International Journal of Innovative Technology and Exploring Engineering (IJITEE) ISSN: 2278-3075, Volume-8, Issue-9S3, July 2019
Abstract: In this article we have described the use of vortex and recently developed ultrasonic flowmeters with high dynamic range of 1 to 1500 for industrial applications. Its software and the software of corresponding computing device is able to avoid gas leakage, to minimize energy consumption and to save human resources while maintaining metrological data. Described is the low power consumption that makes it possible to use this ultrasonic flowmeter in hard remote environment without direct management for a period of several months. Shown is the new telemetry system that was developed to unite flowmeters in the severe conditions of the desert with power supply problems and low GPRS signal quality. Experiments held in Turkmenistan have shown that device indications didn’t drift and remained stable during the year, that is a great advantage in comparison to rotary and turbine flowmeters. Also described is the mobile ultrasonic calibration stand that uses the same physical principles and similar software. Outlined is the usage of modern wireless technologies to collect and transmit metrological data.
Index Terms: telemetry, ultrasonic flowmeter, signal transmission, calibration stand, Wi-Fi, HTTP.
I. INTRODUCTION
TelemetryT isT anT automatedT communicationsT processT byT
whichT measurementsT andT otherT dataT areT collectedT atT
remoteT orT inaccessibleT pointsT andT transmittedT toT
receivingT equipmentT forT monitoringT [1].T SystemsT thatT
needT externalT instructionsT andT dataT toT operateT requireT theT
counterpartT ofT telemetry,T telecommand[2].
AlthoughT theT termT commonlyT refersT toT wirelessT dataT
transferT mechanismsT (e.g.,T usingT radio,T ultrasonic,T orT
infraredT systems),T itT alsoT encompassesT dataT transferredT
overT otherT mediaT suchT asT aT telephoneT orT computerT
network,T opticalT linkT orT otherT wiredT communicationsT likeT
powerT lineT carriers.T ManyT modernT telemetryT systemsT takeT
advantageT ofT theT lowT costT andT ubiquityT ofT GSMT networksT
Revised Manuscript Received on July 22, 2019
Maxim A. Velichko, Belgorod State University, 85 Pobeda St. Belgorod 308015 Russia, Velichko@bsu.edu.ru
Lyudmila V. Krasovskaya, Belgorod State University, 85 Pobeda St. Belgorod 308015 Russia.
Ivan S. Starovoytov, Belgorod State University, 85 Pobeda St. Belgorod 308015 Russia.
Irina А. Starovoytova, Belgorod State University, 85 Pobeda St. Belgorod 308015 Russia
Nataliya A. Korenkova, Belgorod State University, 85 Pobeda St. Belgorod 308015 Russia
Irina N. Galtseva, Belgorod State University, 85 Pobeda St. Belgorod 308015 Russia
byT using SMS to receive and transmit telemetry data.
A telemeter is a device used to remotely measure any quantity. It consistsT ofT aT sensor,T aT transmissionT path,T andT
aT display,T recording,T orT controlT device.T TelemetersT areT
theT physicalT devicesT usedT inT telemetry.T ElectronicT devicesT
areT widelyT usedT inT telemetryT andT canT beT wirelessT orT
hard-wired,T analogT orT digital.T OtherT technologiesT areT
alsoT possible,T suchT asT mechanical,T hydraulicT andT optical.
TelemetryT mayT beT commutatedT toT allowT theT
transmissionT ofT multipleT dataT streamsT in a fixed frame.
II. MATERIALS AND METHODS
The aim of our work was to develop an automated system of control and accounting of associated petroleum gas in remote and inaccessible oil fields in the Kara Kum desert.
Gas was used in the gas-lift method of well operation, which is a logical continuation of the fountain method of oil production. The missing amount of associated petroleum gas for oil recovery was pumped into the well from the surface. It was necessary to constantly monitor the temperature, pressure and volume flow of gas, as well as remotely control solenoid valves and gates for effective management of oil production in wells.
Metrological data had to be transferred to a remote control center, analyzed and archived. The information needed for familiarization or decision-making had to be visualized on the screen of any mobile or stationary device equipped with a modern Web browser. Stakeholders had to have different access rights to this information[7].
For each well, a metering unit for associated petroleum gas was designed and installed. Electronic components such as computing devices (electronic correctors), multiplexers, modems, logic controllers, drivers, power supplies were located inside the instrumentation cabinets (cabinets for instrumentation and automation). Flow meters, valves and plugs were installed directly on the gas pipeline laid in the sands of Kara Kum.
