Non-Intrusive Sensor Array for Empirical Process Measurement
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Solution Overview
Problem
Existing process plant monitoring and control systems face challenges with high installation costs and reduced accuracy due to the intrusive nature of traditional sensors, which limit the number of measurement points that can be effectively monitored, especially in situations where direct contact with the process fluid or equipment is required.
Innovation Solution
A non-intrusive sensor system comprising an array of sensors that measure various process phenomena and a logic unit analyzing these measurements to produce an empirical estimate of output process phenomena, using empirical models to improve accuracy and reduce installation costs without direct contact with the process fluid or equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional intrusive sensors are used to measure process parameters, then measurement accuracy is improved, but installation cost and complexity increase
Solution Approach 1:
The patent replaces traditional intrusive mechanical sensors with non-intrusive sensors that use electromagnetic fields (such as capacitive, inductive, or optical fields) to measure process parameters. This substitution eliminates the need for physical contact with the process fluid, thereby reducing installation complexity and cost while maintaining measurement accuracy through field-based detection mechanisms.
2Loss of information
If more measurement devices are installed to improve process monitoring, then information quality is improved, but total installation cost increases
Solution Approach 1:
The patent designs non-intrusive sensors that can measure multiple process parameters (such as level, temperature, pressure, or flow) using a single device platform. This multi-functionality allows one sensor to replace multiple specialized sensors, thereby improving information quality across different process variables while reducing the total number of devices installed and the associated installation costs.
3Adaptability or versatility
If intrusive sensors are installed in existing process equipment, then measurement capability is improved, but retrofitting requirements and costs increase
Solution Approach 1:
The patent employs non-intrusive sensors that operate through electromagnetic fields, allowing them to be mounted on the exterior of existing process equipment without penetrating or contacting the process fluid. This approach eliminates the need for complex retrofitting work such as drilling holes, installing flanges, or shutting down equipment, thereby enabling easy installation on existing plants while maintaining full measurement capability.
4Ease of operation
If non-intrusive sensors are used to reduce installation costs, then ease of installation is improved, but measurement accuracy deteriorates
Solution Approach 1:
The patent utilizes electromagnetic field parameters (such as capacitance, inductance, or optical properties) to detect process parameters non-intrusively. By changing the measurement paradigm from mechanical contact to field-based detection, the system achieves both ease of installation and maintained measurement accuracy, as these electromagnetic interactions can be precisely measured and calibrated without physical intrusion into the process.
Data Source
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AI summary
A non-intrusive sensor system includes an array of sensors disposed in a process to measure various input process phenomena and a logic unit that analyses the sensor measurements using an empirical model to produce an estimate of a further process phenomenon not measured directly by any of the array of sensors. The sensors within the array of sensors may be non-intrusive sensors that measure input process phenomena in an intrusive or non-intrusive manner but are non-intrusive with respect to the output process phenomenon as none of these sensors comes into direct contact with the process fluid or process element exhibiting the output process phenomenon. The sensors within the array of sensors can be any type of sensors that produce a measurement of a particular process phenomenon at the same or at different locations within a process.