Automatic Wireless Column Scanner

Gamma scanning of process column is one of the popular applications and it is mainly carried out to identify the mechanical damages and operational anomalies such as broken tray, bed depositions, flooding, channeling, downcomer blockage etc. A collimated gamma source and detector is utilized to scan the column.

Technical Specifications:

The Automatic Wireless Column Scanner consists of following subsystems:

1. Main Box

2. Wireless Detector

3. Source Operator and Detector Operator

4. Industrial grade tablet for user interface

5. Wireless camera modules for Source and the Detector

Working Principle

Equipment can be used for distillation column diagnosis using a gamma ray from the source and radiation detector. It provides a vertical density profile revealing status of the distillation column during operation. Scan interval and radiation measurement is automatically controlled by a motorized system and a computer. This equipment consists of an upgraded wireless detector containing data processing circuit, wireless module and power pack, a Co-60 mounted source holder, two operators, two optional tensioner modules, camera modules for source and the detector and the main controller which is in charge of all the operations.

Since wireless detectors do not need cable for power as well as data transmission, issues related to broken / short inner cable are eliminated.

Features

• Automatic system controlled wirelessly by PC
• Detector with built-in Wireless module, signal processing unit and the battery to eliminate need of a coaxial steel cable.
• Control Box and both Operators, can be powered by the external battery as well as 230V mains supply.
• Operators, Control box and PC are interfaced with each other via wireless data link. Thereby eliminating the need to carry bulky cables and connection issues arising from the faulty cables.
• Manual scanning can also be performed through the control box in case of any problem in software/laptop.
• Collected data can be saved to an external device in the control box.
• Level mismatch sensing (Detection and warning for mismatch of source and detector level) (experimental)
• Auto levelling (Automatically finding the best initial level for source and detector for maximum signal strength) (experimental, assuming sufficient signal strength available)
• Powered by 220V/60Hz
• Safety measures by Emergency stop
• 0 ℃ to 60 ℃ operational temperature
• Water and heat resistant enclosures
• Accurate data transmission and error indication
• Immune to the presence of RF noise originating from walkie-talkie
• Compact battery packs to run equipment for more than 12 hours
• More than 200 meter communication range from operators to the PC via control box
• More than 12 hours of operational time on battery power

System block diagram:

Specifications of the Subsystems

1. Main Control Box

Main control box acquires data from the wireless detector. It also controls Source and Detectors operators. It is able to connect to three operators at a time in wired as well as wireless mode. It has an LCD display for data and status indications like high voltage, Window size, Threshold, Count, communication error and switches for calibration and the manual control. Main box also has a facility to record logged data onboard. It has provision for transferring logged data to external storage device. A wireless and wired RS232 interface is provided for communicating with computer / tablet running the control and configuration software.

2. Wireless Detector

Wireless detector module has a BGO integrated PMT, collimator, built in signal conditioning, high voltage source, microcontroller, wireless module and the battery along with the battery management. Settings such as peak height analysis on/off switch (PHA), High voltage value adjustment dial (HV), Threshold value adjustment dial (THR) and Window value adjustment dial (WIN) can be adjusted by opening metal casing of the detector.  It is able to transmit the signal wirelessly to control box up to a distance of 200 meters.

3. Source Operator and Detector Operator

This design has Source and Detector operators as identical and drop-in replaceable. Operators are able to simultaneously move the source and detector over a minimum elevation of 5 mm in automatic mode and 1 mm in manual mode (up and down) with precise and control over the column elevation. The accuracy of positions of the source and detector should be ±1 mm. It has a feedback system to ensure accurate positions of source and detector. Operators has the provision of wired as well as wireless connection with the main control box. It has 200 m of excellent quality ss wire rope which can withstand weight more than 100 kg and a proper guiding mechanism for even wrapping of the wire rope over the spool. Operators have servo motors for position control. Operator has an onboard microcontroller to controls position and velocity of the steel cable. Operator is controlled via the main box over the wireless link. Operators can be powered by mains 230V or by a battery.

4. Industrial grade tablet with user interface

Industrial grade tablet with MS Windows and Office will be provided as per the attached specification (Annexure - II). User interface software will be developed and installed on this tablet and also supplied separately. User interface is compatible with the windows operating system. It will highlight the connection and display the background radiation dose at the detector in CPS. It will be available with idle, level and scan modes. Source and detector location will be highlighted. Manual up/down of the source and detector will be possible with minimum 1 mm elevation. Start, Stop, Resume, Emergency and Reset tabs will be available on the user interface. Live graph (Column Elevation vs Count Rate) will be visible with custom scale axis. The data will be saved in excel format at desired path in the tab storage

5. Wireless camera modules for Source and the Detector (Total 2 pcs, Optional)

Wireless camera modules can be attached to the wire rope of the source and detector operator. They are used for providing live feed of the surroundings when source and detectors are moving up or down. Camera modules are detachable. It is able to rotate and provide 360-degree view of the surroundings. It has a built-in battery for 12 hour operation.

6. Additional detector and operator

An additional detector operator will be provided that can be used as second parallel detector with the same source operator. It will be integrated with main box and controller.

Package contents:

1. Wireless detector assembly (including BGO PMT)-01 no.

2. Spare BGO-PMT-02 no.

3. Source/Detector Operators-03 nos.

4. Control box/ Data acquisition unit (with provision of 3 operators)-01 no.

5. Camera module-02 no.

6. Industrial grade Tablet-01 no.

7. User interface software (on DVD and installed in the tablet as well)

8. Operator’s manual with general troubleshooting procedures

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