Tab ........................................................................................... 29

6.2.4. Booleans Tab ............................................................................................. 30

6.2.5. Events Tab ................................................................................................ 30

6.2.6. Live View Window ....................................................................................... 31

6.2.7. Event View Window..................................................................................... 31

7. Recommended Maintenance & Storage .................................................................. 32

8. Disposal Of Unit ................................................................................................. 33

9. Warranty........................................................................................................... 34

10. Certification Appendix ......................................................................................... 35

ONLINE ELECTRONICS LTD

ID5001P_5001_B00 Page 3 of 36

1. GENERAL DESCRIPTION

The ID5001P (Passive) pig signaller is a fully ATEX and IECEx certified, Exd flameproof, non-

intrusive, pig signaller which detects, signals, and logs the passage of pigs at critical points along

a pipeline both on land and offshore.

The unit uses Passive (listening) techniques to detect pig passage events. Events are signalled

as they occur via a 3” graphical LCD display and high brightness LEDs positioned above and

below the display. Events can also be signalled remotely using several optional outputs.

The unit logs the time and date of up to 99 events which can be viewed at any point using the

local display. The user can turn the unit ON and OFF as well as modify several settings using a

single control button and intuitive menu system.

The unit has two basic parts as shown below. The sensor is permanently connected to the main

housing via a cable and can be quickly and easily attached to the pipeline using ratchet straps

or steel banding. The main housing contains all electronics, batteries (if fitted), display and the

control button and can be mounted onto the pipeline using a mounting plate and straps in a

similar fashion to the sensor or mounted on a wall or post.

ONLINE ELECTRONICS LTD

ID5001P_5001_B00 Page 4 of 36

2. SPECIFICATIONS

GENERAL

External Supply ..................................................................................... 24.0VDC, <2.0W

Battery type ................................................................. 7x Alkaline DURACELL ID1300 cells

Battery life (Alkaline) in LISTENING/LOW POWER MODE at +20°C ............................. 15 days

Battery type ....................................................................... 7x Lithium SAFT LS33600 cells

Battery life (Lithium) in LISTENING/LOW POWER MODE at +20°C.............................. 30 days

Housing Ambient Temperature range (External supply) ...... -40°C to +85°C (-40°F to +185°F)

Housing Ambient Temperature range (Alkaline) .................. -20°C to +54°C (-40°F to+130°F)

Housing Ambient Temperature range (Lithium) ................. -40°C to +85°C (-40°F to +185°F)

Sensor Ambient Temperature Range ......................................................... -55°C to +110°C

Maximum Allowable Pipeline Surface Temperature ............................................ +150°CNOTE1

Typical minimum pig speed .............................................................................0.1m/sNOTE2

Main Housing Ingress Protection................................................................................ IP66

Sensor Ingress Protection......................................................................................... IP68

ATEX/IECEx code .............................................. II 1/2 G Ex d ia [ia Ga] IIC T4..T6 Gb

EU Type Examination Certificate Number ............................................ TRAC 13 ATEX 0008X

IECEx Certificate Number .................................................................. IECEx TRC 13.0006X

Weight in Aluminium .................................................................................................8kg

Weight in Stainless Steel .......................................................................................... 13kg

OUTPUTS

DPDT Relay Output (Volt Free Contacts) .................................................... 2A @ 30VDCNOTE3

Current Loop Output......................................................................................4-20mANOTE4

Serial Data Interface ............................................................................... RS485 MODBUS

NOTE1 Maximum allowable pipeline surface temperature depends on ambient air temperature

and mounting configuration. Only the sensor may be mounted on the pipeline.

NOTE2 Minimum pig speed depends on pig type, pipeline configuration and installation position.

NOTE3 DPDT is equivalent to 2x SPDT.

NOTE4 Current Loop levels are configurable between 4mA and 20mA. Default set state 20.0mA.

Default reset state 4.0mA. Tolerance ±1.0mA.

ONLINE ELECTRONICS LTD

ID5001P_5001_B00 Page 5 of 36

3. RULES FOR SAFE OPERATION

⚠WARNING: The Special Conditions for Safe Use as detailed in section 10 CERTIFICATION

APPENDIX must be followed.

⚠WARNING: The purchaser of this equipment is responsible for the training and competence

of operators and the way in which it is used. This manual should be read through and understood

before installation and commissioning so that the operator is familiar with the equipment.

Contact Online Electronics Ltd immediately should any difficulty arise in the use of this

equipment.

⚠CAUTION: If the equipment is to be placed in storage, always ensure that it is turned OFF

and the batteries (if fitted) are removed and stored separately.

ONLINE ELECTRONICS LTD

ID5001P_5001_B00 Page 6 of 36

4. OPERATION

Familiarise yourself with all of the rules for the safe operation of this equipment as described in

section 3 RULES FOR SAFE OPERATION.

4.1. TURNING ON

If powered from 24.0VDC power supply via

the VEXT connection the unit will turn on

automatically as soon as power is applied. If

powered from batteries simply press and hold

the control button until the COMPANY LOGO

appears on the display and then release, this

takes approximately 5 seconds.

