External Acoustic Solids Level Detection for High-Pressure Vessels
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Solution Overview
Problem
In hydraulic fracturing, existing separator systems require frequent maintenance to remove solids from collection vessels, which can disrupt operations, especially in high-pressure applications where sensor installation is challenging due to safety and regulatory concerns.
Innovation Solution
A mixed fluid collection apparatus using an acoustic signal emitter and receiver outside a cylindrical collection vessel to determine the level of solids without direct penetration, employing a controller to calculate the time delay of the signal and assess the solids level based on propagation speed through the fluid and vessel material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are positioned within the collection vessel to determine sand level, then measurement precision is improved, but device complexity and safety requirements increase due to high-pressure penetration requirements
Solution Approach 1:
The patent introduces an intermediary medium (acoustic signal) that travels through the collection vessel wall to transmit information about the sand level without requiring direct penetration into the high-pressure environment. The emitter and receiver are positioned outside the vessel, with acoustic waves passing through the vessel wall to detect sand level changes, thereby eliminating the need for complex internal sensor installation while maintaining measurement accuracy
Solution Approach 2:
The patent replaces mechanical/electrical sensors that would require direct insertion into the high-pressure collection vessel with an acoustic detection system. Instead of using electrical resistance detectors or vibrating forks that need physical contact with the fluid, the system uses acoustic waves that can penetrate through the vessel wall to sense sand level changes, substituting a non-invasive acoustic field for a mechanical sensor insertion
2Measurement precision
If nuclear technology sensors are used to detect fluid composition, then measurement precision is improved, but safety and regulatory requirements increase
Solution Approach 1:
The patent substitutes nuclear technology sensors with an acoustic detection system. Instead of using nuclear radiation to detect fluid composition, the system employs acoustic waves that travel through the collection vessel wall to sense changes in fluid composition and sand level. This replacement eliminates the safety hazards and regulatory burdens associated with nuclear materials while maintaining the ability to detect fluid composition changes with high precision
3Loss of information
If collection vessel is pierced to install sensors, then measurement capability is improved, but reliability decreases due to potential leakage and safety issues in high-pressure systems
Solution Approach 1:
The patent uses the collection vessel wall itself as an intermediary medium for acoustic wave transmission. Instead of piercing the vessel to install sensors, the system employs acoustic waves that travel through the existing vessel wall structure to detect fluid composition and sand level. This approach maintains the integrity of the pressure-containing structure while still enabling reliable detection, thereby improving both information access and system reliability
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
Enables non-invasive, efficient monitoring of solids levels in high-pressure systems, reducing maintenance frequency and operational disruptions while ensuring safety and compliance with regulatory requirements.
Implementation Method 1
The emitter is configured to emit an acoustic signal into the outer shell. The receiver is configured to detect the acoustic signal emitted by the emitter. The controller is configured to determine a time between when the acoustic signal is emitted and when the acoustic signal is detected, and the controller is configured to determine a level of the second component in the collection vessel based on the time.
Data Source
AI summary
A mixed fluid collection apparatus includes a collection vessel configured to contain a fluid comprising a first component and a second component. The collection vessel includes an outer shell within which the fluid is contained. An emitter is coupled to an outside of the outer shell at a first position, and is configured to emit an acoustic signal into the outer shell. A receiver is coupled to the outside of the outer shell at a second position, with the receiver being configured to detect the acoustic signal emitted by the emitter. A controller is coupled to the emitter and the receiver. The controller is configured to determine a time between when the acoustic signal is emitted and when the acoustic signal is detected, and the controller is configured to determine a level of the second component in the collection vessel based on the time.