Patent Application
20230366705
The invention is in the field of the measurement of properties of pipes to determine their health condition. Pipes are often in subterranean environments, and the invention may be particularly advantageous in such environments.
Pipelines are highly useful fluid transportation systems. For example oil pipes may be used to transport oil around the world. Gas is similarly transported in pipes. Moreover, water is another fluid that is transported with pipes. Water pipes are particularly interesting as the value of the fluid is relatively low, but is essential to agriculture and for drinking supply for local populations. Due to the relatively low monetary value of water, water pipes are often less well maintained as there are fewer resources spent on such pipes. These pipes are often aged, and often have large amount of leaks, which results in a large amount of lost water. Monitoring such pipes in a cost effective way is therefore advantageous. Pipes are also very difficult to monitor given their length and the sought-after nature of the commodities within them.
Fibre optic cables have been used to monitor the properties of pipes, however such systems are costly and difficult to implement. Therefore there is a need for an alternative system that is more cost effective to implement.
Present strain gauges are also known as apparatus to monitor the strain of various surfaces. However, at present many strain gauges are notorious for being liable to breakage. They are often difficult to attach to the surface being measured. Moreover, in environments where they cannot readily be replaced, and where they may be subject to high pressures, and large fluctuations in temperature, present strain gauges are not well suited. A new sensor that may be in the form of a strain gauge is desired that addresses at least one, or alternatively all, of the shortcomings listed above.
Pipes such as water pipes are prone to damage as a result of a number of external factors. For instance, water pipes are often located in subterranean environments which can either be in urban or rural settings.
In urban settings heavy flows of traffic can cause movement of earth surrounding the pipes, and such forces provided by traffic may commonly be at a set frequency (e.g. based on the time between vehicles on a road).
Some pipes may incorporate pumps for example to pump effluent or other fluids up an incline. Such pumping action may induce an acceleration to the pipe at a regular frequency.
In rural settings wear on the pipes may be largely due to freeze-thaw (in winter) or due to the effect of a lack of damping from hardened surrounding earth (in the summer months).
At present pipes are not live-monitored. Instead, water companies simply assign each pipe a lifespan and then seek to replace each pipe as they come up to the end of their lifespan. Therefore there are breakages where pipes fail before they are replaced. This causes complex works, often involving shutting down public roads.
The present application relates to sensors for live monitoring of such pipes so that the health of the pipe may be assessed. This may lead to an early replacement of specific section of pipe. Alternatively, it may mean that when certain parameters are sensed (e.g. hardened surrounding soil) usage of the pipe may be minimised or curtailed.
Such live monitoring is technically challenging as it is difficult to ensure the veracity of data obtained in a subterranean environment, as noise can dominate signals. Moreover it is important that a system is simple and quick to fit such that adding the monitoring to the pipes does not in itself cause large delays in work to public roads and the like.
According to a first exemplary aspect, there is an attachment pad configured to prevent the ingress of moisture into the vicinity of a sensor attached to a pipe, the attachment pad configured to overlie one or more sensors such that the one or more sensors may be positioned between the pipe and the attachment pad. This is advantageous as it may protect a sensor from the environment in which the pipe is located. For example in a subterranean environment the attachment pad may provide mechanical protection to the sensor from soil, sharp debris, stones and anything else that might contaminate or physically damage that sensor.
Optionally, the attachment pad having a first face, a second face, and wherein the first face comprises an indent configured to house at least one sensor when the at least one sensor is coupled to the pipe. The indent may further reduce the pressure applied to the sensor during use.
Optionally, the second face of the attachment pad having a raised portion, aligned with the indent. This allows the thickness of the attachment pad to be substantially uniform to allow the pressure to de dissipated evenly.
Optionally, the attachment pad has a thickness of 1 mm, preferably the thickness being in the range of 1 mm to 10 mm, preferably 6 mm. This thickness may provide additional protection to the sensor. This range of thicknesses may enable ease of installation of the attachment pad. This thickness may also make process of adhering the attachment pad less time consuming.
Optionally, the attachment pad is formed of a resilient material, such that the attachment pad is more resilient than the sensor. This is advantageous as the attachment pad may protect the sensor through its resilience.
Optionally, one or more attachment pads are sufficient to span the entire perimeter of the pipe. Advantageously this ensures that the section of the pipe is entirely covered so that the forces on the pipe are uniform in all directions.
Optionally, the one or more attachment pads span the pipe once but only once.
Advantageously this keeps the thickness of the attachment pads on the pipe constant so that forces on the pipe are equal across the entire perimeter of the pipe.
Optionally, the attachment pad is tessellatable with itself such that two or more attachment pads may span the entire perimeter of the pipe. This enables a single size pad to be used for various pipes of differing circumference.
