Leak Sensor for Prover Shaft Seals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing prover systems lack the capability to accurately detect and quantify fluid leakage through sealed bearings supporting a translating shaft, leading to compromised measurement accuracy and costly downtime due to inability to monitor leakage rates effectively.
Innovation Solution
A housing with an annular cavity around the shaft collects leaking fluid, which is directed to a collection chamber via a conduit, equipped with a liquid level sensor that provides a mechanical or electrical signal when a predetermined amount is reached, triggering maintenance and allowing for drainage of the chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If seals are used to prevent fluid leakage through the shaft, then measurement accuracy is improved, but leakage eventually occurs and requires expensive repair and causes downtime
Solution Approach 1:
The patent implements a collection chamber and sensor system that detects leakage at its earliest stages, enabling preventive maintenance before seals fail completely. This preliminary detection approach allows operators to schedule repairs during planned downtime rather than experiencing unexpected failures, thus maintaining measurement accuracy while optimizing seal replacement timing.
2Measurement precision
If seals are replaced frequently to maintain measurement accuracy, then measurement precision is improved, but productivity decreases due to repeated downtime
Solution Approach 1:
The patent employs a sensor system that continuously monitors fluid leakage through the shaft seals and provides feedback to the control system. When leakage exceeds predetermined thresholds, the system generates alarms that trigger maintenance protocols. This feedback mechanism enables condition-based maintenance, replacing seals only when necessary based on actual leakage conditions rather than fixed schedules, thereby maintaining measurement accuracy while maximizing operational availability.
3Device complexity
If leakage is monitored only by gross accumulation methods, then device complexity is reduced, but measurement precision of leakage rate deteriorates
Solution Approach 1:
The patent introduces a collection chamber as an intermediary component that captures and concentrates leaked fluid in a controlled environment. This intermediary structure enables precise measurement of leakage rates through sensors that detect fluid level or volume in the collection chamber, providing accurate leakage quantification without requiring complex direct measurement systems on the shaft or seals themselves.
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 precise monitoring and indication of fluid leakage rates, preventing excessive leakage and maintaining measurement integrity by providing timely alerts and allowing for scheduled repairs, thus reducing downtime and maintenance costs.
Implementation Method 1
A liquid level sensor within the collection chamber provides a mechanical or an electrical signal reflective of the amount of fluid collected therein
Data Source
AI summary
A leak sensor for sensing fluid flow through the bearings and seals about a shaft extending from a prover. Any leakage of fluid through the bearings and seals will migrate into the annular cavity within a housing and surrounding the shaft. A conduit or passageway in fluid communication with the annular cavity conveys the leaking fluid into a collection chamber. A float within the collection chamber will trigger an electrical or mechanical signal when the float rises a preset distance. If electrical, the signal is transmitted to an alarm unit to trigger a warning indicative of the amount of fluid in the collection chamber.