Radar Level Gauge Fault Detection in Floating Roof Tanks
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Solution Overview
Problem
Existing systems for monitoring the level of a medium in a tank with a floating roof are costly and inefficient, as they require multiple radar level gauges and lack effective diagnostics for fault condition detection.
Innovation Solution
A method and system utilizing a radar level gauge and a level measuring device to detect fault conditions in the measurement of the level of a medium in a tank with a floating roof, by determining and analyzing deviations between the level of the medium and the floating roof, and generating alerts for fault conditions using Big Data analysis and outlier detection methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple radar level gauges are used for monitoring, then measurement reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the functions of multiple radar level gauges into a single radar level gauge by integrating a reference measurement system that measures both the medium level and the floating roof level simultaneously. This single device performs what previously required multiple separate devices, reducing system complexity while maintaining measurement reliability through comparative analysis of the two measurement channels.
Solution Approach 2:
The radar level gauge is designed to perform multiple functions: it measures both the medium level directly and the floating roof level indirectly (via reference distance measurements), and additionally detects fault conditions by analyzing deviations between these measurements. This multi-functionality replaces the need for separate monitoring devices.
2Reliability
If multiple radar level gauges are deployed, then measurement coverage is improved, but cost increases
Solution Approach 1:
The system merges the capabilities of multiple expensive radar level gauges into a single device that performs all necessary measurements (medium level, floating roof level, and fault detection) using integrated reference distance measurements and deviation analysis, significantly reducing the overall system cost.
Solution Approach 2:
The single radar level gauge performs self-diagnosis by comparing its own measurements against reference measurements, automatically detecting fault conditions without requiring additional monitoring devices or manual inspection, thereby eliminating the need for costly redundant systems.
3Reliability
If manual inspection of floating roof is performed, then fault detection is possible, but safety risks and time loss increase
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated electronic monitoring system that continuously measures levels and detects faults automatically, eliminating the need for personnel to physically inspect the floating roof and thereby reducing both safety risks and inspection time.
Solution Approach 2:
The monitoring system operates continuously, providing constant surveillance of the floating roof and medium level, whereas manual inspection can only occur periodically. This continuous monitoring enables immediate fault detection without the time loss associated with scheduling and executing manual inspection cycles.
4Ease of operation
If threshold-based fault detection is used, then simple monitoring is achieved, but measurement precision is insufficient
Solution Approach 1:
The system dynamically adjusts the evaluation criteria from simple fixed thresholds to adaptive reference distance deviations that account for varying operating conditions. By measuring deviations from learned reference values rather than using static thresholds, the system maintains operational simplicity while significantly improving fault detection precision.
Solution Approach 2:
The system incorporates feedback mechanisms where measurement deviations are continuously analyzed and compared against reference values, allowing the system to adapt to changing conditions and improve its fault detection precision over time while maintaining ease of operation through automated analysis.
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
The system provides a reliable and cost-effective means to detect fault conditions in the measurement of the level of a medium in a tank with a floating roof, enabling early addressing of issues and reducing the need for frequent inspections, thereby enhancing safety and operational efficiency.
Implementation Method 1
A radar level gauge, mounted in a fixed position on the tank, is emitting radar signals in the direction of the floating roof and receiving the echo signals reflected on the surface of the floating roof
Implementation Method 2
receiving the echo signals reflected on the surface of the floating roof
Implementation Method 3
a TDR (Time Domain Radar) measuring device is used
Data Source
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AI summary
The invention concerns a Method for detecting a fault condition in the measurement of the level of a medium (1) in a tank (2) with a floating roof (3), whereby the floating roof (3) is floating on the medium (1) and is vertically guided in the tank (2), providing a radar level gauge (4) and a level measuring device (5), whereby the radar level gauge (4), mounted in a fixed position on the tank (2), is emitting radar signals in the direction of the floating roof (3) and receiving the echo signals reflected on the surface of the floating roof (3), and whereby the level measuring device (5) is measuring the level of the medium (1) in the tank (2), comprising the steps of: a) determining and recording data representing the level of the floating roof (3) during a defined time interval, whereby the defined time interval comprises some filling/emptying cycles of the medium (1) in/from the tank (2), b) determining and recording data representing the level of the medium (1) in the tank (2) during said time interval, which comprises some filling/emptying cycles of the medium (1) in/from the tank (2), c) determining the deviations between the data representing the level of the medium (1) in the tank (2) and the corresponding data representing the level of the floating roof (3), d) centering the deviations between the stored data representing the level of the medium (1) and the level of the floating roof (3) reduced by the thickness (D) of the floating roof (3) with the corresponding level data, e) generating an alert message that a fault condition in the level measurement is detected if the centered deviations exceed a tolerance threshold in at least one height of the tank (2).