Optionally, the attachment pad is configured to be adhered to the pipe by adhesive, and/or wherein the attachment pad is curable/weldable to adhere to the pipe. Electrofusion welding for example may be used. This enables the attachment pad to be adhered to the pipe in an easy and reproducible manner.
Optionally, the attachment has a sufficient level of friction with the pipe such that adherence between the pipe and the attachment pad is caused. This is advantageous as it allows the pad to be adhered without the need for adhesive, making the installation simpler.
Optionally, wherein the attachment pad is configured to house an analogue to digital converter configured to convert an analogue signal measured by the sensor into a digital signal.
According to a second aspect there is a sensor for measuring a parameter of a pipe, the sensor comprising a flexible plastic, or metallised plastic, base layer, an ink trace forming an electronic circuit for measuring at least one parameter, preferably a protective layer encasing the ink trace, wherein the sensor has a poisons ratio of 0.35 to 0.45 such that the sensor is configured to elastically deform under dynamic short term loading, as well as through gradual changes to loading through for example the compaction of soil. This is advantageous as it allows ease of installation of the sensor, as it may be handled without a large amount of care, and it may be attached easily to many surfaces. The flexibility may also be particularly good at withstanding the pressure of subterranean environments. Poisson values in the range 0.37 to 0.44 May be particularly advantageous, and a value of 0.44 is even more advantageous.
Optionally, the sensor is configured to measure at least one property of the pipe. This allows features of the pipe to be analysed to check the health of the pipe, and the likelihood of failure.
Optionally, the sensor is configured to measure at least one of strain, temperature, humidity, pressure and acceleration. Strain may allow the likelihood of a fracture to be identified. Temperature may also measure the likelihood of damage from the elements, for example from freeze/thaw. Acceleration may give an indication of any movement of the pipe, or if there is a blockage inside the pipe. Humidity may help understand variability of soil condition leading to irregular loading. Pressure may allow an understanding of the level of load being applied and how this changes over time.
Optionally, at least four sensors are coupled to the pipe, such that the two sensors closest the top of the pipe are equidistant to the top of the pipe. This may enable to a particularly effective form of measurement.
Optionally, the sensor is configured to measure strain in two axis that are perpendicular to one another. This advantageously allows both axial and circumferential strain to be measured. An optional alternative may to measure the strain in an axis, and to measure the strain at another axis at forty five degrees to the first axis, such that the two axis are diagonal from one another.
Optionally, the sensor comprises two measurement modules positioned perpendicular to one another. This advantageously enables simple measurement of both the axial and circumferential strain.
According to a third aspect there is a system for determining one or more properties of a pipe, the system comprising an attachment pad, at least one sensor configured to be coupled to the outside of a pipe wall, wherein the attachment pad is configured to overlie one or more of the at least one sensor such that the one or more sensor may be positioned between the pipe and the attachment pad, and to prevent slippage of the one or more sensors on the pipe. The system may be particularly effective at measuring the properties of a pipe in a cost effective way to enable the health condition of a pipe to be determined. The sensor is also sufficiently protected such that it is less likely to fail, and so reducing the frequency at which the sensor may be needed to be replaced.
Optionally, at least three sensors are coupled to the pipe, and further wherein the top of the pipe nearest the ground is free from a sensor, such that it may be accessed for maintenance, and wherein the sensors are equidistant from each other around the circumference of the pipe. This is advantageous as engineers often have to tap into the top of the pipe in order to enter the pipe to perform maintenance.
Optionally the system further comprising a data acquisition module configured to be in communication with at least one sensor to receive data, the data acquisition module configured to process the data to determine one or more properties of the pipe. This advantageously enables the data from the sensors to be analysed.
Optionally, the system further comprises a plurality of sensors connected to the data acquisition module, wherein the sensors are connected to the data acquisition module by at least one of: direct connections between the plurality of sensors and the data acquisition module, wherein the direct connections are in parallel with one another, direct connections between the plurality of sensors and the data acquisition module, wherein the direct connections are in series with one another, connections between the plurality of sensors and the data acquisition module, wherein said connections are via a connecting element, and wherein the connections between the plurality of sensors and the connecting element are in parallel with each other; or connections between the plurality of sensors and the data acquisition module, wherein said connections are via a connecting element, and wherein the connections between the plurality of sensors and the connecting element are in series with each other.
Optionally, the system further comprises a junction box configured to be connected to the at least one sensor, such that data measured by the sensor can be communicated to the junction box. Advantageously the junction box allows all of the sensors to connect to a single point, such that the connections are less likely to be caught by a subterranean environment.
Optionally, the data acquisition module is configured to be in direct communication with the junction box. Advantageously this enables all of the data to reach the data acquisition module in a single connection.
