Conductivity sensor with void correction

• US 10,416,107 B2
• Filed: 08/19/2016
• Issued: 09/17/2019
• Est. Priority Date: 08/19/2016
• Status: Active Grant

• Current Assignee: Ecolab USA Incorporated (Ecolab, Inc.)
• Original Assignee: Ecolab USA Incorporated (Ecolab, Inc.)
• Inventors: Godfrey, Martin Ray, Tokhtuev, Eugene, Erickson, Joseph
• Primary Examiner(s): Assouad, Patrick
• Assistant Examiner(s): Pretlow, Demetrius R
• Application Number:
  US15/242,132
• Publication Number:
  US 20180052133A1
• Time in Patent Office: 1,124 Days
• Field of Search: 324600, 324649, 324658, 324663, 324669, 324670, 324684, 324685, 324686, 324691, 324693, 324718, 324720, 324721, 324722, 345173, 345174, 702 47, 702 52
• CPC Class Codes: G01N 27/025 a current being generated within the material by induction
• CPC Class Codes: G01N 27/07 Construction of measuring vessels; Electrodes therefor
• CPC Class Codes: G01N 27/08 which is flowing continuously
• CPC Class Codes: G01N 27/226 Construction of measuring vessels; Electrodes therefor
• CPC Class Codes: G01N 27/228 Circuits therefor measuring capacitance per se G01R27/26

Abstract

Systems and methods can be used for correcting for the presence of voids in a fluid when measuring the conductivity thereof. The conductivity of a fluid can be measured using a conductivity sensor. Capacitance electrodes can be used to measure the capacitance of the fluid. The measured capacitance affected by the fluid can be used in combination with the measured conductivity to determine a corrected conductivity value that compensates for possible voids in the fluid. Other parameters, such as the makeup or temperature of the fluid can be used in determining the corrected conductivity measurement. Some such systems include an annular housing and can be inserted or integrated into fluid flow systems so that fluid to be analyzed flows through an aperture defined by the annular housing.

Claims

1. A system comprising:

a conductivity sensor for measuring the conductivity of at least a first portion of a fluid sample;

a first capacitance electrode;

a second capacitance electrode; and

a controller configured to

determine a measured conductivity from the conductivity sensor;

determine a measured capacitance between the first capacitance electrode and the second capacitance electrode; and

determine a corrected conductivity measurement based on the measured capacitance and the measured conductivity;

wherein

the first and second capacitance electrodes are positioned so that the capacitance between the first and second capacitance electrodes is affected by the first portion of the fluid sample.

2. The system of claim 1, further comprising a sensor assembly comprising:

the first and second capacitance electrodes;

an annular housing having an inner surface and an outer surface, the inner surface defining an aperture extending in the direction of fluid flow through the sensor; and

wherein the conductivity sensor comprises;

a first coil positioned in the annular housing, the first coil surrounding the inner surface of the annular housing; and

a second coil positioned in the annular housing and downstream of the first coil, the second coil surrounding the inner surface of the annular housing;

wherein

the first portion of the fluid sample comprises fluid that flows through the aperture of the annular housing such that the first and second coils can be used to determine the conductivity of the first portion of the fluid sample; and

the first and second capacitance electrodes are configured to measure a capacitance that is affected by the fluid flowing through the inner surface of the annular housing.

3. The system of claim 2, wherein the first and second capacitance electrodes are positioned within the annular housing such that the first capacitance electrode is positioned on a first side of the inner surface of the annular housing, and the second capacitance electrode is positioned on a second side of the inner surface of the annular housing, the second side being opposite the first.

4. The system of claim 3, wherein at least a portion the first and at least a portion of the second capacitance electrodes are positioned between the inner surface of the annular housing and at least one of the first and second coils.

5. The system of claim 2, further comprising a flange and an attachment member, the attachment member securing the annular housing to the flange such that the flange can be secured to a fluid reservoir containing the fluid sample and the annular housing is disposed in the fluid sample.