To measure the volume flow rate of associated petroleum gas, full-pass vortex flow meters with nominal flow diameters from 50 to 200 mm were selected. The vortex motion in such flow meters is provided by a flow body located in the path of the moving
flow, which in the cross section has a shape close to the trapezoid. The system of
The Development of Radio and 3G Based
Telemetry System for the Remote Gas
Accounting and Control Nodes
vortices arising behind this obstacle is called the Karman vortex path, and the frequency of the collapsing vortices in the first approximation is proportional to the flow velocity [8]. The flow rate, in turn, allows to calculate the gas flow rate under operating conditions with an accuracy of 1%. The conversion of the flow rate into operating conditions into a unified flow rate under standard conditions was carried out in the computing device, which received the necessary metrological data from the pressure and temperature sensors. These sensors were located in the pipeline together with the flow meters.
Given the instability of electricity metering units, as well as the abundance of solar energy in the desert, instrumentation cabinets were equipped with autonomous power supply from solar panels (panel controllers and batteries were also installed in instrumentation cabinets).
For effective management of the gas lift process, monitoring of metering stations and control of associated gas flows had to be carried out continuously and without interruptions. Also, for the full automation of the process in the future, a thorough analysis of the accumulated statistical data was required, for which a detailed archiving of the transmitted metrological information was necessary[9].
III. RESULTS AND DISCUSSION
The data was transmitted to the server via the Internet. The HTTP protocol was used as the application layer protocol. Users with the appropriate access rights, using modern Web-browsers sent GET-requests to the server. The server stored various temporary archives that contained all the information necessary for monitoring and decision-making (environment temperature, air, gas temperature, atmospheric pressure in the area of the well, pressure drop at different points of the pipeline, the presence or absence of electricity, battery charge, occurrence and description of emergency situations, etc.). These archives were sent to the server by POST requests from the computing devices located in the accounting nodes. POST requests were formed automatically in accordance with the established time schedule [10]. Thus, the server had two types of clients: web-browsers of telemetry system users and special software of the client device developed by our group.
The module developed by our group was used as a transmitting POST-requests device, which was installed in the control point at a distance of no more than 10 km from each of the wells. This IRGA-LT device served as an intermediate between the accounting nodes and the server. It included a 3G module controlled by a special microcontroller with the help of automated AT-commands. It was decided not to install similar 3G modules in each metering station due to 3G communication failures in the vicinity of the fields and the need to pay for and maintain SIM cards, as well as to simplify the transmission system.
Each metering point contained another self-developed device IRGA-NT connected to the computing device using UART protocol. Transfer of data from IRGA-NT to IRGA-LT was carried out via 433 MHz radio frequency [11].
Code and time modulation was used. Each radio module placed in the unit IRGA-NT, was assigned its own unique number, and the data was passed in turn from each node after the receipt of the request from the IRGA-LT radio module. In case of transmission errors signals of emergency situations were generated.
When creating models of IRGA-NT and IRGA-LT devices, AVR microcontrollers installed in Arduino boards (UNO for IRGA-LT and NANO for IRGA-NT) were used to control the operationT ofT radioT modules,T 3GT modulesT andT
otherT electronicT components.T ArduinoT boardT softwareT wasT
developedT inT theT ArduinoT IDET inT theT C++T programmingT
languageT [12].
TheT serverT containedT aT PHPT fileT toT handleT requestsT
fromT theT clientT IRGA-LT,T asT wellT asT theT HTMLT pageT
passedT asT theT responseT toT theT WebT browsers.T TheseT
HTMLT pagesT usedT JavaScriptT language,T especiallyT forT aT
periodicT AJAXT pollT toT theT serverT toT inquireT ifT theT newT
dataT fromT IRGA-LTT hadT arrived.
WeT haveT recentlyT developedT theT newT industrialT
time-of-flightT ultrasonicT gasT flowT meterT IRGA-RUT thatT
hasT alreadyT beenT enteredT intoT theT StateT registerT ofT
measuringT instrumentsT [13].T
ItsT operationT principleT isT basedT onT theT time-to-pulseT
methodT ofT gasT flowT measuring.T ItT consistsT inT measuringT
theT timeT ofT ultrasonicT pulsesT passageT inT theT directionT ofT
theT gasT flowT inT theT pipelineT andT againstT it.T ExcitationT
andT receptionT ofT pulsesT isT carriedT outT byT piezoelectricT
transducers,T whichT areT installedT inT anT all-metalT caseT ofT
theT flowmeterT atT anT angleT (fromT 30°T toT 45°,T dependingT
onT theT version)T toT theT flowT direction.T TheT speedT ofT
ultrasoundT inT theT mediumT dependsT onT theT physicalT andT
chemicalT propertiesT ofT thisT medium:T temperature,T
pressure,T etc.T AtT theT sameT time,T itT isT muchT greaterT thanT
theT speedT ofT theT medium,T soT thatT theT actualT speedT ofT
ultrasoundT inT aT movingT mediumT isT notT muchT differentT
fromT itsT speedT inT aT stationaryT medium.T TheT differenceT inT
transitT timesT ΔtT evenT atT flowT ratesT ofT aboutT 10T m/sT isT aT
fractionT ofT aT microsecond,T whileT theT measurementT errorT
shouldT notT exceedT aT fewT nanosecondsT [14].
