Field Device Sand Detection via Signal Analysis
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Solution Overview
Problem
Natural gas and oil well production is hindered by sand flow, which causes equipment wear, pipe erosion, and calibration shifts, and existing acoustic sensors add complexity and cost while not integrating well with process measurement and control systems.
Innovation Solution
Adapting industrial field devices like pressure transmitters to sense both primary process variables and sand flow using digital signal processing and communication protocols like HART or FOUNDATION Fieldbus, allowing for real-time sand detection and integration with existing process communication systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dedicated acoustic sensors are used to detect sand flow, then sand detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent makes existing industrial field devices (pressure transmitters, flow meters, temperature sensors) perform dual functions: their primary measurement function plus sand detection. The controller analyzes process variable signals for characteristics indicating sand flow, eliminating the need for separate dedicated acoustic sensors and reducing overall system complexity
Solution Approach 2:
The patent combines sand detection functionality with existing process measurement and control devices. The controller integrates analysis of process variable signals (pressure, flow, temperature) to detect sand flow conditions, merging multiple functions into a single device rather than using separate dedicated sensors
2Measurement precision
If dedicated acoustic sensors are used to detect sand flow, then sand detection capability is improved, but cost increases
Solution Approach 1:
The patent makes existing industrial field devices (pressure transmitters, flow meters, temperature sensors) perform dual functions: their primary measurement function plus sand detection. The controller analyzes process variable signals for characteristics indicating sand flow, eliminating the need for separate dedicated acoustic sensors and reducing overall system complexity
Solution Approach 2:
The patent enables existing process control devices to self-diagnose sand flow conditions by analyzing their own process variable measurements. The controller detects sand flow by identifying characteristic signal patterns in the process data already being collected, without requiring additional sensors or external detection systems
3Measurement precision
If dedicated acoustic sensors are used, then sand detection is achieved, but integration with process control systems becomes difficult
Solution Approach 1:
The patent makes existing industrial field devices (pressure transmitters, flow meters, temperature sensors) perform dual functions: their primary measurement function plus sand detection. The controller analyzes process variable signals for characteristics indicating sand flow, eliminating the need for separate dedicated acoustic sensors and reducing overall system complexity
Solution Approach 2:
The patent combines sand detection functionality with existing process measurement and control devices. The controller integrates analysis of process variable signals (pressure, flow, temperature) to detect sand flow conditions, merging multiple functions into a single device rather than using separate dedicated sensors
4Reliability
If sand flow is not detected immediately, then equipment wear occurs, but detection time is delayed
Solution Approach 1:
The patent enables continuous monitoring of process variable signals by the controller, which constantly analyzes the data stream for characteristics indicating sand flow. This continuous analysis allows immediate detection of sand flow conditions as they occur, enabling timely protective actions rather than delayed detection
Solution Approach 2:
The patent implements a feedback mechanism where the controller continuously monitors process variable signals and provides immediate indication when sand flow is detected. The system feeds back real-time sand detection status to operators or control systems, enabling rapid response to prevent equipment damage
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
Reduces system complexity and cost by enabling immediate sand flow detection, allowing for quick remedial actions and reducing the risk of equipment failure through seamless integration with existing control systems.
Implementation Method 1
The process variable sensor has an electrical characteristic that changes based on a variable of a process fluid
Implementation Method 2
The controller is configured to generate communication via the communication circuitry relative to the process variable
Data Source
AI summary
An industrial field device provides information indicative of a process variable. The field device includes a controller, communication circuitry, a process variable sensor and measurement circuitry. The communication circuitry is coupled to the controller. The process variable sensor has an electrical characteristic that changes based on a variable of a process fluid. The measurement circuitry is coupled to the process variable sensor and coupled to the controller. The controller is configured to generate communication via the communication circuitry relative to the process variable, and to provide an indication of sand flow or other solids in the fluid.