Glass-Ceramic Sealed Microwave Probe for Multiphase Flow
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Solution Overview
Problem
Existing multiphase flow measurement systems face challenges in accurately determining water salinity and water-in-liquid ratio in multiphase fluids, especially under high pressure and temperature conditions, due to limitations in sensor design and the need for bulky and expensive enclosures to maintain pressure integrity.
Innovation Solution
A two-piece microwave coaxial probe with a single or long pressure-resistant insulator and a concentric conductor, embedded in a front piece with a glass or ceramic-metal seal, is designed to be flush-mounted in a liquid-rich region of a flow containment structure, using a C-ring or O-ring seal to maintain contact with the conduit wall, and a second member providing compressive support to retain the probe against the conduit wall, allowing for accurate measurement of water properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a glass-to-metal seal is used in the microwave probe to maintain pressure integrity, then measurement reliability is improved, but device complexity and cost increase due to the need for bulky enclosures as second pressure barriers
Solution Approach 1:
The patent extracts and eliminates the second bulky pressure barrier enclosure by using a glass-ceramic seal that provides both electrical insulation and pressure containment in a single integrated component. The glass-ceramic material with its high dielectric strength and chemical inertness allows the probe to withstand high pressure and temperature directly at the measurement point without requiring additional protective enclosures.
Solution Approach 2:
The patent employs composite materials, specifically glass-ceramic compounds, that combine the properties of glass (electrical insulation, chemical inertness) with ceramic characteristics (high temperature and pressure resistance, mechanical strength). This composite material enables the probe to function reliably in harsh downhole environments while maintaining a compact design without bulky enclosures.
2Reliability
If a glass-to-metal seal is used in the microwave probe, then measurement reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent removes the need for separate pressure barrier enclosures and their associated assembly steps, reducing manufacturing complexity and cost. The glass-ceramic seal integrates multiple functions (electrical insulation, pressure containment, chemical resistance) into a single component that can be directly installed in the probe, eliminating the need for additional manufacturing steps and assembly operations.
Solution Approach 2:
The use of glass-ceramic composite materials provides a cost-effective solution by combining the desirable properties of glass and ceramic in a single material system. This eliminates the need for multiple separate components and assembly operations, reducing overall manufacturing cost while maintaining reliability in high-pressure and high-temperature environments.
3Adaptability or versatility
If the microwave probe is designed with pressure resistance for high pressure and temperature conditions, then measurement capability in harsh environments is improved, but device complexity increases
Solution Approach 1:
The patent uses glass-ceramic composite materials that inherently possess high temperature and pressure resistance, chemical inertness, and electrical insulation properties. This single material system allows the probe to adapt to harsh downhole environments (high pressure, high temperature, corrosive conditions) without requiring complex multi-component structures or additional protective systems.
Solution Approach 2:
The glass-ceramic seal material performs multiple functions simultaneously: it provides electrical insulation between the conductor and environment, contains pressure differential, resists chemical corrosion, and withstands high temperatures. This multi-functionality in a single material reduces the overall probe structure complexity while enhancing environmental adaptability.
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 design enhances the detection of water salinity and water-in-liquid ratio in multiphase flows by ensuring reliable sealing and pressure resistance, reducing the complexity and cost of the sensor system while maintaining measurement accuracy across a wide gas-volume-fraction range.
Implementation Method 1
a pressure-resistant insulator surrounding the conductor
Implementation Method 2
a glass or ceramic-metal seal
Implementation Method 3
using a C-ring or O-ring seal to maintain contact with the conduit wall
Implementation Method 4
Microwave sensors for the measurement of multiphase flows can be used with multiphase flow meters to determine water salinity, water fraction, and water-in-liquid-ratio (WLR or water-cut)
Data Source
AI summary
Electromagnetic probes for analyzing a flowing multi-phase fluid are described herein. The probes generally use a probe assembly for measuring liquid properties in a multiphase fluid flowing in a conduit, the probe assembly comprising a first member with a probe portion and a connection portion, the probe portion having a central bore with a conductor and a pressure-resistant insulator surrounding the conductor, the conductor extending from an opening at a distal end of the probe portion into the connection portion, the connection portion having a connector coupled to a distal end of the connection portion, the connection portion having a seal face with a groove extending around the probe portion; and a second member that, when assembled, is in direct contact with the first member at the distal end of the connection portion to apply compression and to retain the first member against a wall of the conduit.