Acoustic Sensors for Container Sediment Detection
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Solution Overview
Problem
Containers used for fluid transportation and storage face issues with particulate matter buildup, leading to obstructions and costly maintenance, especially in the oil and gas industry where sedimentation at the bottom of tanks is uneven and affects crude oil volume estimation.
Innovation Solution
An apparatus and method utilizing a plurality of acoustic sensors mounted on the exterior of containers to transmit and receive acoustic signals, allowing for the detection of objects and sediment surfaces within the container, enabling early identification of issues and targeted maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional maintenance procedures are used to detect and clean container interiors, then cleaning can be performed, but the container must be taken offline resulting in downtime and loss of productivity
Solution Approach 1:
The patent replaces mechanical inspection and cleaning systems with acoustic sensing technology. Acoustic sensors detect sediment buildup, objects, and fluid characteristics without physical contact, eliminating the need to take containers offline for inspection. This substitution of mechanical systems with acoustic fields resolves the contradiction by maintaining productivity while ensuring container cleanliness through non-intrusive monitoring.
Solution Approach 2:
The patent introduces acoustic waves as an intermediary medium to detect container interior conditions. The acoustic sensors transmit sound waves through the container walls and fluid to gather information about sediment, objects, and fluid properties without direct physical access. This intermediary approach allows continuous monitoring during operation, preventing the need to shut down containers for maintenance checks.
2Reliability
If manual inspection and cleaning of container interiors is performed, then particulate matter can be removed, but the process is expensive and time-consuming
Solution Approach 1:
The patent implements preliminary detection of sediment buildup and contamination using acoustic sensors before manual cleaning is required. By continuously monitoring container interiors acoustically, the system identifies when cleaning is needed, allowing for planned maintenance rather than reactive shutdowns. This preliminary action reduces overall maintenance time by eliminating unnecessary inspections and enabling targeted cleaning only when actually needed.
Solution Approach 2:
The patent replaces time-consuming manual inspection procedures with automated acoustic sensing. The acoustic sensors rapidly scan container interiors and provide real-time data about sediment accumulation and contamination levels, eliminating the need for personnel to manually enter and inspect containers. This substitution dramatically reduces maintenance time while maintaining thorough inspection quality.
3Productivity
If sediment buildup is not detected, then containers can operate continuously, but inaccurate volume estimation and potential overfill or underfill situations occur
Solution Approach 1:
The patent implements a feedback system where acoustic sensors continuously monitor sediment buildup and provide data to a processing system. The system analyzes acoustic signal characteristics to determine sediment volume and location, then provides feedback about container status and volume estimates. This feedback loop maintains operational continuity by automatically tracking sediment accumulation without requiring shutdowns, while simultaneously providing precise volume estimation through acoustic analysis.
Solution Approach 2:
The patent utilizes changes in acoustic signal parameters (such as attenuation, reflection, and transmission characteristics) to detect sediment buildup and estimate fluid volume. By monitoring how acoustic waves interact with different media (fluid, sediment, container walls), the system derives precise volume measurements and sediment accumulation data without disrupting container operation. This parameter-based detection resolves the contradiction by maintaining both productivity and measurement precision.
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 approach reduces downtime and maintenance costs by allowing for precise detection of particulate matter and sediment buildup, enabling accurate volume estimation and preventing overfill or underfill situations in containers.
Implementation Method 1
A plurality of acoustic signals is transmitted into the container by at least a portion of the plurality of acoustic sensors
Implementation Method 2
At least one echo of at least one of the acoustic signals is altered by the at least one object within the quantity of fluid
Data Source
AI summary
An apparatus, system, and method for the detection of contents within a container includes a plurality of transducers mounted on an exterior surface of the container. A plurality of acoustic signals is transmitted into the container, and an echo is generated when the signals contact an object. The echo is received at a transducer and a processor analyzes the echo to detect the object. Similarly, two acoustic transducers can be used to angularly transmit the signal into a container. The signal reflects off a sediment surface and is received at another acoustic transducer. The reflection signal can be used to analyze a sediment surface within the container.