Optionally, in use, the junction box is positioned at least far enough away from the sensor so that the junction box does not cause stress or strain on the pipe, and is positioned close enough to the sensor such that noise is not introduced into the signal. This is highly advantageous as it reduces the chance of the measurement system damaging the pipe itself, whilst ensuring the accuracy of the data collected.
Optionally, in use, the junction box is positioned between 0.5 m and 1.5 m away from the sensor. These values may be particularly advantageous for protecting the pipe, and ensuring accurate data protection.
Optionally, the data acquisition module is housed within a meter chamber. This may protect the data acquisition module from the subterranean environment.
Optionally, the meter chamber is machined to make cable accessibility straightforward, and is configured to be weatherproof, such that the data acquisition module is not affected by groundwater. Advantageously this protects the data acquisition module.
Optionally, the meter chamber further comprises a power subsystem to power the data acquisition module. This enables the data acquisition module to be powered locally.
Optionally, the system further comprises a pressure sensor configured to be tapped into the pipe in the vicinity of at least one sensor, to determine the pressure of fluid in the pipe. The pressure in the vicinity of the sensors may be advantageous as it may provide an understanding of hydraulic activity and its subsequent effect on the pipe.
According to a fourth aspect there is a method of installing at least one sensor on a pipe, comprising attaching the one or more of the at least one sensors of the second aspect to the pipe, and overlaying at least one of the one or more sensors, with the attachment pad of the first aspect. This advantageously enables a quick and easy installation method.
Optionally, the method further comprises curing the one or more sensors such that the at least one sensor couples to the pipe wall. Advantageously this increases the bond between the sensor and the pipe.
Optionally, the curing comprises applying a pressure for a set period of time, and/or wherein curing comprises applying heat for a set period of time. Advantageously, this enables the bond between the sensor and the pipe to be strong.
Optionally, the method further comprises curing the one or more attachment pads to permanently couple the attachment pads to the pipe wall. This is advantageous as it allows the attachment pads to have a secure bond to the pipe wall.
Optionally, curing comprises applying a pressure for a set period of time, and/or wherein curing comprises applying heat for a set period of time. This is advantageous for the reasons set out above.
Optionally, the method further comprises connecting the one or more sensors to a data acquisition module. This enables the data to be analysed effectively so that any faults in the pipe may be found.
Optionally, connecting the one or more sensors to a data acquisition module comprises connecting the one or more sensors to a junction box, and then connecting the junction box to a meter chamber containing a data acquisition module. This enables the connections to be secure, and to ensure the cables are at less risk of damage.
Optionally, attaching the one or more sensors to the pipe comprises positioning the at least one sensor correctly in both the longitudinal and circumferential axis. This ensures that the calculations to determine axial strain and circumferential strain are simpler and so require less processing power.
Optionally, attaching the one or more sensors to the pipe comprises attaching the one or more sensors to the outer surface of the pipe with an adhesive or epoxy, or by curing/welding, for example electrofusion welding. This may advantageously allow a quick and easy bond to be formed.
A fifth aspect comprises a pipe for transporting fluids, the pipe extending from a distal point, to a proximal point, wherein the pipe is configured for fluid to flow through the pipe from the distal point to the proximal point, wherein the pipe comprises a pipe wall comprising an inside surface, and an outside surface, and wherein a lumen is encapsulated by the inside surface of the pipe wall such that fluid may flow through the lumen, and further wherein the pipe is coupled to the sensor of the second aspect, and to the attachment pad of the first, such that the sensor may be positioned between the pipe and the attachment pad. Advantageously this secures a sensor to a pipe such that it may monitor various aspects of the pipe to determine faults.
In accordance with a sixth aspect of invention there is provided a sensor for measuring parameters of a pipe, the sensor comprising a sensor body comprising a pipe engaging surface; a first measurement device positioned within the sensor body and configured to contact the surface of the pipe when the pipe engaging surface is in contact with the surface of the pipe, wherein the first measurement device is configured to measure a first parameter of the pipe; a data conduit configured to pass the measurement from the measurement device to an external unit. This may advantageously allow for the sensor to be surrounded by a sensor body. This may reduce the risk of damage to the measurement device, e.g. from the subterranean environment or water ingress.
Optionally, the first measurement device is configured to output an analogue measurement, and wherein said analogue measurement is converted to a digital signal in the vicinity of the pipe. This may be particularly advantageous. Sensors located in subterranean environments may output analogue signals and these may be susceptible to noise during transit to the surface (e.g. to an external unit on the surface). Therefore analogue to digital conversion in the subterranean environment in the vicinity of the pipe may address this problem. This may either be through an analogue to digital converter situated within the sensor itself, or an analogue to digital converter situated in a junction box that is configured to be adjacent the sensor and the pipe. The junction box may be connected to multiple sensors so as to provide efficient signal conversion.
