1. Field of the Invention
The present invention relates generally to systems for managing stratified layers of liquids in containers. More particularly, the present invention relates to a sonar sensing device (or other types of devices, such as ultrasonic sensors, electrical impedance sensors or optical sensors), disposed in a liquid storage tank, for identifying stratified layers of liquids and for enabling an operator to accurately add to or remove a selected layer of liquid.
2. Related Art
It is not uncommon for liquid storage tanks to contain liquids of different densities. For example, tanks for the storage of natural gas, crude oil, petrochemicals, wastewater, etc., frequently include, for example, a layer of water, along with one or more layers of less dense hydrocarbon materials. These will naturally separate into stratified layers of different liquids, the more dense liquids naturally resting at the bottom of the tank. Because of this phenomenon, a liquid that is desired from the tank may not be the liquid at the bottom of the tank. Consequently, apparatus and methods have been developed to allow extraction of or addition to liquids from different levels in liquid containers such as storage tanks. Useful apparatus and methods are disclosed in U.S. Application Ser. No. 60/651,239 filed Feb. 9, 2005, and assigned to the same Assignee as this application, the disclosure of which is incorporated herein in full.
In order to determine the location of a desired layer of liquid in a storage tank, various types of sensing systems and methods have been devised. These systems and methods allow a user to identify the various stratified layers, and determine the relative volume of the each layer of liquid in the tank. For example, fixed-height sonar sensing equipment in an oil storage tank may readily identify the precise point where the light-oil layer ends and the heavy-oil layer begins, for example, 26″ down from the top of the tank. Using this information, the operator may then go to the top of the tank and manually position an outlet valve at the 26″ level, and then remove the light-oil layer.
The outlet valve may incorporate a measuring device that protrudes through the top of the tank, to indicate the distance from the inlet valve to a fixed point on the top of the tank. In such cases the operator goes to the top of the tank to see the measuring device in relation to the fixed point and to manually position the inlet of the valve. The positioning of the valve may be automated and controlled without going to the top of the tank.
At present, fixed-height sensors must generally be installed through the tank wall. Unfortunately, this may not be practical to install on tanks that are currently in service. Further, a fixed-height sensor must be installed as near the bottom as possible, yet if the sensor is installed too near the bottom, BS&W (bottom sediment & water) could engulf the sensor, rendering it ineffective. Likewise, if the sensor is installed too high up in the tank, the liquid could drop below the level of the sensor, again rendering it ineffective. Another limitation of fixed-height sensors, which must reside near the bottom of the tank and face upward, is the tendency of sedimentation in the tank to settle on the face of the sensor, causing its signal to degrade and, ultimately, to be eliminated altogether.
It has been recognized that it would be advantageous to develop an automated system that would allow the monitoring of a liquid storage tank and the accurate, remote management of a stratified layer of liquid from a tank.
In accordance with one aspect thereof, a variable elevation, in-tank sonar transducer may be used with a telescoping valve, a motorized drive unit for adjusting the telescoping valve; an external power source; and wireless, data-transmission/reception technology, allowing for long-range remote monitoring and control of the telescoping valve based on sonar data. Further, a desk-top computer software application may enable an operator to view a graphical representation of each tank and with the computer providing various types of analytical reports for individual tanks, as well as for groups of tanks in a region. Additionally, a hand-held computer device may be used on-site to monitor the storage tank and to adjust the valve.
The in-tank sonar sensing device may be of any type (fixed-height, through-the-wall; variable-height on a float system; bi-directional, transducer mounted to the housing for the inlet/outlet orifice of a telescoping liquid management valve). The operator, working on top of the storage tank, utilizes information from the sonar system and manually adjusts (either by crank and gears moving an adjusting rod or by moving the adjusting rod by hand) the inlet/outlet orifice of the telescoping valve to a precise point corresponding with a stratified layer of liquid. For example, the sonar system may identify the light oil layer as beginning 12″ down from the top and extending to 26″ down from the top of the tank. Using this information, in conjunction with the measuring and adjusting rod on the telescoping valve, the operator may position the orifice of the valve at or near the 26″ level.
The sonar transducer and other devices for determining the level of each liquid may accurately identify each transition between different types of liquids. When the transition is readily identifiable, the orifice may be positioned at or near the transition of the selected liquid above the unwanted liquid. When the transition is not clearly identifiable, the orifice may be positioned a fixed distance above the zone where the transition takes place.
The sonar transducer may be a bi-directional, multi-phase transducer mounted to the inlet/outlet orifice housing of a telescoping valve with a motorized drive unit for adjusting the position of the orifice, as well as other components listed above. By mounting the transducer to the orifice housing, the sonar console knows precisely where the valve is located in relation to the stratified layers.
The sonar transducer may be mounted to a floating ring-shaped device that encircles the measuring and adjusting rod and floats on top of the clean oil layer.
A sonar transducer may be mounted to a floating ring-shaped device that encircles a telescoping pole, or rod, that secures itself to the top and bottom of the tank via pressure and friction as the pole is lengthened via telescoping action during installation. The pole is positioned close enough to the inlet/outlet orifice to allow the transducer to detect the orifice of the telescoping valve even when the liquid in the tank is very low. The pole and float vertically align the transducer with the orifice of the telescoping valve. The transducer is positioned in such a way that the sonar consul knows precisely where the orifice is located in relation to the stratified layers.
A through-the-tank-wall, sonar transducer is placed to detect the orifice of the telescoping valve. A horizontal, protruding member may be added to the housing of the orifice of the telescoping valve to facilitate detection by the transducer.
A bi-directional, specified-height transducer may be attached to a telescoping pole at a fixed distance from the bottom of the tank specified at installation, depending on the type of tank in question and the types and quantities of stratified liquids in question.
