Permasense WT210 WiHART User manual

1 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
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 .........................................................................................................................8
Task 4. Fitting the lanyard ...............................................................................................................................................9
Re-installing a sensor (if required) ...............................................................................................................................10
Re-provisioning a sensor (if required).........................................................................................................................10
Maintenance .....................................................................................................................................................................11
Installation guide - WT210 WiHART sensors

2 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
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 BP10, BP10E, BP20 or BP20E power modules.
Use supplied lanyard to prevent sensor falling from heights, causing injury.
Ensure the device is installed with the antenna at least 20cm (8”) from all persons.
Changes or modifications not expressly approved by the party responsible for compliance could void the user’s
authority to operate the equipment.
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device
may not cause harmful interference, and (2) this device must accept any interference received, including interference that
may cause undesired operation.
Potential electrostatic charging hazard when fitted with a tip seal. Do not rub or clean with solvents or a dry cloth.
Compatibility
Permasense WT210 WiHART sensors are compatible with Emerson 1420, 1410, 1410D & 781 fieldlink gateways with
the HART-IP order option, and the Permasense GC20 turnkey WiHART gateway.
Permasense BP10 and BP20 power modules can be used but note that they have a narrower ambient temperature
range than the recommended BP10E and BP20E.
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 -50°C to +75°C (-58°F to +167°F) and the
potentially hot mounting location which can be up to 600°C
(1112°F).
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.
Antenna
Power module
Head
(Contrining
Stabiliser
Waveguides
Thermocouple
Foot
Waveguide spacer

3 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
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.

4 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
Installation requirements
Before sensor installation:
Emerson 1420 gateway must be installed.
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.
Pairs of M8 (5/16") studs must be welded to the pipe work at the desired sensor
locations.
See Installation Guide –Stud welding.
Required hardware
(Supplied with Permasense WT210 sensors)
Permasense WT210 sensor
Permasense BP10E or BP20E power modules 1 per
sensor
M3 x 16mm stainless steel power module retaining
bolts, 2 per sensor
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, cable lock, release key.
Required tooling
(Supplied in Permasense IK200 Installation Kit)
Rugged tablet PC, preloaded with Permasense
installation software
CC21 USB powered commissioning communicator
Torque wrench, 3/8" sq. drive. 2 - 24Nm range, set
to 5Nm
Deep socket, 6-point. 13mm, 3/8" drive
3/8" drive extension bar, 8"
Hey key, 2.5mm
Telescopic inspection mirror
Consumables
(Supplied in Permasense IK200 Installation Kit)
Loctite 8009 anti-seize compound
Additional hardware required
(Not supplied in Permasense IK200 Installation Kit)
Full plain nuts, to suit welded stud thread and
metallurgy:
Thread: M8 or 5/16"
Material: Stainless steel, or other suitable
corrosion resistant steel
Socket for 5/16” nuts

5 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
Task 1. Mounting the sensor
1. Record the installation location, sensor ID, MAC address of the sensor, and power module 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. The sensor ID and MAC addresses may be found on the sensor label.
2. Ensure the studs are aligned. They must be parallel to each other and perpendicular to the pipe, as
shown. Consult the Stud alignment section if studs are
not aligned.
3. Smear the threads with Loctite 8009 anti-seize
compound.
4. Examine the thermocouple of the sensor and make sure
it is protruding past the tip of the waveguide by about
3mm (1/8”) so that it will press onto the pipe when the
sensor is tightened.
5. Locate and place the WT210 sensor over the studs, ensuring the waveguides are positioned centrally
to ±5mm [0.2”]
=
=

✓
✓
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✓

6 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
6. Place Nord-Lock washers over the studs.
7. Thread nuts onto the studs, and run them down several threads.
8. Observe the sensor contact from the side and ensure the sensor feet are parallel to the pipe surface.
9. Carefully secure the sensor in this position by finger tightening each nut. Rocking the sensor back and
forth while finger tightening the nuts can help to ensure both waveguide tips are well seated and fully
contacting the pipe surface.


7 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
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. Attach the CC21 to the sensor.
3. Double-click the Permasense WT210 installation app desktop icon.
The Permasense installation tool software will open within about 10 seconds.
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 4 or 5 digit network ID and the 32 hexadecimal (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 be completed, but the
sensor is unlikely to join the network without additional sensors to extend the mesh.
9. Click the Installation tab
10. Check that:
Torque wrench is set to a value of 5Nm (3.7 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 below.