Optionally, the sensor body is comprised of a casted material. This may advantageously minimise any water ingress to the measurement device.
Optionally, the sensor body is formed from a polymeric material, such as silicone or polyurethane. These may be materials that do not allow the infiltration of water or other materials form the subterranean environment.
Optionally, the sensor body is formed from polyurethane or silicone that is set around the first measurement device and the data conduit. This may offer the maximum protection of the measurement device. It may also allow the connection between the measurement device and the pipe to be flush and less susceptible to fluid ingress.
Optionally, the first measurement device is configured to lie flush with the pipe engaging surface of the sensor body. This may allow the connection between the sensor and the pipe to be as strong as possible, and to minimise the chance of an external shock changing the position the sensor relative to the pipe.
Optionally, the system further comprises a second measurement device configured to contact the surface of the pipe when the pipe engaging surface is in contact with the surface of the pipe, wherein the second measurement device is configured to measure a second parameter of the pipe. This may allow two parameters to be measured in proximity to one another such that the interrelation between these parameters can be used to determine the health of the pipe.
Optionally, the second measurement device is configured to lie flush with the pipe engaging surface of the sensor body. This may allow the connection between the sensor and the pipe to be as strong as possible, and to minimise the chance of an external shock changing the position the sensor relative to the pipe.
Optionally, the first measurement device is configured to measure strain. This may allow the displacement of the pipe relative to a reference length to be determined. This measure may be linked to potential breakage events if the strain becomes too large and plastic deformation ensues.
Optionally, the second measurement device is configured to measure temperature. Temperature and strain may be linked, and so this may allow changes in strain in the pipe to be understood, and where those changes are not as a result of temperature to be identified as strain events.
Optionally, the controller is configured to modify the strain measurements to take into account temperature fluctuations that have been detected. This may allow the health of the pipe to be assessed.
Optionally, the system further comprises an accelerometer configured to detect any acceleration or motion of the sensor. This may detect events that cause breakages or damage to the pipe.
Optionally, a notification is created if an acceleration over a first threshold is detected, wherein the first threshold is indicative of an external subterranean stimulus such as seismic activity, and/or wherein the threshold is indicative of accelerations that are repeating at a frequency associated with damage of infrastructure. This may be advantageous for detection of local subterranean shocks—e.g. due to a vehicle with a heavy load, or a travelling at a high speed, or larger scale events such as earthquakes. Additionally where the threshold relates to a frequency at which an acceleration is applied this may allow any potential resonance events to be identified. For example, pumps or traffic that operate at a system may be identified, and if the system is additionally identified as becoming undamped (e.g. because of a lack of moisture in the surrounding soil) then this may result in an alarm condition.
Optionally, the system further comprises an additional sensor such as a load cell or a moisture detection unit. These sensors may provide additional information to aid the monitoring of the pipe network.
Optionally, the load cell is encapsulated within the sensor body, and wherein the load cell is configured to be positioned at the top of the pipe. The encapsulation of the load cell may reduce the possibility of it being damaged by an external event. Whilst the position of the load cell may allow it to accurately determine the vertical load on the pipe, as this can be linked to breakage events or damage.
Optionally, the moisture detection unit is configured to indicate when the moisture level drops below a pre-set threshold, wherein said threshold indicates that the soil no longer provides sufficient damping and so damage is more likely. This may be advantageous for determining when the pipe is in an undamped state and therefore susceptible to damage, e.g. from resonance events.
Optionally, the pipe is positioned underground, and wherein the sensor is configured to be positioned on the pipe underground. This may allow for direct local measurements of the pipe in situ and during use.
Optionally, the external unit is situated above the ground. This may allow data from the measurement device to be sent to a usable location.
Optionally, the data is passed to the external unit via a junction box. In some instances this may allow the junction box to gather multiple sources of data, e.g. from multiple sensors. This may allow for efficient transmission to the external device.
Optionally, the sensor body is cylindrically shaped, wherein the diameter of the cross sectional area is larger than the depth of the cylinder, such that the sensor body is approximately disc or puck shaped. This may allow the sensor to be simple to manufacture, and advantageously simple and time efficient to fit to a pipe. This may be particularly advantageous for embodiments in which no controller is present in the sensor, as this may allow for simple manufacture (and in such embodiments other shapes may also be used).
Optionally, the sensor further comprises a controller encapsulated within the sensor body, wherein the controller is configured to convert measurements from the first measurement device into a digital signal. This may allow the measurement form the measurement device to be converted to a digital signal entirely locally so that no transmission of an analogue signal is required. This would therefore minimise any noise being induced into the signal.
Optionally, the data conduit is configured to pass the digital signal of the measurement to the external device. A digital signal is less susceptible to noise, and so this is advantageous.
