Downstream Pressure Sensor for Corrosive Tank Level Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional tank level sensors in chemical treatment systems for hydrocarbon production fail due to corrosion and reactivity issues when exposed to harsh and corrosive chemicals, leading to inaccurate fluid level measurements.
Innovation Solution
A pressure sensor is placed in the discharge manifold downstream of an isolation valve and upstream of a pump intake, which sends signals to a tank level sensor module that averages pressure readings over a predefined time window to account for pump strokes and valve slam cycles, ensuring accurate fluid level determination despite pressure fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor is placed in the chemical tank to measure fluid level, then the tank level measurement is achieved, but the sensor fails due to corrosion and reactivity of the chemical composition
Solution Approach 1:
The patent introduces an intermediary fluid (water or inert fluid) that fills the chemical tank and isolates the corrosive chemicals from the pressure sensor. The pressure sensor measures pressure in this intermediary fluid rather than directly in the chemical composition, thereby preventing corrosion while maintaining accurate tank level measurement capability
Solution Approach 2:
The patent replaces direct chemical-mechanical interaction (sensor exposed to chemicals) with an indirect mechanical measurement system. By measuring pressure in the intermediary fluid and converting it to tank level data through calculation, the system eliminates direct contact between the sensor and corrosive chemicals while preserving measurement functionality
2Measurement precision
If pressure readings are taken continuously to ensure accurate tank level monitoring, then measurement accuracy is improved, but pressure spikes from pump operations and valve slamming cause inaccurate readings
Solution Approach 1:
The patent implements preliminary timing logic that identifies when pump operations and valve cycling are occurring, then proactively excludes pressure readings taken during these periods from the averaging calculation. This preliminary identification and exclusion of harmful data points prevents pressure spikes from corrupting the tank level measurement
Solution Approach 2:
The patent uses feedback from pump operation status and valve position to dynamically adjust which pressure readings are included in the calculation. By continuously monitoring system state and providing feedback to the measurement algorithm, the system can distinguish between valid pressure changes反映ing tank level and invalid spikes from operational cycles
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 solution provides reliable and accurate tank level measurements by filtering out pressure spikes caused by pump operations, thereby extending the lifespan of the sensor and improving the efficiency of chemical delivery in hydrocarbon production systems.
Implementation Method 1
The pressure sensor determines the hydrostatic pressure at the bottom of the tank
Implementation Method 2
whether a check valve is shutting, also known as slamming, which causes a pressure increase or spike due to the shock wave
Data Source
AI summary
A chemical tank level system for a wellbore chemical injection tank is provided. The system includes a pressure sensor is located downstream of the chemical injection tank where the fluidic pressure is essentially the same as the fluidic pressure at the base of the chemical tank. The pressure sensor sends a signal indicative of the fluidic pressure to a tank level sensor module. The tank level sensor module receives the signal from the pressure sensor. A processor takes a series of pressure sensor signals over a sample window and calculates an average of the signals over a defined time window.