DSP-06 Particle Monitor 

 

The ClampOn DSP-06 Particle Monitor is based on the ClampOn “Ultrasonic Intelligent Sensor” technology. The sensor is installed two pipe diameters after a bend, where the particles/solids impact the inside of the pipe wall, generating ultrasound. The ultrasonic signal is transmitted through the pipe wall and picked up by the acoustic sensor.
 
In the patented intelligent ClampOn sensor, the signal is processed internally by a DSP engine and filtered before being sent onwards to the computer or the control system (no Calculating Interface Unit required). Here the user can evaluate the data in real time and make the decisions needed for profitable production.

 

Sand production in oil and gas wells is a serious issue facing oil and gas producers. The challenge is not merely to avoid sand production, but also to increase commercial well productivity, as even small quantities of particles in the well flow can cause significant damage. As an operator you are interested in maximum production and profit from your wells, no matter what technology you use. Operators all over the world have made ClampOn their preferred supplier of sand monitoring systems, due to the patented technology that turns their wells into profit generators.

The ClampOn DSP-06 model incorporates a new filtering technique that makes the particle monitor an extremely useful tool for analyzing the true nature of sand production, helping to control it and finally, increasing the profit from the well! This filtering technique is the result of integrating our experience of thousands of wells, analyzing data and using the results to enhance the technology used in our DSP-06 model.

The enormous capacity of the DSP sensor (the only one on the market) makes it possible to scan through a frequency range of 1 MHz 128 times per second. This illustrates the capacity of our technology and of the filtering technique that is at the heart of acquiring and processing sand data. 

The following figures show a sensor installed close to a choke valve on a gas well operating at high pressure and high velocity. The figures illustrate what the signal looked like when using a traditional/alternative system compared to using the new DSP-06 filtering technology. The new filter (ref. Figure 2) was able in this case to reduce unwanted noise by a factor of 500 compared to alternative solutions.

Digital signal processing – the way ahead

The DSP-06 features complete digitalisation, eliminating analogue filters, circuits and amplifiers. The technology incorporates a powerful DSP unit with a large amount of flash RAM, running-feature packed modular software. The sensor operates simultaneously in several ultrasonic frequency ranges, allowing a whole series of new signal processing features to be implemented, including the latest filtering technique. Different types of chokes or flow conditions that generate sound unrelated to sand noise are analyzed and reduced dramatically via the advanced processing and filtering technique in the DSP-06 model. It also improves accuracy and repeatability, important factors in quantifying sand production and a crucial tool in your daily sand management operation.

No other technology comes close to what the ClampOn 2006 model offers customers who need to generate profitable and sand-free production!

 

 

Figure. 1. The signal from the sensor experienced on a high flow rate – high pressure gas well using a traditional/alternative sensor without DSP-06 filtering technology.	Figure 2. Sensor signal experienced on the same well, now with the new ClampOn DSP-06 filter. This shows how the sensor has completely removed the flow noise, allowing the operator to monitor the true nature of the sand being produced.

 

 

All our instruments are equipped with both digital and analogue interface, and comply with all common protocols. Our instruments can easily be integrated into any existing or new control system. A computer with our software is often used in-between our instruments and the control system. The computer will be used for sand calculation by using the RAW data from our sand detectors and flow data from third party systems, then output calculated sand rate to the control system. All recorded data will also be stored for analyzing and calibration purposes. We always recommend using the digital interface due to following benefits:

 

 

 

SAFE AREA EQUIPMENT
Mains power supply	12 - 48 VDC or 100-240 VAC 50-60 Hz
Power consumption	Max 2,1 W per sensor + computer rack module Signal and power barriers and converters supplied for DIN-rail mounting, in portable enclosure or for 19” rack mounting.

TOPSIDE PARTICLE
Ingress protection	Ex ia: IP68, Ex de: IP66
Housing material	AISI 316 Stainless Steel
Dimensions / Weight	Ex ia: ø80 x 105 /144mm (ø3.1” x 4.1 /5.7”) / 2,6 / 2.8 kg (5.7 / 6.2 lbs) Ex de: ø101 x 211mm (ø4.1” x 8.7”) / 7.2 kg (15.9 lbs)
Cable interface	Ex ia: M20 cable access Ex de: 3off M25 cable access
Power / Safety Barriers	Ex ia: ClampOn IS power barrier, IS approved signal barriers. Ex de: Power 12-28VDC. No IS barriers for signal or power
Power Consumption	Ex ia: Typical 1,5 Watt, max. 2,1 Watt per sensor Ex de: Typical 1,2 Watt, max 2,1 Watt per sensor
Cabling	Minimum 4x 0.75 mm2 (pending system configuration)

INTRINSICALLY SAFE ( IS) APPROVAL
ATEX	II 1 G EEx ia IIB T2–T5, Zone 0 II 2 G EEx de IIC T5, Zone 1
CSA C&US	Ex ia IIB T5, Class I Division 1 Group C,D, Zone 0
INMETRO	BR–Ex ia IIB T2–T5, Zone 0 BR-Ex de/dem IIC T5, Zone 1
GOST-R / GGTN	2Ex de IIC T5, Zone 1

ClampOn has since the beginning in 1994 grown to be the largest supplier of passive ultrasonic systems for sand/particle monitoring to the international oil and gas sector.

 

All products supplied by ClampOn, particle monitor, PIG detector, corrosion-erosion monitor, vibration monitor and leak monitor are based on the same, well proven technology platform. Both the topside and the subsea instruments incorporate Digital Signal Processing (DSP), complete digitalization eliminating analogue filters, circuits and amplifiers.

The ClampOn Ultrasonic Intelligent Sensor processes all data in the sensor itself (patented principle), thus enabling the instrument to discriminate between sand-generated and flow-generated noise. This is of importance to the user since changes in flow rates and the gas/oil ratio will not affect the performance of the system.

A good signal to noise (s/n) ratio is vital for quality measurements of this sort, and ClampOn’s sensors are the very best in this respect. With the new version, the external noise has been completely eliminated.
The sensors has memory capacity for storing up to 60 days of data, and can even be reprogrammed between being a sand monitor, a PIG detector or a leak monitor.

 

ClampOn Ultrasonic Intelligent Sensor

• Non-invasive
• Digital Signal Processing (DSP)
• Complete digitalisation
• No analogue filters, circuits or amplifiers
• Two-way communication
• Real-time measurement
• Easy to relocate
• Contains no moving parts
• Can be mounted in hostile environments
• Incorporates sensitive, intelligent, intrinsically safe sensors
• Can be upgraded by software download
• Can store up to 60 days of  measurement data within the sensor itself
• Self-testing capabilities
• Built-in temperature sensor and  accelerometer (optional)
• User-friendly software for Windows™ XP/Vista/2000-2008
• Versatile - one and the same sensor can perform particle detection, PIG detection, spectrum analysis and more, all available in the software package of your choice.