Chemical Sensor Analyzer for pH and Chloride Error Correction
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Solution Overview
Problem
Current monitoring technologies in chemical plants produce a large volume of false data, making real-time monitoring of pH, metal ion concentrations, and chloride ion concentrations difficult, leading to inefficient corrosion prevention and increased operational costs due to unnecessary remedial chemistry applications.
Innovation Solution
A method to correct sensor measurement errors in chemical process systems by identifying and removing dynamic and steady-state error components, using an analyzer to process data from multiple sensors and a controller to enact remedial measures, including the addition of chemicals, to maintain process variables within acceptable ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current monitoring technologies are used to measure pH, metal ion concentrations, and chloride ion concentrations in real-time, then the ability to detect abnormal conditions is improved, but the volume of false data increases making real-time monitoring difficult
Solution Approach 1:
The patent introduces an intermediary processing system that receives raw sensor data and applies multiple correction algorithms. This intermediary layer separates the raw measurement process from the final decision-making process, allowing false data to be identified and corrected before being used for control decisions. The system uses intermediate correction factors for dynamic state errors, steady state errors, and additional errors to bridge the gap between raw sensor output and reliable measurements.
Solution Approach 2:
The patent implements feedback mechanisms where the corrected measurements are continuously compared against expected ranges and historical data. When deviations are detected, the system adjusts correction factors and triggers remedial actions. The feedback loop includes comparing corrected values against setpoints, tracking trends over time, and using this information to refine future measurements and control decisions, thereby improving both accuracy and reliability over time.
2Reliability
If real-time monitoring is implemented with frequent measurements, then the ability to prevent corrosion is improved, but the cost of remedial chemistry increases due to false alarms
Solution Approach 1:
The patent applies preliminary correction actions to sensor measurements before they trigger remedial chemistry application. By pre-processing the data through multiple error correction stages (dynamic state correction, steady state correction, and additional error correction), the system prevents false alarms from initiating unnecessary chemical additions. This preliminary action filters out spurious readings that would otherwise waste remedial chemistry.
Solution Approach 2:
The system uses feedback to verify that corrected measurements truly indicate abnormal conditions before triggering remedial actions. The feedback mechanism compares corrected values against multiple criteria including expected ranges, historical trends, and rate of change thresholds. This multi-layered feedback verification ensures that remedial chemistry is only applied when genuinely needed, reducing waste while maintaining effective corrosion prevention.
3Loss of substance
If manual operator intervention is used to prevent false alarm remediation, then the waste of remedial chemistry is reduced, but the operational costs increase
Solution Approach 1:
The patent implements a self-service automated system that performs the functions previously requiring manual operator intervention. The system automatically corrects sensor measurements, identifies true abnormal conditions, and triggers appropriate remedial actions without human input. The automated correction algorithms and decision logic replace the need for operators to manually evaluate each reading, eliminating labor costs while maintaining or improving remedial chemistry efficiency through consistent, rule-based decision making.
Solution Approach 2:
The automated system uses feedback loops to continuously monitor measurements and automatically adjust remedial chemistry application based on corrected data. The feedback mechanism includes automatic comparison against setpoints, trend analysis, and trigger-based control that replaces manual operator decisions. This automation maintains high remedial chemistry efficiency by systematically applying corrections and actions only when genuinely needed, while eliminating the operational costs of manual monitoring and decision-making.
Data Source
AI summary
A method of correcting measurements of a chemical sensor used in an industrial facility. The method involves correcting for errors known to occur in the steady state and the dynamic state for specifically recognized situations. This method allows for correcting errors that occur due to deadtime, false zero measurements, and non-linear disturbances. The method combines automated measurement techniques and human know how to progressively learn and refine the accuracy of the corrections.