Intrusive Probe Design for Repeatable Solid Particle Detection
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Solution Overview
Problem
Conventional sand detection methods in oil and gas industries are inaccurate and difficult to use due to variations in signal quality caused by changes in flow regimes and mounting locations, making it challenging to manage data effectively.
Innovation Solution
A method and apparatus involving a probe that vibrates at a predetermined frequency to detect solid particles in fluid flow, using a piezoelectric device to convert impulse responses into electronic signals, and a detector to identify these signals, with a specific probe design and calibration to ensure repeatable and accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external detectors are mounted on pipe elbows to detect particles, then particle detection is enabled, but signal quality varies and repeatability is poor due to changes in flow regimes and mounting locations
Solution Approach 1:
The patent replaces the conventional external ultrasonic detection system with an internal probe system that directly contacts the fluid flow. The probe contains a piezoelectric element that generates and detects acoustic signals within the flow, eliminating dependence on external mounting conditions and flow regime variations. This substitution of the detection mechanism from external to internal resolves the contradiction by providing stable, repeatable signals independent of external mechanical variations.
Solution Approach 2:
The probe acts as an intermediary element inserted into the flow to mediate between the detection system and the particles. By placing the piezoelectric element directly in contact with the fluid, the probe creates a controlled interaction zone where particle detection occurs under consistent conditions, eliminating the variability introduced by external mounting on pipe elbows.
2Measurement precision
If the probe intrudes into the fluid flow to detect particles, then detection accuracy is improved, but the probe structure becomes more complex
Solution Approach 1:
The detection system is segmented into distinct functional components: a piezoelectric element for signal generation and detection, a housing for protection, and a mounting mechanism for insertion. This segmentation allows each component to be optimized independently while maintaining overall simplicity. The piezoelectric element itself is a compact, self-contained component that requires no additional complex structures to function.
Solution Approach 2:
The piezoelectric element serves multiple functions: it generates acoustic waves to detect particles, detects particle impacts, and can potentially measure flow characteristics. This multi-functionality reduces the need for separate components, thereby simplifying the overall probe structure while maintaining high detection accuracy.
3Measurement precision
If field calibration is performed to account for variable conditions, then measurement accuracy is maintained, but operational time and complexity increase
Solution Approach 1:
The probe is pre-calibrated and standardized during manufacturing to provide consistent detection characteristics. The piezoelectric element is selected and positioned to ensure optimal performance across expected operating conditions. This preliminary standardization eliminates the need for extensive field calibration, as the device is designed to perform accurately under varying flow regimes without additional site-specific adjustments.
Solution Approach 2:
The detection system is designed with parameters (such as piezoelectric element orientation, acoustic frequency, and signal threshold) that are inherently robust to variations in flow conditions. By selecting parameters that naturally compensate for expected variations, the system maintains accuracy without requiring time-consuming field calibration procedures.
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
Provides precise and repeatable detection of solid particles, eliminating the need for field calibration and improving data quality by controlling the impact area and using unique vibration responses to enhance signal extraction and identification.
Implementation Method 1
a piezoelectric device in ultrasonic communication with the probe, adapted to convert impulse response vibration into an electronic signal
Implementation Method 2
the probe adapted to vibrate at a frequency in an impulse response envelope to the solid particles; the frequency is in an ultrasonic range
Data Source
AI summary
An apparatus, system and method of detecting solid particles in a flow is described herein. A pipe with fluid flow containing solid particles has a thru-pipe mounted intrusive probe. The intrusive probe provides impact surfaces for solid particles. Each particle impact generates an impulse response. The material composition and design shape of the probe determines unique impulse response frequencies, durations, and amplitude envelope. The method and design controls the generation, and facilitates identification of the unique impulse response. The unique impulse response is identified by isolation and extraction of amplitude envelope wavelets. The impulse response or particle impact may be counted to facilitate calculating the quantity of solid particles.