TheseT circumstancesT necessitateT theT useT ofT complexT
electronicT circuitsT inT combinationT withT microprocessorT
technology,T providingT compensationT forT theT influenceT ofT
theseT factors.
Structurally,T theT flowT meterT consistsT ofT threeT blocks:T
primaryT flowT converter,T whichT isT aT housingT withT
built-inT ultrasonicT transceivers;T
electronicT unit,T whichT carriesT outT theT receptionT andT
transmissionT ofT signalsT throughT ultrasonicT transceivers,T
theirT conversion,T processingT andT calculationT ofT theT
volumeT flowT ofT gasT underT operatingT conditions,T followedT
byT theT formationT ofT theT outputT signal;T
powerT supplyT unitT withT built-inT sparkT protectionT
barrierT toT provideT explosionT protectionT circuitsT ifT
necessary.
TheT electronicT unitT
controlsT ultrasonicT
International Journal of Innovative Technology and Exploring Engineering (IJITEE) ISSN: 2278-3075, Volume-8, Issue-9S3, July 2019
receiving,T processing,T convertingT andT transmittingT
signalsT toT theT computingT device.T TheseT signalsT contain,T
inT particular,T informationT aboutT theT propagationT timeT ofT
theT ultrasonicT pulses,T thatT isT requiredT toT calculateT theT
volumetricT gasT flowT rateT inT operatingT conditionsT [15].
TheT designT ofT flow meter eliminates the possibility of
unauthorized influence on the flow meter software and measurement information. We have developed and successfully tested our own control circuits for piezoelectric transceivers, and also created new original algorithms for processing received signals[16]. It allowedT usT toT
significantlyT expandT theT dynamicT rangeT ofT gasT flowT
measurementT toT valuesT ofT theT orderT ofT 1:2000;T increaseT
theT accuracyT ofT measurementsT toT 1%T inT mostT tasks;T
useT ourT flowmeterT onT pipelinesT ofT almostT anyT
diameter;T
measureT theT flowT rateT ofT variousT physicalT andT
chemicalT propertiesT ofT gasT media;T
carryT outT measurementsT atT highT speed,T inT aT wideT
rangeT ofT temperaturesT andT pressures;
notT toT introduceT additionalT pressureT lossesT intoT theT
pipeline.
AtT theT sameT time,T ourT flowT meterT hasT aT fairlyT simpleT
designT andT doesT notT requireT significantT lengthsT ofT
straightT sectionsT beforeT andT afterT itsT installation.
WeT haveT alsoT masteredT andT successfullyT testedT theT
technologyT ofT applyingT anti-adhesiveT coatingT onT theT
innerT wallsT ofT theT flowmeterT toT avoidT stickingT ofT theT
solidT fractionT ofT theT measuredT medium.T ThisT helpedT usT
toT reduceT theT probabilityT ofT non-reproducibilityT ofT
measurementT resultsT byT 0.2%T [17].T InT futureT itT willT alsoT
leadT toT calibrationT intervalT decrease.
InT ourT flowmeterT designT weT haveT usedT modernT
time-to-digitalT microcontrollerT convertors,T thatT applyT
energyT savingT technologies.T WeT haveT alsoT developedT
energyT efficientT algorithmsT ofT transmission,T receivingT
andT processingT ofT ultrasonicT pulses.T PowerT consumptionT
hasT decreasedT toT severalT µW.T ItT helpedT usT toT implementT
autonomousT powerT supplyT fromT rechargeableT batteries.T
OurT colleaguesT fromT TurkmenistanT gaveT usT aT
possibilityT toT testT ourT deviceT poweredT byT solarT panelsT inT
desertT conditionsT withT almostT cloudlessT weatherT andT
periodicT changesT inT energyT supply.T ExperimentT hasT
shownT thatT ourT flowmeterT isT ableT toT operateT withoutT
directT maintenanceT forT monthsT [17].