Optionally, the data conduit is a data transmitter, and is configured to send the measurement from the measurement device to an external unit.
Optionally, the pipe engaging surface further comprises a first flange extending from a central portion. The flanges may allow for a particularly effective bond between the pipe and the sensor to be created.
Optionally, the central portion extends longitudinally in a first direction and is dimensioned such that the longest side of the central portion extends in the first direction.
Optionally, the first flange extends further in the first direction.
Optionally, the pipe engaging surface comprises two side flanges extending from the central portion. The flanges may allow for a particularly effective bond between the pipe and the sensor to be created.
Optionally, the first direction is perpendicular to the two side flanges. The flanges may allow for a particularly effective bond between the pipe and the sensor to be created.
Optionally, the first measurement device is housed in the first flange. This may allow the parameters of the pipe to be measured effectively.
Optionally, the second measurement device is housed in the first flange. This may allow the parameters of the pipe to be measured effectively. This may also allow the two parameters to be measured on the same local portion of pipe.
Optionally, the controller is housed in the central portion. This may best protect the controller form external forces.
Optionally, the accelerometer is housed in the central portion. This may provide a more accurate acceleration reading, as it would not be based on relative movement of the flanges relative to the central portion.
Optionally, the load cell is housed in the central portion. This may provide the most accurate measurement of load on the pipe.
Optionally, the data conduit comprises a wired connection. This may further reduce noise in the signal that is sent. In particular, if the wired connection is directly to a junction box, and even more particularly where the analogue to digital conversion is performed after the signal is sent to the junction box.
Optionally, the wired connection is positioned to extend away from the central portion in the opposite direction to the first flange. This may make the sensor simple to install on the pipe.
In accordance with a seventh exemplary aspect, a system is provided that comprises a junction box; at least one sensor in accordance with the first aspect; wherein the sensors are each attached to the junction box via the data conduit. This may allow for efficient management of the data from the measurement devices in the one or more sensors.
Optionally, the system further comprises an analogue to digital converter for converting the measurement from the measurement device to a digital signal. This may be advantageous, especially if the converter is present in the junction box and multiple sensors are attached to the junction box. This may reduce the amount of power required for the system as only one processor is used. As the system is in a subterranean environment, and as the system is for ease of deployment it may be powered by a battery. And therefore reducing the power consumption of the system may prolong the life of the system.
Optionally, the at least one sensor is a plurality of sensors, and optionally wherein the plurality of sensors comprises four sensors. This may provide sufficient data to characterise the health of the pipe.
Optionally, the attachment between the junction box and the data conduit is configured to be water resistant. This may reduce noise on the signal, and increase the lifespan of the system.
Optionally, wherein the data conduits of the sensor is encapsulated within the junction box. This may mean that the sensors and the junction box and the data conduit form a single piece to be fitted to the pipe. This may reduce the time associated with installation. This may also reduce any chance of water ingress.
Optionally, the data conduit of the sensor is attached to the junction box via a stuffing gland. For embodiments in which the junction box is not encapsulated a stuffing gland may allow an encapsulated sensor/data conduit to be attached to an non-encapsulated junction box in a water resistant manner.
Optionally, the attachment is via two stuffing glands forming a male to female connection. This may allow for ease of attachment, and a water resistant connection.
Wherein at least one sensor comprises a load cell encapsulated in the sensor body, optionally wherein said sensor is configured to be positioned atop the pipe. This may allow the load on the pipe to be determined and monitored live during use of the pipe.
Optionally, the system further comprises a moisture gauge, configured to detect the moisture level of the surrounding earth or soil. This may advantageously allow any dry conditions resulting in an undamped pipe to be identified.
Optionally, the moisture gauge comprises a first and second prong and comprises a capacitive moisture sensor.
Optionally, the moisture gauge is connected to the junction box. This may provide a single point at which each sensor is connected.
Optionally, the moisture gauge is configured to output an analogue measurement, and wherein the analogue measurement is configured to be converted to a digital signal.
Optionally, the conversion is configured to take place in the subterranean environment. This may reduce any noise in the signal. In embodiments where this conversion takes place in the junction box power may also be saved.
In accordance with an eighth exemplary aspect, a method is provided of taking a subterranean measurement of a pipe situated beneath the ground, the method comprising measuring a first parameter of the pipe using a first measurement device; converting the measurement from the first measurement device into a digital signal, wherein said conversion takes place locally under the ground and adjacent the pipe; sending the digital signal to an external unit situated above the ground.
This may reduce the noise in the signal received above ground.
In accordance with a ninth exemplary, a method is provided of taking a subterranean measurement of a pipe situated beneath the ground, the method comprising measuring a first parameter of the pipe using a first measurement device; passing the analogue signal to a junction box situated below the ground, wherein the external unit comprises a controller; converting, at the controller, the measurement from the first measurement device into a digital signal; and sending the digital signal to a secondary external unit situated above the ground. This may provide an alternative embodiment in which noise is reduced, and power used by the system is also reduced.
