Retractable Optical Sensor Calibration Without Process Shutdown
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Solution Overview
Problem
Calibration and verification of optical sensors, particularly Raman analyzers, require process shutdowns due to manual removal and reinstallation of probes, leading to non-productive time and potential errors.
Innovation Solution
A retractable fitting system with a calibration unit and automated calibration procedure that allows optical sensors to be calibrated without process shutdown, maintaining integrity and enabling automated cleaning and verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual removal and reinstallation of probes is performed for calibration, then calibration can be done, but process shutdown is required and time is lost
Solution Approach 1:
The system separates the calibration function from the measurement function by introducing a dedicated calibration unit that can be independently activated. The calibration unit includes separate calibration targets and optical paths that allow calibration without removing the probe from the process medium, thus eliminating shutdown time while maintaining calibration accuracy.
Solution Approach 2:
A calibration unit acts as an intermediary between the optical sensor and the external calibration equipment. This unit provides calibration targets and reference materials that can be introduced into the optical path without requiring probe removal, enabling calibration to proceed while the probe remains in situ and the process continues uninterrupted.
2Measurement precision
If probe is removed from process for calibration, then calibration can be performed, but process integrity is compromised and cleaning protocols are required
Solution Approach 1:
The calibration function is extracted from the probe assembly itself and placed in a separate calibration unit. This allows calibration targets and reference materials to be introduced into the optical path without extracting or removing the probe from the process medium, thereby maintaining process integrity and eliminating the need for cleaning protocols.
Solution Approach 2:
The calibration unit serves as an intermediary that provides calibration references without requiring direct access to the process medium. Calibration targets are introduced through dedicated ports or optical paths that remain sealed to the process, ensuring that process integrity and contamination control are maintained throughout the calibration procedure.
3Productivity
If automated calibration system is implemented, then calibration time is reduced, but device complexity increases
Solution Approach 1:
The calibration unit is integrated with the existing probe housing and optical sensor assembly, combining calibration functions with the measurement system. This integration approach automates calibration procedures through coordinated movement of calibration targets and optical components while avoiding the need for completely separate automated calibration equipment, thus limiting the increase in overall system 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
Reduces shutdown times and resource usage, saving time and money by allowing fully automated calibration and verification of optical sensors.
Implementation Method 1
an optical sensor which is designed to measure at least one variable of a medium in a vessel
Implementation Method 2
the calibration unit comprises at least one light source, which emits light in the direction of the optical sensor in the calibration position
Implementation Method 3
the retractable fitting comprises one or more seals in the region of the opening, which seal the environment with respect to the service chamber
Data Source
AI summary
A measuring system includes: an optical sensor for measuring a variable of a medium in a process vessel; a retractable fitting for mounting the optical sensor, including a hollow cylindrical housing with a housing wall, which includes a service chamber within the housing, and an immersion tube, which is axially movable within the housing between a service position, in which the immersion tube is withdrawn from the medium, and a process position, in which the immersion tube is in the medium, wherein the optical sensor is disposed in the immersion tube, and wherein the housing wall includes an opening adjacent the service chamber; and a calibration unit movably mounted in the opening between a rest position and a calibration position, wherein the calibration unit is outside the service chamber in the rest position, and wherein the calibration unit is in optical contact with the optical sensor in the calibration position.