The method and apparatus described herein relate generally to fluid level sensors and, more particularly to in-situ verification of level output signal accuracy of differential temperature fluid level sensors.
It is necessary, in many instances, to monitor the fluid depth in containers or in storage or holding pools. Where the stored fluid is potentially toxic, the requirement for fluid depth monitoring is of enhanced importance.
Along with appropriate sensors and readout systems, the persons responsible for the fluid storage need to feel confident that the depth or fluid level gauge is accurate at all times. Some kind of operability verification apparatus and procedure is required. In the past, removing the gauge to a remote location for calibration and function testing was the recognized way to verify the operability and accuracy of the system.
Embodiments of the concept as shown herein speed up and simplify the process of calibration and verification of accuracy of a differential temperature depth or fluid level gauge.
The fluid level gauge itself is known and operates on the known heated sensor principle. Examples of elongated, continuous sensing fluid level gauges are described in U.S. Pat. Nos. 4,977,385 and 5,167,153. An elongated resistance temperature detector (RTD) sensing wire or cable is mounted inside an elongated, mineral-filled tube. The mineral is electrically insulative and thermally conductive. This RTD provides continuous fluid level readings which result from the resistance changes which result from wet/dry changes at different levels along the RTD.
In some embodiments of elongated continuous sensing gauges, there are heater elements, usually wires, adjacent to unheated elements of similar size. A relatively low electrical power, about 0.5 watt per foot of wire length, for example, is applied to the heated wire. This causes the electrical resistance to increase in the dry RTD wire. Parallel to the heated wires are unheated, or reference, wires. When the wire or the surrounding tube and mineral filling are submerged, the fluid dissipates heat from the heated wire and the RTD resistance decreases. The change, or delta, of the resistance is a proportional measure of the fluid level and associated instrumentation provides readings of the fluid level in the container. Calibration prior to installation is necessary for this output to properly indicate fluid level.
The RTD element may be heated by an adjacent, parallel elongated heater wire supported by an insulator or it may be self-heated and function as a heater and as a sensor on a possible time-shared basis. An electrical signal proportional to the fluid level is connected to electronic circuitry at a remote location (the instrumentation) which provide appropriate readouts of the fluid level.
In order to verify proper operation of the RTD gauge without removing the apparatus from the fluid container, the sensor, which includes the RTD, is encased in a still well, which is open at the bottom, similar in length to the RTD element. When operating normally, the fluid is in the still well is at the same depth as is the surrounding fluid in the container.
Discrete or point RTD sensors are exposed on the inner tube at predetermined levels. Pressurized air or an appropriate inert gas is pumped into the top sealed still well, thereby lowering or reducing the fluid therein to any desired level. Readings of the RTD gauge are taken as the fluid reaches the desired predetermined levels, such as, 100%, 75%, 50%, and 25% of maximum fluid level, and the outputs are compared with the known levels, as determined by the discrete, or point sensors and, selectively, by the applied gas pressure. Basic point sensor heated RTD type sensors are described in U.S. Pat. Nos. 3,366,942, 3,898,638, and 6,340,243, for example. Point sensors operate on the same principle as described above. Fluid dissipates more heat than does air, so when a heated sensor is dry, its resistance is higher than when it is wet and indicates that the fluid level is at or above the point sensor. The unheated sensor is employed as a reference sensor. Alternatively, a single sensor can be alternately heated and unheated to provide both functions on a time-shared basis, or if the media temperature remains with 50° F. of a predetermined value, the sensor can be powered sufficiently so that a reference sensor is not needed.
Corrective action can be taken if the sensor fluid level differs by a predetermined amount from the levels determined from the point sensors. In some instances the gauge may be recalibrated electronically, without removing it from the container.
Alternative apparatus and testing methods are described herein.
The advantages and features of this concept will be more readily perceived from the following detailed description, when read in conjunction with the accompanying drawing, wherein:
With reference now to the drawing, and more particularly to
Elongated, continuous sensing element 13 is a hollow perforated tube with elongated RTD elements inside, as will be described in greater detail below. Tube 13 is encased within still well 14 with space 16 therebetween. Tube 13 is formed with a multiplicity of holes 15 to allow the fluid to contact the RTD elements inside and allow heated fluid to escape.
Nipple 17 is connected to line 18 for transportation of a gas to and from space 16. The other end of line 18 is coupled to pressure regulator 21 within control box 22. Pressure gauge 23 provides an instantaneous pressure reading of the gas applied to line 18. The pressure regulator is conventional and includes an ON/OFF switch or control to selectively open and close the line to the pressurized gas.
Tank 24 represents a source of pressurized air or some other gas such as nitrogen. The pressurized gas may be supplied from any source and need not be an actual tank. Pressurized gas is coupled through valve 25 to pressure regulator 21 through line 26.
As an alternative to a manually operated valve on the pressure regulator, any kind of electronic or solenoid valve may be operated by a simple push button or a rheostat, or it could be on a timer, or it could be operated remotely from a control that is connected by wires or wirelessly to the valve control. A remote pressure gauge could also be employed to enable the operator to have full information of the fluid level and the condition of the gauge from a distance. The tank, control box, and line 18 are removable and are only used for calibration and verification tests.
As set up in this example, the maximum fluid level (100%) is 20 feet above the base (0%) level. The bottom 31 of gauge 13 is at or slightly below the base fluid level. For testing purposes, interim fluid levels (75%, 50%, and 25%) are shown. Of course, other interim levels may be employed, and the fluid depth is not limited to 20 feet. It could be less or much more, ranging from as low as 10 inches to 60 feet or more.