In accordance with a tenth exemplary aspect, a method is provided of attaching the sensor that comprises covering either the pipe or the pipe contacting surface of the sensor body with adhesive; pressing the first flange of the sensor to the pipe; pressing the central portion of the sensor to the pipe; and pressing the side flanges of the sensor to the pipe such that the measurement device is in contact with the pipe. This may provide a secure connection between the pipe and the sensor.
In accordance with an eleventh exemplary aspect, a method of manufacturing the sensor is provided that includes positioning the first measurement device and the data conduit in a mould; pouring a fluid into the mould such that the fluid fills the mould; curing the fluid; and removing the sensor from the mould. This may provide a simple, cost effective method of manufacture to reduce cost of the sensors.
Optionally, positioning the first measurement device and the data conduit in the mould further comprises positioning the controller in the mould. This may reduce steps of manufacture.
The Figures are described below, and each Figure is merely an illustration of an embodiment. The features shown in the Figures are not considered essential unless otherwise stated.
The attachment pad 2 is configured to prevent the ingress of moisture and dirt into the vicinity of a sensor attached to a pipe, and to overlie one or more sensors such that the one or more sensors may be positioned between the pipe and the attachment pad 2.
The indent 4 shown in
The attachment pad 2 may be formed of a resilient material, such that the attachment pad 2 is more resilient than the sensor. This may enable the attachment pad 2 to withstand higher forces, pressures, or temperatures than the sensor could withstand on its own. The attachment pad 2 may therefore protect the sensors housed therein from such forces though its resilience.
The three sensor elements may allow both the axial and circumferential strain to be measured. For example, the central sensor 23 element may be positioned so as to measure axial strain. Both of the outer sensor elements 27, 29 may be used to measure the circumferential strain. For example the outer elements 27, 29 may be positioned to directly measure circumferential strain alone, or as shown, the elements may be positioned to measure a mixture of both circumferential and axial strain. Using the measurements form the central sensor element the circumferential strain alone may then be measured. There may also be benefits to measuring off the axis of the circumferential strain, in a diagonal direction, as this may detect any strain events associated with helically applied loads.
It is noted that any of the embodiments shown in
The substrate 50 shown in
The use of conformable substrates also allows the circuitry to be printed directly onto the substrate 50, such that the sensor elements do not have to be formed from traditionally metal wires. Such wires are liable to breakage, and can make attaching the sensor to external circuitry particularly fiddly, and difficult to use. The printed circuitry enables the connection to be made easily, and the deformable nature of the substrate aids with installation. Moreover, during use earth around the pipe may slip slightly, and therefore compress, or distort the sensor. Traditional sensors would be hampered in such an environment and would likely fail. However, the use of the conformable substrate means that the present sensor may withstand such deformation, and so enable the use of the claimed sensors in subterranean environments.
It is also noted that the sensor may further comprise a protective layer to encase the ink trace. The protective layer is similarly deformable, such that both the protective layer, and the flexible plastic, or metallised plastic base layer are flexible as described above.
The sensor substrate 60, or base layer, may be formed from polyethylene terephthalate, polyaryletherketone or polyimide.
An alternative to the sensor described above may comprise foil strain gauges such as those provided by HBM and Omega. The performance of these strain gauges are known from manufacturers datasheets, and therefore the signals sent by the strain gauges can be readily understood. These devices may also be well encapsulated so that they can withstand moist and high pressure environments.
It is noted that in other embodiments the pads 82 may not be fully tessellatable such that there may be gaps between the pads 82. This embodiment may not have the technical benefits associated with the tessellation described above, but for embodiments where coverage is not needed across a full pipe 88 circumference may still provide adequate protection for the sensors.
It is noted that the sensors are not shown in
Installation may be undertaken by attaching one or more sensors to a pipe, and overlaying one or more attachment pads over said sensors.
The first step 120 in
The second step 121 is optional and comprises curing the one or more sensors to the pipe. The curing step may comprise exerting a force on the sensor to use pressure to cure the sensor to the pipe. Alternatively the sensor may be cured to the pipe through the application of temperature. In some embodiments both temperature and pressure may be used in the curing process.
The third step 122 of
The fourth step 123 is optional and comprises curing the one or more attachment pads to the pipe surface. The curing step may comprise exerting a force on the attachment pad to use pressure to cure the attachment pad to the pipe. Alternatively the attachment pad may be cured to the pipe through the application of temperature. In some embodiments both temperature and pressure may be used in the curing process. Alternatively the attachment may be achieved by electrofusion welding.