Several sets of electrical impedance sensors may be attached to a telescoping pole to provide readings of the specific gravities of liquids in a tank at close intervals, for example, every ½ inch or every inch, and used in conjunction with a telescoping liquid management valve.
Several sets of optical sensors may be attached to a telescoping pole to provide readings of the specific gravities of liquids in a tank at close intervals, for example, every ½ inch or every inch and used in conjunction with a telescoping liquid management valve.
Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention, and wherein:
Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used-herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.
The invention advantageously combines components and methodology of electronic automation with telescoping liquid management valves and in-tank, variable-height sonar sensing equipment to enable the accurate management of stratified layers in an oil storage tank, or other similar type of tank in a different industry, without the operator physically going to the top of the tank and adjusting the position of the inlet/outlet orifice of the valve to the correct height.
Such tanks generally have three openings at the top (two 4″ openings 4,5, with threaded caps and one 8″ opening 6 with a spring loaded pressure cap), one large opening 7 in the side of the tank for entry into the tank, and a pressure release valve, designed to prevent pressure inside the tank from exceeding a certain, pre-specified limit.
Managing liquids at variable levels within a storage tank may be accomplished using an adjustable height inlet/outlet orifice of a telescoping liquid management valve disclosed in U.S. Provisional Patent Application Ser. No. 60/651,239 filed Feb. 9, 2005. The telescoping liquid management valve allows a user to selectively add to or remove a selected liquid layer from a tank containing multiple liquid layers. A multi-stage telescoping liquid management valve 8 designed to work in the lower portion of a storage tank is shown in
A sonar transducer 21 with a bi-directional pulse reflector 101 may be used as shown in
A motor-driven alternative to the cranking system of
A sonar transducer 44 may be affixed to a Viton® float 45 (Viton is a DuPont plastic that is highly resistant to high temperatures as well as hydrocarbons and other toxic chemicals) as shown in
A sonar transducer 53 is affixed to a Viton® float 50 that moves vertically on a guide pole 55 as shown in
The pole 55 has a threaded insert at one end 56, allowing the installer to lengthen the pole so that it compresses to the top and bottom of the tank. The pole has enlarged, flattened areas 57, 58 at either end, to prevent the pole from slipping against the top and bottom of the tank. The pole is positioned close to the valve so that the transducer 53 can identify the position of the inlet/outlet orifice of the liquid management valve, even when liquid in the tank drops very low.
A diagram of the front of a programmable, Bluetooth-enabled PDA is shown in
Application software for the PDA may have the following characteristics:
A radio transmitter/receiver operating in the 900 MHz range, which is available from MaxStream of Lindon, Utah, may be used to transmit sonar data to a central location. In some instances, a 900 MHz device may be sufficient. In other instances, however, a repeater, or cellular modem, may be necessary to transmit/receive data.
A bi-directional, specified-height transducer 59 is attached to a telescoping pole 61 as shown in
A through-the-wall, fixed-height sonar transducer 63, placed in close proximity to a valve, is shown in
An in-tank sonar transducer 66 used in combination with a variable height inlet/outlet orifice of a valve is shown in
An in-tank, sonar transducer 69 mounted to a surface float 70 is shown in
Several sets of electrical impedance sensors 72 attached to a telescoping pole 75 in such a way so as to provide readings of the specific gravities of liquids in a tank at close intervals, for example, every ½ inch or every inch is shown in
The sensor pole 75 is used in conjunction with a variable height inlet/outlet orifice. This type of sensor does not detect the position of the orifice, and, therefore, the position of the orifice is set to the desired elevation by hand, based on data gathered from the sensor. Alternatively, a software feature may be added to both the desktop application and the handheld application to calculate the necessary position of the orifice based on a pre-set zero point for the orifice. The software, based on input from the sensor, knows where the desired level is relative to the zero point, and makes the necessary adjustment based on calculations involving the diameter of the gears and the number of revolutions of the drive motor shaft necessary to move the orifice the required distance.
This approach may be used with pairs of optical sensors, rather than electrical impedance sensors. Optical sensors detect the clarity of the liquid in the different stratified layers of liquids.
A graphical interface for a desktop software application that could be used to proactively manage hundreds, or even thousands, of storage tanks throughout a local oil field or a world-wide oilfield is shown in
Salient features of the desktop software application are as follows:
By way of example, and without limitation, the invention may be described as a system for managing stratified liquids in a container, such as a storage tank, comprising a variable height, in-tank sonar transducer (the transducer is moveable vertically in the container), configured to identify liquid layers of differing densities and to indicate an elevation of the liquid layers, and a motorized drive unit for adjusting the orifice of a liquid management valve to intercept a selected layer. In a manual system, an extended hand-crank may be provided to enable an operator to manually position the orifice while standing on the ground.
An external power source and a hand-held computer with a visual read-out that receives feedback from the in-tank sonar sensor via a wireless connection may transmit coordinates to the motor drive unit regarding orifice positioning. The hand-held computer automatically turns the motor off when the orifice has reached the optimal position, or alternately, notifies the operator that the orifice is in the optimal position. The hand-held computer includes on-board memory for storing tank management data, for example, which operator removed—or added—liquid from or to a stratified layer, the date and time of the operation and the volume of the liquid transported. The hand-held computer functionality may be replaced by other types of computers at remote locations which communicate with the in-tank sensor via various long-distance vehicles, such as radio frequency or microwave.
It is to be understood that the above-referenced arrangements are only illustrative of the application of the principles of the present invention in one or more particular applications. Numerous modifications and alternative arrangements in form, usage and details of implementation can be devised without the exercise of inventive faculty, and without departing from the principles, concepts, and scope of the invention as disclosed herein. Accordingly, it is not intended that the invention be limited, but rather the scope of the invention is to be determined as claimed.