InformationT fromT IRGA-RUT wasT transferredT toT theT
computingT deviceT andT thenT transmittedT viaT aboveT
describedT telemetryT system.T TheT sameT systemT wasT alsoT
usedT toT uniteT ourT flowmetersT intoT theT network.
ThoughT ultrasonicT flowmetersT areT veryT effectiveT inT aT
highT dynamicT range,T theyT alsoT haveT toT beT calibrated,T thatT
meansT thatT theirT indicationsT haveT toT beT synchronizedT
withT theT etalonsT [18].T ThisT isT aT standardT procedureT forT
allT metrologicalT devicesT despiteT ofT theirT prices,T
conditionsT used,T dynamicT ranges,T types,T sizesT andT otherT
properties.
VerificationT canT produceT onlyT specializedT
organizationsT withT high-precisionT stands,T thatT haveT toT beT
includedT intoT theT StateT registerT ofT measuringT
instruments.T UsuallyT theseT standsT areT bulkyT systemsT thatT
requireT aT lotT ofT freeT spaceT andT aT highlyT skilledT operator.T
InT addition,T suchT standsT orT theirT partsT (e.g.T nozzles,T inT
theT caseT ofT standsT onT criticalT nozzles)T themselvesT requireT
periodicT recalibrationT inT standardizationT organizationsT
[19].T SuchT standsT costT aboutT severalT millionT rubles.
WeT haveT appliedT similarT toT IRGA-RUT principlesT ofT
flowT measurement,T electronicT circuitsT andT signalT
processingT algorithmsT whileT developingT andT creatingT
ultrasonicT testingT facility,T whichT weT haveT calledT
KRAB-UM.T TheT principleT ofT itsT operationT liesT in
automatic selection of verification points and a set of conditions for measurements, monitoring the readings of temperature and pressure sensors, automatic flow control,T
comparisonT ofT theT volumesT ofT gasT passedT throughT theT
householdT meterT andT throughT aT high-precisionT ultrasonicT
referenceT system,T analysisT ofT theT measurementsT andT
decision-makingT onT theT successT ofT verificationT [20].
ItT isT theT firstT ultrasonicT mobileT calibrationT stand,T
whichT amongT otherT thingsT usesT wirelessT technologyT forT
transmission,T storageT andT displayT ofT metrologicalT andT
otherT data,T andT isT ableT toT workT onT batteriesT forT 8T hours.T
TheT picosecondT accuracyT ofT electronicT calculationT ofT theT
timeT differenceT betweenT theT ultrasonicT pulsesT passingT
betweenT theT receiverT andT theT transmitter,T whichT wasT
impossibleT untilT recently,T asT wellT asT theT improvedT designT
ofT theT referenceT deviceT hydraulicT part,T madeT itT possibleT
toT developT aT compactT high-precisionT reliableT stand.T
ESP8266T boardT [21]T wasT chosenT asT theT mainT moduleT
ofT theT standT control.T ItT hasT accumulatedT dataT fromT
ultrasonicT sensorT controlT module,T
powerT managementT module,T
digitalT thermometer,T digitalT pressureT sensor,T andT
reedT switchT connectedT toT theT verifiableT domesticT
meter.T
BasedT onT theT resultsT ofT dataT processingT obtainedT fromT
variousT modules,T theT ESP8266T controllerT generatedT
informationT aboutT theT referenceT gasT flowT rateT inT
operatingT conditions.T TheT referenceT flowT rateT wasT
calculatedT fromT theT calibrationT tableT recordedT inT theT
ESP8266T EEPROMT memory[22].T (EEPROM-ElectricallyT
ErasableT ProgrammableT ReadT —T OnlyT MemoryT isT
electricallyT erasableT reprogrammableT memory,T aT typeT ofT
nonvolatileT memoryT usedT inT computersT andT otherT
electronicT devicesT toT storeT relativelyT smallT amountsT ofT
dataT butT withT theT abilityT toT read,T delete,T orT writeT bytesT
individually.)T
ForT domesticT gasT metersT equippedT withT aT slotT forT
connectingT anT electromagneticT sensorT (reedT switch)T [23],T
anT outputT forT readingT signalsT fromT suchT aT sensorT wasT
providedT inT theT ultrasonicT calibrationT unit.T InterfacingT
withT householdT metersT withT theT helpT ofT reedT switchT
madeT itT possibleT toT significantlyT simplifyT theT processT ofT
verificationT andT improveT
itsT accuracy,T reducingT toT
zeroT theT operator'sT error.T
provideT forT theT connectionT ofT theT reedT switch,T theT
operatorT hadT toT visuallyT monitorT theT passageT ofT aT certainT