The fifth step 124 is optional and comprises connecting the one or more sensors to a junction box. A junction box is a connection hub that is configured to receive signals. Connecting the one or more sensors to the junction box enables the sensors to send measured data to the junction box. The junction box may be particularly advantageous if multiple sensors are used as it may serve as a connection point for receiving signals from all of the sensors, such that all of the data is collected at a single point. It is also noted that sensors may connect via a wireless protocol such as Bluetooth or Wi-Fi instead of through the use of a wired connection to a junction box. In yet another embodiment a junction box is not used and instead each of the sensors is directly connected with a meter chamber.
The final step 125 is similarly optional and comprises connecting the junction box to a meter chamber comprising a data acquisition module. The meter chamber may also comprise a power source such as a battery, or a mains connection in order to power the data acquisition module. The power may also feed the sensors, although in some iterations the sensors may have their own in-built power sources. The meter chamber may be designed to stop the ingress of moisture into the data acquisition module. The data acquisition module acquires data from the sensors. The data acquisition module may process the data locally to determine the health condition of the pipe, or alternatively may transmit the data elsewhere for further processing.
It is noted that each of the optional features may be removed from the method shown in
The attachment pad 132 may be connected to the pipe 138 by adhesive. Alternatively the attachment pad 132 may be cured to the pipe 138 without the use adhesive. Alternatively there may be sufficient friction between the attachment pad 132 and the pipe 138 to keep the attachment pad in situ. Similarly the sensor 130 may be attached with adhesive, through curing, or by the use of friction.
The data acquisition module 135 is configured to be in communication with at least one sensor 130 to receive data, the data acquisition module 135 configured to process the data to determine one or more properties of the pipe 138. This may be as shown in
The meter chamber 133 is configured to be weatherproof, such that data acquisition module 135 is not affected by ground water. The power source 137 may be mains or a local source such as a battery.
Although not shown in
Analogue signals are often harder to reconstruct than digital signals once they have been distorted. In the present use case signals may be distorted by vibrations in the earth for example, and therefore some distortion may occur between the sensor and the data acquisition module. Positioning the digital to analogue converter 196 adjacent the sensor 194 and the attachment pad 192 may therefore increase the quality and/or usefulness of the signals that are received by the data acquisition module.
The analogue to digital converter 196 may be directly coupled with the sensor 194. They two elements may be manufactured together. The attachment pad 192 may contain a second recess for the analogue to digital converter, or alternatively the first recess may be large enough to encompass both the sensor and the analogue to digital converter. The recess or recesses may be potted with silicone to reduce forces transmitted to the analogue to digital converter or the sensor. The attachment pad may be moulded directly over the sensor, and optionally over the digital to analogue converter 196 during manufacture. The analogue to digital converter 196 may for example be miniaturised and may be situated on a multilayer PCBA or a flexible substrate.
In particular,
The sensor 200 seen in
The underside surfaces of these flanges 221, 223, best seen in
In the embodiment seen in
The two measuring instruments 215, 217 that are held within the sensor body 211 in
The above described flush arrangement enables the sensor body 211 to, firstly, form a seal with the pipe around the delicate instruments 215, 217, and secondly, allows the instruments access to directly contact the pipe surface. This seal prevents fluid ingress into the instruments which may otherwise lead to damage of the instruments or inaccuracy in their performance. The direct access to the pipe enables the instruments to perform their duties with maximal accuracy. The seal that is achieved with such arrangement may also achieve a substantially strong connection between the pipe and sensor which may minimise the chance of an external shock changing the position of the sensor 200 relative to the pipe.
To achieve the above flush fit, the sensor body 211 may be formed by method of casting around the instruments 215, 217 and controller 213 (and data conduit 225) to be held. This will be explored in
The two measuring devices 215, 217 seen in
Alternatively, it may be entirely possible and of use to include only one of a particular instrument, i.e. either a strain sensor 215 or thermometer 217. Equally, it may be possible to utilise a plurality of further instruments alongside the strain sensor 215 and thermometer 217. Additional instruments (not shown) that may be accommodated within either the flanges 221, 223 or the central portion of the sensor body 211 include, an accelerometer for detecting any acceleration or motion of the sensor, a load cell and a moisture detection unit. Each of these instruments may provide data that is of use in and of themselves. A moisture detection unit may be located outside of the sensor, and may be situated within or adjacent soil or earth adjacent the sensor or pipe. The moisture detection unit may be part of the same system, or connected to the pipe.