To reduce the level of fluid in the still well a gas pressure of 0.433 pounds per square foot (psi) per vertical foot is required to be applied through line 18 to space 16. Assuming the starting level is maximum, or at the 100% level, to reduce the fluid level by 25% (5 feet in this example), the valve in control box 22 would be opened sufficiently to allow pressure in line 18 to build to 2.165 psi, as shown on gauge 23, thereby forcing the fluid level in still well 14 down by 5 feet. Increasing the pressure to 4.33 psi reduces the fluid level in space 16 to 10 feet. Increasing the pressure at the top of space 16 to 6.495 psi forces the level of the fluid in the still well to 5 feet, or at the 25% level. Zero level is achieved by applying 8.66 psi of pressure to the top of the still well space 16 for a 20-foot fluid depth. Intermediate levels can be verified by applying 0.433 psi per vertical foot to any desired level from 0-20 feet in this example.
As stated previously, elongated gauge 13 is a conventional continuous sensor. Added to gauge 13 are point sensors 32, 33, 34, 35, and 36. These provide predetermined readings of fluid level in still well 14 at 100%, 75%, 50%, 25%, and 0% depths, respectively. While shown in
Whenever the validity of the fluid level output readings of gauge 13 is to be checked, without removing the entire gauging apparatus 37 the process outlined above is initiated. At the starting point, the fluid level in container 12 can be anywhere between full (100%) and empty (0%). The fluid level in space 16 in the still well will be the same as the level in the container at the outset. A third factor is the pressure shown by gauge 23. When the level of the fluid in still well 14 is at the 50% level for this 20-foot example, the readout for the RTD and point sensor 34 should be the same, that is 50% or 10 feet. Also, the pressure shown on gauge 23 should read 4.33 psi.
Assuming the fluid level at the start of the validity test is at 100%, pressure is first applied through line 18 to reduce the fluid level in space 16 to, for example, the 75% level, as determined by readouts in remote instrumentation box 41. The electronic level indicator in instrumentation 41 would read one foot below full when a pressure of 0.433 psi is applied. For permanent installations, there are two sets of level reading systems in box 41. One is for instantaneous and continuous fluid level readings of the fluid 11 in container 12. The other is to provide readings from the point sensors on gauge 13 in the still well when validation tests are performed. When sensor 33 goes dry (it is no longer immersed in the fluid), a reading will indicate the 75% level, or 15 feet in this example. The actual container fluid level reading should show exactly the same reading from gauge 13. To be sure the fluid level in space 15 is at the 75% level for test purposes, the pressure applied to still well 14 is toggled so that sensor 33 is alternately wet and dry to be sure the dry level reading accurately reflects a 75% level. Pressure gauge 23 should read 2.165 psi, providing further confirmation of the fluid level in the still well. This factor shows that pressure gauge readings are a third check on fluid level sensor accuracy. Any two of these readings can be compared to indicate sensor accuracy.
Readings are then taken in the same way at the lower levels, by engaging point sensors 34, 35, and 36 in order to cheek the point sensor level readings against the readings of continuous level gauge 13 as the fluid level is reduced during validation testing, and obtaining confirmation from gauge 23. Instrumentation box 41 also includes a conventional signal comparator which provides a visual and possibly an audible indication of the coincidence of the sensor level signals. If fluid level indications from the sensors do not agree by a chosen predetermined amount, 1 or 2% for example, an audible alarm can be activated along with a visual signal of “error” being provided. The visual pressure readings on gauge 23 provide a third check of fluid level indication accuracy. If gauge 23 shows 4.33 psi but one or both level sensors do not show a fluid depth reduction of ten feet, there is lack of coincidence and the operator knows some aspect of the level sensor system is incorrect. Thus the accuracy of electronic output 41 is concurrently validated at any desired level with respect to pressure gauge 23.
It should be noted that the testing can be accomplished, as above described, in the reverse order, that is, the fluid in the still well can be forced to 0% initially, so that all point and continuous sensors are dry. Then pressure in space 15 is reduced sequentially to hit any increasing fluid levels, especially at 25%, 50%, 75%, and 100%. As a matter of fact, the testing can be double checked by starting at the top, taking readings at the different pre-established levels, and then taking parallel readings from the bottom up. Air may be allowed to escape through nipple 17, or a separate exhaust valve may be included at the top of still well 14 or in top meter element 43.
As a detail, top mounting flange arrangement 42 seals the top of still well (stand pipe) 14 and secures gauge 13 and still well 14 in fixed relationship when tube 18 is connected to nipple 17. This couples the signals from gauge 13 as well as from point sensors 32-36 to remote instrumentation 41.
A cross section of a typical continuous sensing RTD cable is shown in
The RTD wires are normally configured in pairs because they are a long loop, extending full length of casing 51 and returning to the electronics in enclosure 41.
Examples of dimensions involved in the RTD cables are: casing 51 is about 0.118 inches in diameter, perforated tube 13 may be about 3 inches in diameter, and still well 14 may be 4.0-4.5 inches or larger, in diameter. The mineral filling may be magnesium oxide (MgO) or any other substance that is stable, is electrically insulative, and is at least somewhat thermally conductive. RTD wires 54 (
An alternative structural embodiment, which operates with the same principles, is shown in
Pressurized gas is applied via inlet 76 and exhaust, typically somewhat heated, gas leaves through outlet 77. RTD cable 81 could be the reference RTD and cable 82 could be the heated RTD. Point RTD sensors 84 are shown mounted on tube 83. These are shown in pairs because point sensors are often comprised of a heated or active sensor and a nearby unheated or reference sensor. Tube 83 provides a conduit for the point RTD connecting wires.
A top sectional view of
To perform the verification of functionality tests employing the apparatus of
While the embodiments described above are preferred, in that the testing can be conducted without moving the sensor apparatus from the container, an alternative manner of employing the same technical principles is shown in
Another alternative embodiment of the verification concept is shown in