Ultrasonic liquid level monitoring system

• US 4,984,449 A
• Filed: 07/03/1989
• Issued: 01/15/1991
• Est. Priority Date: 07/03/1989
• Status: Expired due to Term

• Current Assignee: ADS Services Incorporated, Simmons Company (Serta Simmons Bedding LLC), Thomas K. Regan
• Original Assignee: Caldwell System Corporation
• Inventors: Caldwell, Joseph W., Slobodnik, Mark W.
• Primary Examiner(s): Williams, Hezron E.
• Assistant Examiner(s): Roskos, Joseph W.
• Application Number:
  US07/376,666
• Time in Patent Office: 561 Days
• Field of Search: 73/492, 73/290 V, 73/592, 73/1 DV, 367/908
• US Class Current: 73/49.2
• CPC Class Codes: G01F 23/2962 Measuring transit time of reflected waves
• CPC Class Codes: G01M 3/3245 using a level monitoring device G01M3/3272 takes precedence

Abstract

A liquid level measuring system having a tubular ultrasonic probe with a length in excess of the depth of liquid to be measured; for vertical insertion into a tank. A transducer inside the tube, at a first distance above the bottom end of probe body, responds transmits a sinusoidal acoustical pulse through the probe to the surface of the liquid. An echo returns from the surface of the liquid to the transducer and provides a sinusoidal echo signal. A receiver responds to the echo signal by providing a start signal corresponding to the transmitter signal crossing a predetermined amplitude in a predetermined direction and by providing a stop signal corresponding to a first selected echo signal crossing a second predetermined reference level in a predetermined direction. The speed of sound in the liquid is measured by measuring the echo time to a calibration rod in the tube at a known distance from the transducer. A timer measures the time between the start and stop signals and provides the time to a sequential controller. The depth of the liquid and the leak rate of the tank are calculated for display.

Claims

1. An ultrasonic probe for insertion into a tank for the measurement of the depth of petrochemical liquid stored in the tank, and for the detection of leaks in the tank in excess of a predetermined limit, the probe comprising:

a substantially cylindrical probe body having a top end and a bottom end, and a length in excess of the depth of liquid to be measured, the probe body having a back ranging target at the bottom end of the body, the probe body being made of a high thermal resistance material;

means for holding the probe body in a substantially vertical position within the tank, the probe body extending downward vertically through the surface of the liquid, the bottom end of the probe body being held in contact with the base of the tank;

transducer means positioned within the probe body at a first distance above the bottom end of the probe body for transmitting bi-directional pulses along the longitudinal axis to the surface of the liquid and to the bottom end of the probe body, the back ranging target being positioned to reflect a portion of the bi-directional pulses back to the transducer, and the transducer being operable to receive echoes from the back ranging target and from the surface of the liquid; and

at least two calibration rods within the probe body, between the transducer and the top end of the body, each calibration rod being positioned at a successively greater predetermined distance from the transducer, and each respective calibration rod having a larger reflective surface.

2. A process for measuring the leak rate of liquid in a container by performing a plurality of qualifying liquid level measurements over a known interval of time, the liquid level measurements being convertible into liquid quantity values, the process for measuring a leak rate comprising:

positioning an ultrasonic probe into a tank containing liquid, the ultrasonic probe having a length in excess of the depth of liquid to be measured;

the ultrasonic probe having a transducer coupled to the probe body at a first distance above the bottom end of the probe body;

driving the transducer with a substantially sinusoidal voltage pulse, the voltage pulse starting with the same polarity change sequence on each successive liquid level measurement;

sampling the substantially sinusoidal voltage pulse and providing a start signal corresponding to the sampled voltage pulse crossing a predetermined threshold;

receiving an echo returning from the surface of the liquid to the transducer, the transducer providing a corresponding substantially sinusoidal echo signal, and conditioning the echo signal to provide an amplified signal;

providing a stop signal corresponding to the amplified signal first crossing a predetermined reference level in a predetermined direction and then crossing a second predetermined reference level with a predetermined change in polarity; and

means for measuring the time between the start and stop pulses.

3. The process for measuring the leak rate of liquid in a container of claim 2 further comprising the step of:

determining if the plurality of liquid level measurements were made during an interval in which the speed of sound in the liquid remained within predetermined limits.

4. The process for measuring the leak rate of liquid in a container of claim 2 further comprising the step of:

determining if the plurality of liquid level measurements were made during an interval in which liquid was not being added to or taken from the tank by determining that the liquid levels measured were within predetermined level limits based on a previous sequence of liquid level measurements.