An accelerometer may aid in detecting events that cause breakages or damage to the pipe. These may include recording seismic activity and more particularly, monitoring the seismic activity such that it is alerted to a user should it rise above a predefined threshold. A load cell may monitor the load experienced by a particular location on a pipe such that a concentrated load area may be identified. This may also detect the load for example from vehicles and the like. This may show areas of high stress, due to heavy loads, or vehicles travelling at high speeds. Such loads may damage the pipe or reduce its lifespan, so monitoring of these loads may allow better planning of maintenance. And a moisture detecting unit may aid in determining the moisture levels atop or adjacent a pipe, and monitoring these levels such that they are kept at below a predefined threshold. When moisture levels drop below a certain threshold the damping effect of the earth on the pipe is reduced and so pipes are more prone to damage. Monitoring this may allow the usage of pipes to be changed when such low moisture events are detected in order to reduce the risk of pipe breakage. These may aid in identifying prone areas of pipes that may need further maintenance attention.
It is of note that the accommodation of larger hardware, such as a controller 213 or accelerometer may be best suited for the central portion 219 as to being embedded within the flanges 221, 223. This is because there may be greater depth to the sensor body 211, and therefore available space, in the central portion 219. Equally, more fragile instruments 215, 217 may be kept in the central portion 219 as it may provide a greater thickness of rubberized material encapsulating it for added protection as compared to the flanges 221, 223. Alternatively, it may be entirely possible to accommodate controllers 213, and larger or more fragile architecture in an entirely separate location adjacent to the sensor 10 in a place such as a junction box (not shown). This will be explored in
The sensor of
Alternatively, prior to sending data to an external box, the data may be sent to a junction box (not shown) located adjacent the pipe and sensor 200 and below ground level. Such an arrangement may be useful in that it may allow data from a plurality of sensors 200 at different locations on a pipe (or on different locations on different pipes) to be processed centrally and packaged in a form that may enable more favourable transport of the data over a longer distance. This may improve the overall efficiency of the system.
One practice of data processing that may aid such efficiency and improve system accuracy may be to convert analogue signals as measured by any of the measuring instruments to digital signals prior to transmitting them to the external unit. This would allow the analogue data recorded from measurement devices to be converted into a digital form that is less susceptible to transit noise or interference. This operation may be conducted in a controller 213 within the sensor of
With such embodiment of sensor 250, it may be that only smaller sensory instruments 215, 217 are accommodated within the sensor as shown with a wired conduit 225 connecting the sensor 250 to a junction box that may house the controller. Once again, the sensors 215, 217 accommodated within the sensor form a flush connection with a pipe along with the underside of the cylindrical sensor as best seen in
Due to the more compact shape of the sensor embodiment of
For example, each sensor upon the pipe may accommodate one of a load cell, accelerometer, moister gauge, strain gauge or thermometer as their main measuring instrument and the system of the plurality of sensors shown in
Alternatively, the data conduit may be connected to the junction box via a stuffing gland 280 as seen in
The benefits of utilising the arrangement of a plurality of sensors (200 or 250) feeding into a singular junction box 270, as seen in
For operations such as data conversion from an analogue signal to a digital one prior to transit, such an arrangement may be ideal as many different analogous signals from the plurality of sensors may be processed concurrently, in a power and time efficient manner. This may be especially useful for a moisture gauge that measures data in analogue form.
The invention extends to methods, system and apparatus substantially as herein described and/or as illustrated with reference to the accompanying figures.
The invention also provides a computer program or a computer program product for carrying out any of the methods, processes or determinations described herein, and/or for embodying any of the apparatus features described herein, and a computer readable medium having stored thereon a program for carrying out any of the methods, processes or determinations described herein and/or for embodying any of the apparatus features described herein.
The invention also provides a signal embodying a computer program or a computer program product for carrying out any of the methods described herein, and/or for embodying any of the apparatus features described herein, a method of transmitting such a signal, and a computer product having an operating system which supports a computer program for carrying out the methods described herein and/or for embodying any of the apparatus features described herein.
Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied to apparatus aspects, and vice versa. As used herein, means plus function features may be expressed alternatively in terms of their corresponding structure, such as a suitably programmed processor and associated memory.
Furthermore, features implemented in hardware may generally be implemented in software, and vice versa. Any reference to software and hardware features herein should be construed accordingly.
It should be understood that the present invention has been described above purely by way of example, and modifications of detail can be made within the scope of the invention.
Each feature disclosed in the description, and (where appropriate) the claims and drawings may be provided independently or in any appropriate combination.
Reference numerals appearing in the claims are by way of illustration only and shall have no limiting effect on the scope of the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2001136.7 | Jan 2020 | GB | national |
This application is a continuation-in-part application of and claims the benefit of priority to U.S. patent application Ser. No. 17/759,444, filed on Jul. 26, 2022, which is a National Phase of PCT/GB2021/050189, filed on Jan. 27, 2021, which claims priority to British Patent Application No. 2001136.7, filed on Jan. 27, 2020, the disclosures of each of which are hereby incorporated by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17759444 | Jul 2022 | US |
| Child | 18360423 | US |