volumeT ofT gasT andT thenT manuallyT recordT itT inT theT
inspectionT program.T TheT mobileT unitT allowedT toT checkT
upT toT 4T domesticT metersT atT theT sameT time,T butT itT madeT
senseT onlyT whenT usingT reedT switches,T otherwiseT 4T
operatorsT wouldT beT neededT forT accurateT visualT controlT ofT
householdT meters.T
TheT flowT rateT generatedT inT ESP8266T tookT intoT accountT
theT differenceT inT gasT temperatureT duringT verificationT andT
duringT theT initialT calibrationT ofT theT installationT itself.T
TheT instantaneousT temperatureT valueT wasT alsoT displayedT
asT referenceT informationT inT theT verificationT program.T AT
platinumT resistanceT thermometerT [24]T mountedT nearT theT
locationT ofT oneT ofT theT ultrasonicT sensorsT wasT usedT toT
measureT theT temperature.T ToT digitizeT theT thermometerT
signal,T aT 24-bitT analog-to-digitalT converterT wasT used,T
whichT madeT itT possibleT toT measureT theT temperatureT valueT
upT toT aT fractionT ofT aT degreeT [25].T TheT inertiaT ofT theT
thermometerT isT highT enough,T butT theT temperatureT ofT theT
gasT inT theT pipeline does not undergo sudden changes, so this
fact does not significantly affect the accuracy of measurements.
When carrying out verification without removing the domestic counterT sealT onT itT shouldT remainT intact,T soT toT
accountT forT theT pressureT drop,T weT wereT forcedT toT
measureT theT pressureT atT leastT twiceT atT eachT pointT ofT
verification:T withT theT inletT valveT closedT andT open.T TheT
digitalT pressureT sensorT usedT dataT transmittedT onceT aT
minuteT toT theT ESP8266T controllerT viaT theT UARTT
protocol[26].T ItT didT notT needT additionalT analog-to-digitalT
converters.T ButT itT wasT necessaryT toT useT aT softwareT
UART,T asT theT built-inT UARTT inT ESP8266T wasT alreadyT
reserved.T OpeningT /T closingT ofT theT valveT wasT carriedT outT
byT theT operatorT manually,T theT informationT aboutT theT
measuredT pressureT wasT storedT alreadyT inT theT verificationT
program,T soT theT pressureT dropT wasT takenT intoT accountT inT
theT flowT valueT outsideT theT ESP8266T controller.
TheT KRAB-UMT canT beT usedT bothT onT theT gasT pipelineT
thatT allowsT toT carryT outT verificationT ofT domesticT andT
communalT gasT countersT withoutT removal,T andT asT
stationaryT referenceT installationT (inT thisT caseT itT needsT aT
flowT compressor).
Thus,T theT mobileT calibrationT usingT ourT ultrasonicT standT
canT greatlyT facilitateT lifeT forT privateT gasT consumersT [27],T
savingT themT fromT necessityT toT removeT theT countersT andT
takeT themT forT testing,T asT wellT asT forT industrialT
enterprises.T ItT isT quiteT easyT toT workT withT ourT stand,T
becauseT theT wholeT processT isT automatedT andT requiresT
onlyT toT moveT betweenT pagesT inT aT WebT browser,T andT
pressingT oneT button.T TheT informationT onT theT performedT
verificationT isT storedT andT encrypted,T whichT ensuresT theT
reliabilityT ofT theT resultsT andT theT abilityT toT traceT theT
processT ofT allT measurements.
KRAB-UMT doesT notT needT anyT additionalT calculatingT
devicesT toT beT connectedT toT theT aboveT describedT telemetryT
system.T SoT itT canT remotelyT performT verificationT andT theT
dataT canT beT alsoT remotelyT archived.T
IV. CONCLUSION
WeT haveT developedT andT effectivelyT testedT theT telemetryT
systemT inT aT setT ofT applicationsT andT conditions.T ThisT
systemT unitedT gasT flowT monitoringT andT controlT nodesT atT
oilT fields,T givingT usT theT opportunityT toT manageT oilT
productionT processT fromT anotherT city.T ItT alsoT combinedT
severalT highT dynamicT rangeT ultrasonicT flowmetersT inT theT
network,T providingT gasT consumptionT mapT ofT theT region.T
AtT theT sameT time,T weT managedT toT testT ourT newT
flowmetersT inT real operating conditions. This telemetry
system also helped us to remotely verify domestic gas flowmeters by our new ultrasonic mobile stand.
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