Sensor-Carrying Process Gasket for Simpler Vessel Measurement
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Solution Overview
Problem
The complexity and cost of installing process variable sensors in industrial control systems are increased due to the need for multiple connections and penetrations into process vessels, which reduces reliability and increases the size and weight of the transmitter installations.
Innovation Solution
A process gasket is used to carry a process variable sensor, reducing the number of connections required by forming a seal with the process fluid vessel, allowing the sensor to be exposed to the fluid through existing penetrations and using integrated or separate measurement circuitry for data output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional piping and flange connections are used to couple process variable sensors to process fluid, then the sensor can measure process variables, but the installation complexity and cost increase due to multiple connections and penetrations
Solution Approach 1:
The process gasket combines multiple functions into a single component: it provides sealing between flanges, carries the process variable sensor, and creates the necessary fluid access. This merging eliminates the need for separate impulse lines, additional flange connections, and multiple penetrations, thereby reducing installation complexity while maintaining measurement reliability
Solution Approach 2:
The gasket is designed as a multi-functional element that simultaneously serves as a seal, a sensor mounting platform, and a fluid access provider. By making the gasket universal in its functions, the invention reduces the number of separate components and connections needed, directly addressing the contradiction between reliability and installation complexity
2Reliability
If multiple connections and penetrations are used to access process fluid, then the sensor can be coupled to the process fluid, but the size and weight of the transmitter installation increase
Solution Approach 1:
By combining the seal, sensor carrier, and fluid access functions into a single gasket component, the invention eliminates the weight of separate impulse lines, additional flanges, and multiple connection hardware. This merging directly reduces the overall weight of the transmitter installation while maintaining seal reliability
3Measurement precision
If multiple connections are used to couple sensors to process fluid, then the sensor can measure process variables, but the installation cost increases
Solution Approach 1:
The invention merges multiple installation steps and components into a single gasket assembly that can be installed in one operation. This reduces installation time, labor costs, and material costs while maintaining the precision of process variable measurements through the integrated sensor design
4Ease of operation
If penetrations into process vessels are increased, then the sensor can be coupled to the process fluid, but the system reliability decreases
Solution Approach 1:
The gasket is designed to provide all necessary fluid access functions through a minimal number of penetrations. By making the gasket multi-functional, the invention reduces the number of penetrations required while maintaining ease of operation for fluid access, thereby improving system reliability
Data Source
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AI summary
A process variable transmitter (260) for sensing a process variable of process fluid in an industrial process includes a process gasket (200) having a surface configured to form a seal with a process vessel face. The process gasket (200) is exposed to the process fluid through an opening in the process vessel face. A process variable sensor (220) is carried by the process gasket (200) and configured to sense a process variable of the process fluid and provide a sensor output (222). Measurement circuitry (282) coupled to the process variable sensor (220) provides a process variable transmitter output related to the process variable output.