Remote Pressure Sensor Testing With Constriction Back Pressure
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Solution Overview
Problem
Existing pressure sensors and relief valves in storage silos for particulate materials are often located in inaccessible areas, making maintenance complex and time-consuming, and can become clogged or fail, leading to potential silo damage from excessive pressure.
Innovation Solution
A pressure sensor assembly with a constriction in the channel for generating back pressure and a telescopic cylinder for testing the pressure relief valve remotely, allowing for easier inspection and operation from ground level, and a removable pressure relief valve assembly for quick maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure sensor and pressure relief valve are located in the upper internal region of the silo for monitoring and safety functions, then the safety monitoring capability is improved, but the accessibility for maintenance and testing deteriorates
Solution Approach 1:
The system is divided into two functional segments: the pressure sensor assembly that remains installed in the upper internal region for continuous monitoring, and the external testing apparatus that can be connected and disconnected as needed. This segmentation allows the sensor to maintain its safety monitoring function while enabling external access for testing and maintenance without requiring removal from the silo.
Solution Approach 2:
A testing interface or connection mechanism is introduced as an intermediary between the externally accessible testing apparatus and the pressure sensor assembly. This intermediary allows test signals to be transmitted to the sensor and test results to be retrieved, enabling maintenance operations from ground level without direct access to the upper internal region where the sensor is installed.
2Reliability
If the pressure relief valve is set to open at high pressure (around 50 millibar) to prevent over-pressurisation, then the safety protection is improved, but the risk of clogging and sealing shut increases
Solution Approach 1:
Regular testing of the pressure relief valve is performed using the externally accessible testing apparatus before normal operation begins. This preliminary action ensures the valve is properly functioning and not clogged, allowing operators to detect and address clogging issues before they lead to valve failure during critical safety events.
Solution Approach 2:
The testing system provides feedback on the operational status of the pressure relief valve by measuring its response to test signals. This feedback mechanism allows operators to verify that the valve is not clogged and is ready to function properly when needed, enabling early detection of sealing issues before they compromise safety.
3Ease of operation
If the pressure sensor assembly uses a constriction in the channel to generate back pressure for testing, then the testing capability is improved, but the device complexity increases
Solution Approach 1:
Instead of making the entire channel complex, a localized constriction is introduced only in the specific region where back pressure generation is needed for testing. This local modification provides the necessary testing functionality without requiring complex mechanisms throughout the entire pressure sensor assembly, thereby limiting the increase in overall device complexity.
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
Facilitates remote testing and maintenance of pressure sensors and relief valves, reducing the risk of silo damage by ensuring proper functionality and simplifying the maintenance process.
Implementation Method 1
a constriction is formed in the channel, the pressure sensor assembly further comprising: an air injection system adapted to inject a test pulse of air into the enclosed chamber, between the constriction and the second opening, wherein the constriction is configured to create back pressure in the enclosed chamber in response to the test pulse of air
Data Source
AI summary
A pressure sensor assembly (19) for remote testing of a pressure sensor (15) adapted to monitor the air pressure developed in an interior (21) of a container (1), the pressure sensor assembly (19) comprising: an enclosed chamber having (25): a first opening (31) arranged to communicate with the interior of the container (1); and a second opening (33) arranged to communicate with the pressure sensor (15) for monitoring air pressure developed in the interior (21) of the container (1); wherein the chamber (25) defines a channel for transmission of pressure between the first opening (31) and the second opening (33) and wherein a constriction (55) is formed in the channel, the pressure sensor assembly (19) further comprising: an air injection system (45) adapted to inject a test pulse (47) of air into the enclosed chamber (25), between the constriction (55) and the second opening (33), wherein the constriction (55) is configured to create a back pressure in the enclosed chamber (25) in response to the test pulse of air (47), and functional operability of the pressure sensor (15) is verified based on the pressure measured in response to the test pulse of air (47).