6. The system of claim 5, wherein the flange is configured for securing the annular housing to a tee-pipe.

7. The system of claim 2, wherein the annular housing comprises

a non-conductive pipe defining the inner surface of the annular housing;

a first flange positioned on a first side of the non-conductive pipe; and

a second flange positioned on a second side of the non-conductive pipe, the second side opposite the first;

wherein

the first and second flanges are configured to interface with fluid flow vessels in a fluid flow system; and

when the first and second flanges interface with respective fluid flow vessels, the annular housing and the fluid flow vessels create a continuous fluid flow path therethrough.

8. The system of claim 7, wherein a portion of outer surface of the annular housing comprises an electrically conductive material.

9. The system of claim 7, wherein the diameter of the inner surface of the annular housing defined by the non-conductive pipe is approximately the same as the inner diameter of the fluid flow vessels so that the system does not impede the flow of fluid through the system.

10. The system of claim 1, wherein the conductivity sensor measures the conductivity of the first portion of the fluid sample and the first capacitance electrode and the second capacitance electrode are used to measure a capacitance affected by the first portion of the fluid sample substantially simultaneously.

11. The system of claim 1, further comprising a user interface in communication with the controller wherein:

a user can select at least one constituent of the fluid sample via the user interface; and

determining the corrected conductivity measurement based on the measured capacitance is further based on the selected at least one constituent of the fluid sample.

12. The system of claim 1, further comprising a temperature sensor in communication with the controller, and wherein the determining the corrected conductivity measurement is further based on a measured temperature of the fluid flowing through the system.

13. A method for performing a conductivity measurement of a flowing fluid comprising:

flowing a fluid sample past a conductivity sensor;

measuring the conductivity of the fluid sample;

flowing the fluid sample past a first capacitance electrode and a second capacitance electrode;

measuring a capacitance affected by the fluid sample using the first and second capacitance electrodes;

correlating the measured capacitance with a conductivity correction; and

determining a corrected conductivity value by adjusting the measured conductivity based on the conductivity correction.

14. The method of claim 13, wherein measuring a capacitance affected by the fluid sample and measuring the conductivity of the fluid sample comprises measuring the conductivity of and a capacitance affected by approximately the same volume of the fluid sample.

15. The method of claim 14, wherein measuring the conductivity of the fluid sample comprises measuring the conductivity of a portion of the sample that is flowing between the first and second capacitance electrodes such that the conductivity of and the capacitance affected by approximately the same volume of the fluid sample are measured simultaneously.

16. The method of claim 14, further comprising

measuring the flow rate of the flowing fluid sample;

and

determining a lag time between a conductivity sensor for measuring the conductivity of the fluid sample and a capacitance sensor for measuring the capacitance affected by the fluid sample based on the flow rate; and

wherein

the steps of measuring the capacitance of the fluid sample and measuring the conductivity affected by the fluid sample are separated by the determined lag time.

17. The method of claim 13, further comprising:

receiving an input identifying at least one characteristic of the fluid sample; and

wherein

wherein determining the corrected conductivity value comprises calculating the corrected conductivity and incorporating the at least one characteristic of the fluid sample in the calculation.

18. The method of claim 17, wherein the at least one characteristic of the fluid sample comprises a constituent in the fluid sample.

19. The method of claim 13, further comprising inserting the sensor assembly of the sensor into a tee pipe of an existing flow system and securing a flange of the sensor to a flange of the tee pipe.

20. The method of claim 13, wherein the conductivity sensor is an inductive conductivity sensor.

21. A sensor for determining the conductivity of a fluid in a fluid flow system comprising:

a sensor board made from a flexible printed circuit board (PCB) material and including a first electrode, a second electrode, a temperature sensor, and a connector, the sensor board being wrapped around a fluid flow path so that at least some of the fluid flowing in the fluid flow system flows between a portion of the first electrode and the second electrode;

an excitation toroid coil and a measuring toroid coil, the excitation and measuring toroid coils each surrounding a portion of the fluid flow path so that at least some of the fluid flowing through the fluid flow system flows through both the excitation and measuring toroid coils; and

a controller configured to;

communicate with the excitation and measuring toroid coils in order to determine a measured conductivity of the fluid flowing through the flow system;

determine the capacitance between the first and second electrodes of the sensor board;

determine the temperature of the fluid flowing through the fluid flow system; and

determine a corrected conductivity value for the fluid flowing through the fluid flow system based on the measured conductivity, the determined capacitance, and the determined temperature.