Multivariable Transmitter Welded Base for High Pressure
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Solution Overview
Problem
Current multivariable process fluid transmitters are not suitable for high-pressure environments, such as subsea use, due to seal failure and corrosion issues, requiring multiple devices for accurate measurement of process variables.
Innovation Solution
A multivariable process fluid transmitter module with a base and pedestals, using corrosion-resistant materials like Alloy C276, and robust welds to withstand high pressures, integrating a differential pressure sensor and line pressure sensors with redundant temperature measurement, allowing a single device to operate in high-pressure environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bolted connections with deformable seals are used to connect process fluid flange to transmitter base, then assembly is easy to manufacture and install, but seal fails at high pressures causing fluid leakage
Solution Approach 1:
The patent replaces the mechanical bolted connection with deformable seal with a weld connection system. The process fluid flange and transmitter base are joined through welding, which eliminates the deformable seal component entirely. This substitution of mechanical assembly with welding resolves the contradiction by providing both ease of manufacture through standardized welding procedures and reliable seal integrity that can withstand high pressures without leakage.
Solution Approach 2:
The patent introduces an intermediary welding joint between the process fluid flange and transmitter base. This weld acts as a mediator that transfers loads and maintains sealing without relying on deformable materials. The weld connection serves as an intermediate solution that satisfies both the ease of assembly requirement and the high-pressure seal integrity requirement.
2Ease of manufacture
If standard materials are used in process fluid pathways, then manufacturing is simpler and less expensive, but corrosion occurs in harsh process environments
Solution Approach 1:
The patent employs composite material construction for components exposed to harsh process fluids. Specifically, Alloy C-276 is used for the process fluid flange, isolator diaphragms, and fill fluid pathways. This alloy combines nickel, chromium, and molybdenum to create a material that resists corrosion from aggressive chemicals while maintaining manufacturability through established welding and fabrication techniques. The composite approach uses specialized materials only where corrosion resistance is critical, balancing manufacturing complexity with performance requirements.
3Measurement precision
If multiple process fluid transmitters are deployed in high-pressure environments, then measurement coverage is improved, but system complexity and expense increase
Solution Approach 1:
The patent designs a universal transmitter module that can measure multiple process variables (differential pressure, line pressure, and temperature) simultaneously using corrosion-resistant materials and high-pressure-capable sensors. This multi-functional design allows a single transmitter to replace multiple specialized transmitters, reducing system complexity while maintaining comprehensive measurement capability in high-pressure environments up to 15,000 psi.
Solution Approach 2:
The patent combines multiple measurement functions into a single integrated transmitter unit. The module integrates differential pressure sensing, line pressure sensing, and temperature sensing capabilities within one corrosion-resistant housing. By merging these functions, the system reduces the number of separate transmitters needed while improving measurement coverage and reducing overall system complexity and expense.
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 measurement of multiple process variables in high-pressure environments, such as subsea, with a single device, reducing the need for multiple transmitters and minimizing corrosion and seal failure.
Implementation Method 1
Pressure is transferred from the process fluid to the differential pressure sensor through a substantially incompressible fill fluid carried in a passageway extending from each isolator diaphragm to the differential pressure sensor
Implementation Method 2
a pair of isolator diaphragms that are positioned in the process fluid inlets and isolate the differential pressure sensor from the harsh process fluids being sensed
Implementation Method 3
The process fluid temperature sensor responds to the temperature of the process fluid with an electrical indication, such as a voltage or resistance, that is related to the temperature of the process fluid
Data Source
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AI summary
A multivariable process fluid transmitter module (100) includes a base (108) having a pair of recesses. A pair of pedestals (218, 220) is provided with each pedestal being disposed in a respective recess (217, 219) and being coupled to a respective isolation diaphragm (222). At least one line pressure assembly is mounted proximate one of the pedestals. The at least one line pressure assembly (302, 304) couples a respective isolation diaphragm (222) to a line pressure sensor (305). A differential pressure sensor (208) has a sensing diaphragm (214) fluidically coupled to the isolation diaphragms by a fill fluid. At least one additional sensor (306) is disposed to sense a temperature of a process fluid. Circuitry (216) is coupled to the line pressure sensor (305), the differential pressure sensor (208), and the at least one additional sensor (306) to measure an electrical characteristic of each of the line pressure sensor (305), the differential pressure sensor (208), and the at least one additional sensor (306). The circuitry (208) is configured to provide an indication of fluid flow based on the measured electrical characteristic of each of the line pressure sensor (305), the differential pressure sensor (208) and the at least one additional sensor (306).