The COMPANY LOGO will be displayed for 5

seconds as shown by the COUNTDOWN

INDICATOR located at the top left-hand side

of the display.

When the COUNTDOWN INDICATOR reaches

zero or the CONTROL BUTTON is pressed, the

next screen will appear.

The next screen shows the PRODUCT LOGO

and firmware version at the bottom of the

screen.

The next screen shows the current system

date and time. If the date and time are blank

as shown then the date and time will require

setting via the menu system or RS485

MODBUS serial interface.

The unit now enters STABILISATION. During

STABILISATION the unit will initialise the

detection filters and acquire the ambient

noise level of the pipeline.

Once STABILISATION is complete the unit

will enter LISTENING mode.In LISTENING

mode, the display will be switched off and the

LEDs will flash every 5 seconds to indicate

that the unit is active. See section 4.2

LISTENING for more information.

COUNTDOWN

INDICATOR

DATE & TIME

NOT SET

STABILISING

PRESS/

TIMEOUT

PRESS/

TIMEOUT

LISTENING

COMPANY

LOGO

PRODUCT

LOGO

SYSTEM

DATE & TIME

PRESS/

TIMEOUT

PRESS/

TIMEOUT

ONLINE ELECTRONICS LTD

ID5001P_5001_B00 Page 7 of 36

4.2. LISTENING

While in LISTENING mode the unit continuously monitors the acoustic energy produced by the

pipeline as it waits for a pig passage to occur. The unit is configured to recognize the unique

sound signature produced by a pig as it passes the sensor. The unit uses the algorithm described

in section 4.4 DETECTION ALGORITHM to detect a pig passage.

While in LISTENING mode the display will be off and the LEDs above and below the display will

flash every five seconds to indicate that the unit is active. The relay and current loop outputs

will be in LISTENING state.

There are two things that may cause the display to change:

CONTROL BUTTON – If the control button is pressed the unit will enter the MENU system.

The menu system is described in section 4.5 SINGLE BUTTON MENU INTERFACE.

PIG APPROACH – If the unit detects a possible pig approaching

the sensor then the display will show a PIG APPROACH message

as shown. From this point the unit will continue running through

the detection algorithm until either the approach is cancelled, in

which case the display shall turn off, or it will signal pig detected

as per section 4.3 DETECTION.

4.3. DETECTION

When a pig is detected the display will show a PIG DETECTED

message including the time and date of the event as shown. The

LEDs above and below the display will flash every second and the

relay and current loop will be in the DETECTION state. The time

and date of the pig passage are stored in internal memory and

can be viewed later using the menu interface.

The unit will remain in the DETECTION state for the length of time defined by the OUTPUT DELAY

before returning to LISTENING mode. The OUTPUT DELAY can be bypassed by pressing the

CONTROL BUTTON.

OUTPUT DELAY – The OUTPUT DELAY controls how long the unit will signal an event for. Usually

it will be configured to give the pig enough time to get out of range of the sensor after it has

been detected to avoid re-trigger. When dealing with pig trains, the expected pig speed and

separation should be used to configure a suitable value for the OUTPUT DELAY such that the unit

will not detect the same pig twice but will enter LISTENING mode in time to detect the next pig.

LATCHED DETECTION – If the OUTPUT DELAY HH (hours) field

is set to 99 then when an EVENT occurs the unit will LATCH in

DETECTION mode showing the EVENT information and flashing

the LEDs every 1 second. To begin LISTENING again the CONTROL

BUTTON must be pressed or the detection reset using the serial

interface.

ONLINE ELECTRONICS LTD

ID5001P_5001_B00 Page 8 of 36

4.4. DETECTION ALGORITHM

Below is a simplified flowchart for the ID5001P detection algorithm which is running while the

unit is in LISTENING mode.

Periodically calculate 100 bin FFT

(200Hz per bin)

Calculate Power In Band (PIB) between Lower

Frequency bin (LF) and Upper Frequency bin (UF)

Calculate Average Noise (AN)

over Average Noise Time (ANT)

period in minutes

Calculate Average Value (AV)

over Average Value Time (AVT)

period in seconds

Calculate Difference Level (DL)

= Average Value (AV) – Average Noise (AN)

DL > HT?

Display

“PIG APPROACH”

DL < LT?

Was DL > HT for

longer than DT?

PIG DETECTED

YES

Clear

“PIG APPROACH”

ONLINE ELECTRONICS LTD

ID5001P_5001_B00 Page 9 of 36

Below is a graphical representation a typical pig passage.

PIB = Power In Band (between Lower Frequency bin (LF) and Upper Frequency bin (UF))

AN = Average Noise (PIB averaged over Average Noise Time (ANT) period in minutes)

AV = Average Value (PIB averaged over Average Value Time (AVT) period in seconds)

DL = Difference Level (Average Value (AV) – Average Noise (AN))

HT = High Threshold (user set High Threshold)

LT = Low Threshold (user set Low Threshold)

DT = Delta Time (time DL goes above HT before returning below LT in seconds)

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