EFSS Transient Sensor Failure Recovery

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Solution Overview

Problem

Oil and gas production systems face challenges with transient sensor failures due to harsh operating conditions, leading to inaccurate measurements and difficulties in distinguishing between expected and erroneous data, which existing methods struggle to address effectively.

Innovation Solution

An enhanced flow soft sensing (EFSS) system that includes a computing device configured to determine an estimated mass flow rate, generate expected measurements, and compare them with actual measurements to detect transient sensor failures, using a smooth variable structured filter to converge back to a correct estimated state.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If static parameter ranges are used for sensor validation, then the system is simple to operate, but it cannot adapt to varying operating conditions and masks transient sensor failures

Engineering Contradiction:

Improvesimplicity of parameter specificationVSAvoidability to detect transient sensor failures

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent transforms static parameter ranges into dynamic, adaptive ranges that automatically adjust to current operating conditions. The system uses historical data and machine learning models to continuously update expected parameter ranges, enabling the validation logic to adapt to varying operating conditions while maintaining simplicity of operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the parameters used for validation from fixed static values to dynamic values that evolve with operating conditions. By using time-varying parameter ranges derived from historical data and predictive models, the system maintains reliability across different operating scenarios without requiring manual reconfiguration.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If wide parameter ranges are used to accommodate transient conditions, then the system is adaptable to various operating conditions, but it fails to distinguish between expected and erroneous measurements

Engineering Contradiction:

Improveaccommodation of operating conditionsVSAvoidability to distinguish erroneous measurements

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The system performs preliminary actions by continuously learning and establishing baseline parameter ranges during normal operation. Before transient failures occur, the system has already captured historical data and trained models to recognize normal variations, enabling it to distinguish between expected transient conditions and actual sensor failures when they occur.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback from historical measurement data and model predictions to continuously refine parameter validation ranges. By comparing actual measurements against dynamically updated expected ranges and analyzing residuals, the system maintains measurement precision while adapting to varying operating conditions.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If narrow parameter ranges are used to detect sensor failures, then the system can distinguish erroneous measurements, but it masks valid measurements during transient conditions

Engineering Contradiction:

Improvedetection of erroneous measurementsVSAvoidaccommodation of transient conditions

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The system employs dynamic parameter ranges that automatically expand or contract based on current operating conditions and historical variability. During transient conditions, the ranges naturally widen to accommodate expected variations, while maintaining narrow precision bounds for detecting actual sensor failures, thus resolving the contradiction between detection sensitivity and adaptability.

Inventive Principle:

Principle #15Dynamics

4Ease of manufacture

If manual parameter specification is used, then the system is easy to configure, but it requires significant operator expertise and time to set appropriate ranges

Engineering Contradiction:

Improveease of system configurationVSAvoidtime to specify parameters

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The system performs self-service by automatically generating and updating parameter validation ranges without requiring manual operator input. The machine learning models continuously learn from historical data and autonomously configure appropriate parameter ranges, eliminating the time-consuming manual specification process while maintaining ease of operation through automated adaptation.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10101194B2System and method for identifying and recovering from a temporary sensor failure

Publication Date: 2018.10.16 GENERAL ELECTRIC CO

AI summary

A sensor system for identifying a transient sensor failure in an industrial system and for recovering from an erroneous estimation of an expected mass flow rate resulting from the transient sensor failure. The sensor system includes one or more sensors for measuring at least one fluid property of the industrial system. The sensor system includes an enhanced flow soft sensing (EFSS) computing device configured to determine an estimated mass flow rate. The EFSS computing device is also configured to generate expected measurements to be received from one or more sensors. If an error value is not within predetermined parameters, the transient sensor failure is detected. The EFSS computing device is further configured to identify a resurgence of the sensor from the transient sensor failure. An erroneous expected mass flow rate then converges toward a correct expected mass flow rate.