Rollover Detection Proof Testing Using Simulated Stratification Data
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Solution Overview
Problem
Existing rollover detection systems in LNG tanks require physical inspection and measurement processes that are time-consuming and inefficient, posing a risk of undetected failures.
Innovation Solution
A method and system for proof testing rollover detection systems by simulating temperature and density values indicative of stratification, allowing verification of the system's functionality without physical inspection, using a proof testing control unit to provide simulated values to a sensor arrangement and a rollover evaluation unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical measurement with LTD device is used for proof testing, then measurement accuracy is ensured, but testing time increases and efficiency decreases
Solution Approach 1:
The patent uses simulated temperature and density values as copies of actual physical measurements to test the rollover detection system. Instead of performing physical measurements with LTD devices, the system injects simulated sensor data that replicates stratification conditions, allowing rapid validation of detection algorithms without time-consuming field measurements.
Solution Approach 2:
The patent replaces the mechanical measurement system (LTD device with physical probes) with a data simulation system. The proof testing control unit generates simulated temperature and density values that substitute for actual sensor readings, eliminating the need for physical intervention in the tank while maintaining testing validity.
2Reliability
If physical inspection and modification of tank components is performed, then system functionality is verified, but operational complexity and cost increase
Solution Approach 1:
The patent introduces a proof testing control unit as an intermediary that communicates simulated sensor data to the rollover detection system through the existing communication interface. This intermediary layer allows functionality verification without direct physical access to tank components, simplifying the testing process while maintaining reliability validation.
Solution Approach 2:
The system creates virtual copies of sensor data and communication protocols to test the entire detection chain. By replicating how actual sensors would communicate with the detection system, the patent verifies functionality without physical inspection or modification of tank components.
Data Source
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AI summary
A method of proof testing a rollover detection system in a field device system (100) comprising a fill level sensor (102) for determining a fill level (116) of a product (118) in a tank (114), and a sensor arrangement (106a-f) configured to determine at least one of temperature and density at multiple locations in the tank, the method comprising: by a proof testing control unit (108), providing (400) simulated temperature and/or density values for the sensor arrangement, the simulated temperature and/or density values being indicative of stratification of a product in the tank; by a system hub (110), acquiring (402) a fill level of the product in the tank, and the simulated temperature and/or density values for the sensor arrangement, and providing (404) the fill level, and the simulated temperature and/or density values to a rollover evaluation unit (112); and by the system hub, receiving (406), from the rollover evaluation unit, an output indicative of a risk of rollover in the tank resulting from the fill level and the simulated temperature and/or density values.