Acoustic Sensor Solids Level Detection Sand Separator
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Solution Overview
Problem
Current methods for determining when to purge a sand separator in natural gas recovery facilities rely on operator familiarity with sound profiles, which can be subjective and inefficient, leading to potential plugging and erosion issues due to inaccurate timing of sand removal.
Innovation Solution
An acoustic system comprising a sensor and processor that analyzes the sound profile within the sand separator to determine the optimal time for dumping the solids and liquids, using a calibrated frequency range to alert operators when the mixture has reached a predetermined level, potentially incorporating additional sensors for pressure, temperature, and weight data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operator familiarity with sound profiles is used to determine purge timing, then operational simplicity is maintained, but measurement precision and reliability deteriorate
Solution Approach 1:
The patent replaces the human operator's auditory system and subjective judgment with an electronic acoustic sensor system that objectively measures sound frequency and intensity. The sensor detects acoustic emissions from the sand separator and transmits signals to a processor that analyzes frequency content to determine solids level, replacing the mechanical/manual assessment method with an electronic measurement system.
Solution Approach 2:
The patent introduces an acoustic sensor as an intermediary between the sand separator's internal state and the operator. The sensor acts as a mediator that converts internal solids level information into measurable acoustic signals, which are then processed to provide objective feedback about the separator's condition without requiring direct operator exposure to the harsh environment.
2Measurement precision
If acoustic sensors and signal processing are implemented, then measurement precision and reliability improve, but device complexity increases
Solution Approach 1:
The patent extracts the core function of solids level detection from the complex task of overall sand separator monitoring. By focusing specifically on acoustic emission analysis, the system isolates the most critical detection function and implements a dedicated sensor and processing pathway for this purpose, rather than attempting to monitor all parameters simultaneously.
Solution Approach 2:
The patent changes the measurement parameter from subjective auditory assessment to objective acoustic frequency analysis. By measuring specific frequency ranges and intensity thresholds of sound emissions, the system transforms an ambiguous qualitative assessment into a quantifiable physical measurement that can be processed electronically with high precision.
3Productivity
If accurate solids level detection is achieved, then productivity is improved through optimal purge timing, but loss of time increases due to system calibration and setup
Solution Approach 1:
The patent performs preliminary calibration of the acoustic sensor system during installation or initial setup, establishing baseline frequency thresholds and sensitivity settings before production begins. This preliminary action ensures that the system is ready for immediate use with minimal ongoing adjustment, reducing time loss during normal operation.
Solution Approach 2:
The system incorporates automatic signal processing and interpretation algorithms that enable the sensor to self-calibrate and adapt to varying operating conditions without requiring manual intervention. The processor automatically adjusts measurement parameters and thresholds based on real-time acoustic patterns, allowing the system to maintain accuracy while minimizing operator time investment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system provides a more reliable and objective method for determining the solids level, reducing the risk of plugging and erosion by ensuring accurate timing of sand removal, thereby improving operational efficiency and equipment longevity.
Implementation Method 1
an acoustic sensor operably connected to the sand separator and configured to detect a sound profile within the sand separator
Data Source
AI summary
A system and method for determining when a sand separator should be purged to remove solids from the sand separator. The system can include an acoustic sensor which detects the frequency of audible sound coming from the inner chamber of the vessel and generate a signature signal representative of the frequency of audible sound. There is a processor connected to the acoustic sensor and configured to compare the signature signal with a set frequency range of audible sound which in turn generates a signal indicating when the signature frequency and the set frequency are in overlapping relationship.