5. The process for measuring the leak rate of liquid in a container of claim 2 wherein the step of providing a stop signal corresponding to the amplified signal first crossing a predetermined reference level in a predetermined direction and then crossing a second predetermined reference level with a predetermined change in polarity further comprises the steps of:

conditioning the echo signal to provide an amplified signal; and

detecting a first threshold on the amplified signal to providing a first threshold detected signal corresponding to the received signal having an amplitude in excess of a first reference level; and

providing the stop signal by detecting the amplified signal penetrating a second threshold as the received signal crosses a second predetermined reference level with a predetermined change in polarity sequence.

6. The process for measuring the leak rate of liquid in a container of claim 2 wherein the step of providing a stop signal corresponding to the amplified signal first crossing a first predetermined reference level in a predetermined direction and then crossing a second predetermined reference level with a predetermined change in polarity further comprises the steps of:

setting a flip-flop to a predetermined state as the amplified signal first crosses a first predetermined reference level in a predetermined direction; and

using the output signal of the flip-flop to enable the detection the amplified signal crossing a second predetermined reference level with a predetermined change in polarity.

7. An ultrasonic probe for insertion into a tank for the measurement of the depth of liquid stored in the tank, the probe comprising:

a probe body in the form of a closed tube with a central longitudinal axis, a top end and a bottom end, and a length in excess of the depth of the liquid to be measured;

means for holding the probe body in a fixed reference position within the tank, the probe body extending downward vertically through the surface of the liquid, the bottom end of the probe body being held in contact with the base of the tank; and

transducer means coupled to the probe body at a first distance above the bottom end of the probe body for transmitting bi-directional pulses along the longitudinal axis to the surface of the liquid and to the bottom end of the probe body, and for receiving echoes from the bottom end of the probe body and from the surface, the transducer means comprising;

an ultrasonic transducer having a top surface and a bottom surface; and

a damping washer, having a hole;

the damping washer being positioned onto the bottom surface of the ultrasonic transducer, the bottom surface of the ultrasonic transducer being directed toward the bottom of the probe body through the damping washer hole, and the hole diameter being selected to provide a predetermined level of attenuation of transmitted signal energy in the downward direction; and

encapsulation means for sealing the ultrasonic transducer and damping washer into a fixed parallel plane relation, the ultrasonic transducer and the damping washer being protected from liquid in the tank.

8. The ultrasonic probe of claim 7, wherein the probe body further comprises:

a closed tube having a circular cross-section;

at least a first calibration reflector within said tube at predetermined distance between the transducer and the top end of the body; and

vent hole means for flooding the probe body and for preventing the accumulation of bubbles under the transducer means.

9. The ultrasonic probe of claim 8, wherein the closed tube is formed of fiberglass tubing.

10. An ultrasonic probe for insertion into a tank for the measurement of the depth of liquid stored in the tank, and for the detection of leaks in the tank in excess of a predetermined limit, the probe comprising:

a tubular probe body with a central bore along its longitudinal axis, the probe body having a top end and a bottom end, and a length in excess of the depth of liquid to be measured, the probe body having a back ranging target at the bottom end;

means for holding the probe body in a substantially vertical position within the tank, the probe body extending downward vertically through the surface of the liquid, the bottom end of the probe being held in contact with the base of the tank;

transducer means, coupled to the probe body at a first distance above the bottom end, for transmitting bi-directional pulses along the longitudinal axis to the surface of the liquid and to the bottom end, the back ranging target being positioned to reflect a portion of the bi-directional pulses back to the transducer means, and the transducer means being operable to receive echoes from the back ranging target and from the surface of the liquid; and

a cable guideway mounted longitudinally on the outer surface of the probe body from the top end to a point above the transducer means, the cable guideway having a hollow cross section for passing a cable from the top end of the probe body to the end of the cable guideway above the transducer means, the cable passing to the transducer for connection to the transducer means.

11. An ultrasonic probe for insertion into a tank for the measurement of the depth of liquid stored in the tank, and for the detection of leaks in the tank in excess of a predetermined limit, the probe comprising:

a probe body of tubular cross section with a central bore along its longitudinal axis, the probe body having a top end and a bottom end, and a length in excess of the depth of liquid to be measured, the probe body having a back ranging target at the bottom end;

means for holding the probe body in a substantially vertical position within the tank, the probe body extending downward vertically through the surface of the liquid, the bottom end of the probe being held in contact with the base of the tank;

transducer means, coupled to the probe body at a first distance above the bottom end, for transmitting bi-directional pulses along the longitudinal axis to the surface of the liquid and to the bottom end, the back ranging target being positioned to reflect a portion of the bi-directional pulses back to the transducer means, the transducer means being operable to receive echoes from the back ranging target and from the surface of the liquid; and

a temperature measuring circuit operable to provide a signal indicative of a temperature value.

