Multiphase Liquid Level Sensor Using Nested Float and Overburden Detection
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Solution Overview
Problem
Current systems are unable to simultaneously measure the levels and thicknesses of multiple multiphase liquids with different specific gravities, as they require multiple devices that often cannot fit in restricted spaces, such as tanks and wells, and lack the capability to automatically compute and report these measurements.
Innovation Solution
A multiphase-liquid level sensing system featuring an elongated stem with a float and level sensor that senses the interface between two liquids of different specific gravities, combined with an overburden sensor and computational circuit to calculate layer depth and thickness, allowing for simultaneous measurement of multiple liquid phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate devices are used to measure levels of multiphase liquids, then measurement capability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple measurement functions (level sensing, pressure measurement, temperature sensing) into a single integrated sensor assembly. The float mechanism with magnetic coupling detects interface levels between liquid phases, while a pressure transducer measures total liquid head, and a temperature sensor provides thermal data. This integrated assembly eliminates the need for multiple separate devices and automatically computes multiphase liquid levels and thicknesses.
Solution Approach 2:
The sensor assembly is designed to perform multiple functions simultaneously: it measures the level of multiple liquid phases with different specific gravities, measures total liquid pressure, monitors temperature, and computes layer thicknesses. The float mechanism with magnetic coupling can detect interfaces between any number of liquid phases, making the device universally applicable to various multiphase measurement scenarios.
2Measurement precision
If multiple devices are installed to measure multiphase liquid levels, then measurement precision is improved, but ease of operation deteriorates due to restricted installation space
Solution Approach 1:
The sensor assembly employs a nested structure where the float is positioned within an elongated stem, and the magnetic coupling mechanism is nested within the float structure. The pressure transducer and temperature sensor are integrated within the same assembly. This nested configuration allows the entire multi-functional measurement system to be installed through a single access point, such as a wellhead or tank opening, eliminating the need for multiple installation points in restricted spaces.
3Device complexity
If a single device is used to measure multiphase liquids, then device complexity is reduced, but measurement capability deteriorates
Solution Approach 1:
The patent uses magnetic coupling as an intermediary mechanism between the float and the level sensing system. The float contains magnets that couple with reed switches or Hall effect sensors within the elongated stem, allowing the float to move freely at the liquid interface while the sensing elements remain protected within the stem. This intermediary magnetic coupling enables accurate level detection without direct mechanical contact, maintaining measurement capability while simplifying the overall device structure.
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
Enables accurate, real-time monitoring of layer depths and thicknesses of multiphase liquids in various environments, preventing over-pumping and maintaining well capacity by determining the specific gravity and true height of each phase, even in spaces where multiple devices cannot be deployed.
Implementation Method 1
The first float has a negative buoyancy relative to the liquid of the first phase and a positive buoyancy relative to the liquid of the second phase
Implementation Method 2
A magnet that is affixed to the annular floatation member. The magnet is configured to generate a sensible magnetic field
Data Source
AI summary
A multiphase-liquid level sensing system for sensing a layer depth and thickness of a liquid of a first phase that floats on a liquid of a different second phase includes an elongated stem that defines an elongated cavity. A float, which exhibits a sensible property, is disposed coaxially around the elongated stem and has negative buoyancy relative to the liquid of the first phase and positive buoyancy relative to the liquid of the second phase. A level sensor senses the sensible property and indicates a second phase liquid distance from the float to the bottom of the stem. An overburden sensor extends downwardly from the stem senses total liquid thickness of the liquid above the overburden sensor. A computational circuit calculates a layer depth and thickness of the liquid of the first phase, based on input from the level sensor and the overburden sensor.