Sensor Network Inverse Modeling for Reactor Condition Monitoring
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Solution Overview
Problem
In process plants, such as petroleum refineries, obtaining accurate internal condition measurements is challenging due to high temperatures, pressures, and flow velocities, making direct internal measurements intrusive, costly, and limited in scope, while non-intrusive methods can be hazardous and expensive.
Innovation Solution
A method and system that obtain multiple sets of parameter measurements from the outside surface of components, using a predetermined model to develop a continuous surface condition profile, allowing for the estimation of internal conditions without direct internal measurement, by processing data from sensors arranged along multiple dimensions, including linear combinations of basis functions and coefficient generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If permanent temperature or pressure probes are installed inside the component, then direct internal measurements can be obtained, but the measurement system becomes intrusive and limited to fixed measurement points
Solution Approach 1:
The patent uses the component wall itself as an intermediary medium. Temperature sensors are placed on the outer surface to measure wall temperature, which then serves as a proxy to infer internal conditions through heat conduction modeling, eliminating the need for direct internal probe installation
Solution Approach 2:
The patent replaces direct mechanical contact measurement (internal probes) with indirect thermal field measurement (external surface sensors combined with heat conduction equations). The mechanical intrusion of probes is substituted by thermal field analysis through the wall material
2Ease of operation
If non-intrusive radiation methods are used to measure internal conditions, then direct measurement without installation is achieved, but the equipment becomes expensive and hazardous
Solution Approach 1:
The patent uses inexpensive, easily replaceable temperature sensors on the outer surface instead of expensive radiation sources. The sensors are simple thermocouples or RTDs that can be safely installed and replaced without special licensing or safety protocols required for radiation equipment
Solution Approach 2:
The patent converts the potentially harmful radiation method into a safe thermal conduction method. Instead of using penetrating radiation that requires hazardous materials, the solution uses natural heat conduction through the wall, turning a dangerous approach into a safe one by exploiting the same thermal field that naturally exists in the system
3Measurement precision
If sensor density is increased to obtain high spatial frequency estimates of wall profile, then measurement accuracy improves, but installation and maintenance cost increases
Solution Approach 1:
The patent uses a sparse array of sensors (partial action) rather than dense coverage. By placing sensors at strategically selected locations and using heat conduction equations to interpolate between them, the system achieves accurate continuous wall temperature profiles without the cost of installing sensors at every possible location
Solution Approach 2:
The patent transitions from a one-dimensional sensor array concept to a two-dimensional analysis by incorporating heat conduction equations that account for temperature distribution through the wall thickness and along the surface. This allows sparse surface sensors to provide comprehensive three-dimensional temperature field information when combined with the mathematical model
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
This approach enables accurate and efficient estimation of internal conditions, such as temperature distributions, with improved spatial frequency information and reduced sensor requirements, enhancing operational safety and cost-effectiveness.
Implementation Method 1
The model includes a forward solution to an equation describing a condition within the component... The predetermined model can be based a heat diffusion equation
Data Source
AI summary
Methods and systems for detecting a condition within a component of a process plant, including obtaining a first and second set of parameter measurements from a first and second plurality of sensor locations along a first dimension of an outside surface of a component, processing the first and second set of parameter measurements to develop a continuous surface condition profile of the component using a predetermined model. The predetermined model includes a forward solution to an equation describing the condition and is linearly separable in at least two dimensions corresponding to the first and second dimension. The model includes an inverse solution to the equation to provide a set of coefficients corresponding to a set of basis functions of the forward solution based on the first and second set of parameter measurements.