Retrievable Subsea Sensor with Pressure Actuator
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Solution Overview
Problem
Sub-sea oil and gas processing systems face challenges in accessing and replacing sensors due to harsh conditions and the need for leak-free operations, leading to costly and risky methods that require stopping production and potentially damaging components.
Innovation Solution
A retrievable sensor device with a sensing element, separation diaphragm, and actuator that allows for easy installation and removal without stopping fluid flow, using a sensor cavity and actuator to adjust pressure and prevent leakage, enabling remote access and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are disposed in a flange or bore in a pipe wall to allow direct measurement of process fluid, then measurement accuracy is improved, but accessibility for repair and replacement deteriorates
Solution Approach 1:
The sensor system is divided into separate components: a sensor assembly that can be removed from the housing, and a housing that remains in the pipe wall. This segmentation allows the sensor to maintain direct contact with process fluid for accurate measurement while enabling easy removal and replacement of the sensor assembly without disturbing the pipe wall installation.
Solution Approach 2:
The sensor assembly is nested within the housing structure, which itself is installed in the pipe wall. This nested configuration allows the sensor to be positioned for direct measurement while being accessible through the housing opening, enabling repair without removing the entire pipe wall assembly.
2Productivity
If existing techniques are used to retrieve and replace sensor components, then production can be maintained, but the whole construction must be pulled to the surface requiring lengthy stoppage and incurring high costs
Solution Approach 1:
The sensor assembly is extracted as a separate, independently removable component from the housing and pipe wall system. This extraction design allows the sensor to be replaced in-situ without pulling the entire construction to the surface, enabling quick replacement while production continues and eliminating lengthy stoppages.
3Ease of operation
If sensors are made readily accessible for easy removal, then maintenance becomes easier, but the risk of process fluid leakage and component damage increases
Solution Approach 1:
Pressure equalization is performed as a preliminary action before removing the sensor assembly. The actuator equalizes the pressure between the process fluid side and the sensor cavity, eliminating pressure differential that could cause leakage or damage during removal. This preliminary pressure balancing enables easy sensor removal while maintaining system reliability and preventing leaks.
4Reliability
If an actuator is added to adjust pressure during installation and removal, then component damage and leakage are prevented, but device complexity increases
Solution Approach 1:
A pneumatic or hydraulic actuator is used to adjust and equalize pressure in the sensor cavity. This actuator mechanism, while adding some complexity, provides reliable pressure control that prevents damage and leakage during sensor installation and removal, ensuring system integrity and safe operation.
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 sensor replacement without stopping production, reduces risk of damage, and maintains a leak-free system, facilitating easier and safer maintenance of sub-sea sensors.
Implementation Method 1
The actuator is configured to equalize a pressure differential between the sensor cavity and the process fluid. The actuator can be configured to adjust a volume of fluid in the sensor cavity and thereby alter a pressure of the sensor cavity.
Implementation Method 2
a separation diaphragm and a sensor cavity in fluid communication with the sensor and the separation diaphragm such that the sensor cavity is configured to transfer a sensed condition received by the diaphragm to the sensor for measurement
Data Source
Figure 1
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AI summary
Retrievable sensor devices and methods are provided that can be easily installed and removed from a sub-sea system without the need to stop the flow of working/process fluid. In particular, a retrievable sensor is provided that can be configured to be located remote from the process fluid to allow for easy access. In other embodiments, an actuator is provided that allows for pressure adjustments to be made during installation and/or removal of the sensor so as to avoid damage to the sensor and/or other system components and to avoid any process fluid/material leakage. Methods are also provided for installing/removing a retrievable sensor, as well as for adjusting a pressure of a retrievable sensor.