12. An ultrasonic probe for the measurement of the depth of liquid stored in an underground tank having a standpipe and for the detection of leaks in the tank in excess of a predetermined limit, the standpipe having an interior wall with an inwardly extending member, the probe comprising:

a probe body of tubular cross section sized for passage through the standpipe, the body having a central bore along its longitudinal axis, a top end, and a bottom end, and a length in excess of the depth of liquid to be measured, the probe body having a back ranging target at the bottom end of the body;

holding means for holding the probe body in a substantially vertical position within the tank, the probe body extending downward vertically through the surface of the liquid, the bottom end of the probe being held in contact with the base of the tank; and

transducer means coupled to the probe body at a first distance above the bottom end, for transmitting bi-directional pulses along the longitudinal axis to the surface of the liquid and to the bottom end of the probe, the back ranging target being positioned to reflect a portion of the bi-directional pulses back to the transducer, and the transducer being operable to receive echoes from the back ranging target and from the surface of the liquid;

wherein the holding means comprises;

a guide bushing having an inner bore and an outer diameter sized for installation into the probe body bore near the top end of the probe body;

a compression rod having top end and a bottom end, the compression rod being slideably engaged in the guide bushing bore, with the bottom end of the compression rod being disposed in the probe body bore above the liquid level;

a clamp disk coupled to the top end of the compression rod, the clamp disk having a diameter selected for insertion into the interior of the standpipe, the clamp disk having at least one notch for complementary receipt and rotary engagement under the inwardly extending member on the standpipe interior wall;

an adjusting collar positioned and locked onto the compression rod at a position between the compression rod top end and the top of the guide bushing; and

a coil spring positioned coaxially on the compression rod between the top of the guide bushing and the bottom of the adjusting collar, the spring length and spring constant being selected to place the spring in compression when the probe body is passed into the standpipe with its bottom end resting on the bottom of the tank and with the clamp disk in the standpipe bore engaged against the inwardly-extending member.

13. An ultrasonic probe for insertion into a tank for the measurement of the depth of liquid stored in the tank, the probe comprising:

probe body in the form of a closed tube of substantially uniform cross-section, having an elongated shape with a central longitudinal axis, the probe body having a top end and a bottom end at opposing ends of the body, and a length in excess of the depth of the liquid to be measured;

means for holding the probe body in a fixed reference position within the tank, the probe body extending downward vertically through the surface of the liquid, the bottom end of the probe body being held in contact with the base of the tank;

transducer means coupled to the probe body at a first distance above the bottom of the probe body for transmitting bi-directional pulses along the longitudinal axis to the surface of the liquid and to the bottom end of the probe body, and for receiving echoes from the bottom end of the probe body and from the surface; and

at least a first calibration reflector within the probe body at a second predetermined distance along the longitudinal axis from the transducer.

14. The ultrasonic probe of claim 13, wherein the probe body further comprises a back-ranging target at the bottom end of the body, the back-ranging target being positioned to reflect a portion of the bi-directional pulses back to the transducer.

15. The ultrasonic probe of claim 13, wherein the probe body further comprises:

at least two calibration reflectors within said tube between the transducer means and the top end of the body, each calibration reflector being positioned at a successively greater predetermined distance from the transducer means, each respective reflector having a larger reflective surface.

16. The ultrasonic probe of claim 15, wherein each calibration reflector is a rod passing through the probe body transverse to the longitudinal axis.

17. An ultrasonic probe for insertion into a tank for the measurement of the depth of a petrochemical liquid stored in the tank, and for the detection of leaks in the tank in excess of a predetermined limit, the probe comprising:

a probe body of substantially tubular cross-section with a central bore along a longitudinal axis extending between a top end and a bottom end, the length of the probe being greater than the depth of the liquid to be measured;

a back-ranging target at the bottom end of the probe body;

means for holding the probe body in a substantially vertical position within the tank, the probe body thereby extending downwardly through the surface of the liquid, with the bottom end of the probe body being held in contact with the base of the tank;

transducer means coupled to the probe body at a first distance above the bottom end, for transmitting bi-directional pulses along the longitudinal axis to the surface of the liquid and to the bottom end of the probe body, the back-ranging target being positioned to reflect a portion of the pulses back to the transducer means, the transducer means thereby receiving echoes from the back-ranging target and from the surface of the liquid; and

a calibration rod passing through the probe body transverse to the longitudinal axis, and positioned at a predetermined distance between the top end of the probe body and the transducer means.