8 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
11. Tighten nuts ¼ turn at a time.
Check the quality of the waveform with each turn.
If the amplitude stops increasing with each turn, stop tightening. The sensor could be misaligned. Loosen the
nuts and realign sensor, starting again.
12. Continue tightening the nuts to 5Nm. Once 5Nm has been reached:
Check that the surface wave is not distorted. If it is, the sensor could be misaligned. Loosen the nuts and realign
sensor, starting again from step 11.
Check that the surface wave is not significantly bigger or smaller than the back wall reflection*. If it is, loosen the
sensor, reposition and go back to the start. The sensor could either be too tight, or the inner surface of the
pipe is too rough to achieve a strong reflection.
13. If the above conditions have been met, and the waveform amplitude is above 40mV, this is a good installation. The
waveform is good quality and there is sufficient torque to secure the sensor to the pipe. Continue with Task 3.
14. If 5Nm has been reached but the waveform amplitude is only between 20mV and 40mV, set the torque wrench to
8Nm and continue turning the nuts. With each ¼ turn, check that the surface wave does not become distorted or
is not significantly bigger or smaller than the back wall reflection*.
If the amplitude does not increase with successive turning of the nuts, finish here. The sensor should not be
tightened further, to avoid overtightening and damaging the waveguide tips. This is a good installation.
If 8Nm has been reached, finish here. Maximum torque has been reached. This is a good installation.
15. If the amplitude remains below 20mV, loosen the nuts and realign sensor, starting again from step 11.
*If the amplitude of one peak is less than 15% the amplitude of another peak, it will not be identified by the software.
Caution: Overtightening the nuts can damage the waveguide tips
Task 3. Completing sensor installation
1. When all of the above criteria are satisfactorily met, press the “Complete” button.
2. Ensure all required sensor information is accurately logged (e.g. sensor ID and location).
3. Remove the CC21 and fit the power module.
When the power module 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 power module.
Sensor installation is now complete.
4. 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.

9 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
Task 4. Fitting the lanyard
Note: The lanyards provided should be used to arrest the fall of sensors should they be accidentally
dropped or become detached
1. Identify a suitable fixing point. The 2m (7ft) lanyard
can be used on pipes up to a diameter of 20”.
When it is not possible to wrap the lanyard around
a pipe, find an alternative attachment point for the
lanyard, if possible, vertically above the sensor
location.
5. For pipes exceeding 20” in diameter, lanyards may be
linked together
6. For sensors in close proximity to each other, a single
lanyard may be used
2. Wrap the lanyard around the fixing point and
thread the bare end through the loop in the
lanyard to secure it.
3. Feed the bare end of the lanyard into the cable
lock and push the cable lock 15cm (6”) up from
the bare end.
4. Feed the bare end between the waveguides near
the sensor head, loop back and feed into the
return hole of the cable lock. One of the
waveguides should now be in the loop.
5. Adjust the position of the cable lock to reduce
slack in the lanyard cable, however do not pull
cable tight.
Note. The wire can be released from the cable lock using
the release key.

10 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
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.
Stud alignment
It is important to check that both studs are parallel to each other and perpendicular to where the sensor will be
contacting the pipe. If the studs do not meet this criteria, follow the steps below:
1. On painted pipe-work, remove a circular patch of the coating about 25mm (1”) diameter midway
between the studs to allow waveguides to contact the pipe directly.
2. Ensure the pipe surface is clean and free of debris so that the waveguide tips can have direct contact
with the bare metal of the pipe.
3. On straight pipes, ensure the studs are perpendicular to the sensor contact point.
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

11 Permasense Ltd, Alexandra House, Newton Road, Manor Royal, Crawley, RH10 9TT, UK
www.permasense.com [e-mail] [phone]
4. When mounting sensors on pipe bends and elbows, studs must be aligned as follows:
a) Fit 2 nuts to the stud, the first 15-20mm down the thread and the second at the top of the thread
as shown below.
b) Use the M13 deep hex socket with extension bar to bring the studs parallel to each other and
perpendicular to the pipe surface at the centre point between the two studs.
c) Correct stud alignment will ensure the correct orientation of the nut and washer with respect to
the sensor foot.
Maintenance
The WT210 sensor is a sealed unit with no user serviceable parts.
See Installation guide - BP series power module if the power module requires changing.
Revision 8, 24/02/2020 © Permasense Ltd. Permasense is a registered trademark of Permasense Ltd.
Side view
Original stud orientation
Stud orientation after bending
Incorrect stud alignment Correct stud alignment