Fluid Sensor Interface Complex for Plant Machinery Monitoring
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Solution Overview
Problem
Industrial plants face high costs and complexity in interfacing on-line fluid sensors with machinery monitoring systems due to vendor-specific interfaces, and there is a need for reconciling sensor data with laboratory data, often requiring skilled personnel for manual reconciliation.
Innovation Solution
A system that includes a fluid sensor/plant machinery monitoring interface complex with on-line fluid property sensors connected to a server for network data output, a remote information management system to store and calculate fluid properties based on both sensor and laboratory data, using models that integrate both data types for improved data reconciliation and recommendation generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If vendor-specific interfaces are used to connect on-line fluid sensors with machinery monitoring systems, then each sensor can be integrated with its monitoring system, but the interface complexity and cost increase significantly
Solution Approach 1:
The patent implements a universal interface architecture where a single standardized communication protocol and data format are used across all sensor types and monitoring systems. This allows different vendors' sensors to interface with different monitoring systems without requiring custom integration for each combination, thereby reducing interface complexity while maintaining adaptability.
Solution Approach 2:
The patent introduces an intermediary layer (standardized interface protocol and data translation module) between the on-line fluid sensors and machinery monitoring systems. This intermediary translates various sensor data formats into a common standard, enabling seamless communication without direct custom interfaces between each sensor and monitoring system pair.
2Measurement precision
If manual reconciliation of sensor data and laboratory data is performed by skilled personnel, then data accuracy can be maintained, but labor costs and time requirements increase
Solution Approach 1:
The patent implements automated data reconciliation systems where the monitoring software automatically compares on-line sensor data with laboratory data, identifies discrepancies, and adjusts calibration parameters without requiring skilled personnel intervention. The system serves itself by maintaining accurate data through automated algorithms.
Solution Approach 2:
The patent establishes feedback loops where reconciliation results automatically feed back into sensor calibration and monitoring parameters. When discrepancies between sensor and laboratory data are detected, the system automatically adjusts calibration factors and notifies relevant personnel, reducing the need for manual intervention while maintaining accuracy.
3Productivity
If automated reconciliation systems are implemented, then labor costs and time requirements are reduced, but system complexity increases
Solution Approach 1:
The patent implements preliminary calibration and data normalization processes where standard reference data and calibration curves are pre-loaded into the system. This preliminary preparation enables the automated reconciliation algorithm to quickly process and compare data without requiring complex real-time calculations, thereby improving productivity while controlling system complexity.
Data Source
AI summary
A fluid sensor/plant machinery monitoring system and method wherein a plurality of on-line fluid property sensors output on-line sensor data and are connected to an interface configured with a server outputting the on-line sensor data via a network. A remote information management system requests and receives the on-line sensor data via the network, stores machine fluid property laboratory data, and calculates an estimate of one or more fluid properties based on both the received on-line sensor data and the stored laboratory data. A manifold unit receives fluid from a machine and includes ports for the on-line fluid property sensors. The remote information management system calculates one or more fluid properties based on both the received on-line sensor data and the stored laboratory data based on models where a machine fluid property is a function of both the on-line sensor data and the stored laboratory data for the machine.