Mr. Bubble Was Confused. A Cliffhanger.

This year we experienced a record-breaking January in Austria – the coldest since 30 years. Our heat pump system produced 14m3 of ice in the underground tank.

The volume of ice is measured by Mr. Bubble, the winner of The Ultimate Level Sensor Casting Show run by the Chief Engineer last year:

The classic, analog level sensor was very robust and simple, but required continuous human intervention:

Level sensor: The old way

So a multitude of prototypes had been evaluated …

Level sensors: The precursors

The challenge was to measure small changes in level as 1 mm corresponds to about 0,15 m3 of ice.

Mr. Bubble uses a flow of bubbling air in a tube; the measured pressure increases linearly with the distance of the liquid level from the nozzle:

blubber-messrohr-3

Mr. Bubble is fine and sane, as long as ice is growing monotonously: Ice grows from the heat exchanger tubes into the water, and the heat exchanger does not float due to buoyancy, as it is attached to the supporting construction. The design makes sure that not-yet-frozen water can always ‘escape’ to higher levels to make room for growing ice. Finally Mr. Bubble lives inside a hollow cylinder of water inside a block of ice. As long as all the ice is covered by water, Mr. Bubble’s calculation is correct.

But when ambient temperature rises and the collector harvests more energy then needed by the heat pump, melting starts at the heat exchanger tubes. The density of ice is smaller than that of water, so the water level in Mr. Bubble’s hollow cylinder is below the surface level of ice:

Mr. Bubble is utterly confused and literally driven over the edge – having to deal with this cliff of ice:

When ice is melted, the surface level inside the hollow cylinder drops quickly as the diameter of the cylinder is much smaller than the width of the tank. So the alleged volume of ice perceived by Mr. Bubble seems to drop extremely fast and out of proportion: 1m3 of ice is equivalent to 93kWh of energy – the energy our heat pump would need on an extremely cold day. On an ice melting day, the heat pump needs much less, so a drop of more than 1m3 per day is an artefact.

As long as there are ice castles on the surface, Mr. Bubble keeps underestimating the volume of ice. When it gets colder, ice grows again, and its growth is then overestimated via the same effect. Mr. Bubble amplifies the oscillations in growing and shrinking of ice.

In the final stages of melting a slab-with-a-hole-like structure ‘mounted’ above the water surface remains. The actual level of water is lower than it was before the ice period. This is reflected in the raw data – the distance measured. The volume of ice output is calibrated not to show negative values, but the underlying measurement data do:

Only when finally all ice has been melted – slowly and via thermal contact with air – then the water level is back to normal.

In the final stages of melting parts of the suspended slab of ice may break off and then floating small icebergs can confuse Mr. Bubble, too:

So how can we picture the true evolution of ice during melting? I am simulating the volume of ice, based on our measurements of air temperature. To be detailed in a future post – this is my cliffhanger!