Patent Application
20240175776
Flow controls play a significant role in many industrial settings. Power plants and industrial process facilities, for example, use different types of flow controls to manage flow of material, typically fluids, throughout vast networks of pipes, tanks, generators, and other equipment. In some applications, like those that transport hydrocarbons or fossil fuels, performance of the flow control is subject to significant regulation or operating parameters to satisfy contractor, purchasers, or end users, including allowable amounts of emissions that may emanate from the device.
The subject matter of this disclosure relates to improvements to address emissions in or around devices on a process line. Of particular interest are embodiments that are sensitive to “fugitive” emissions. The embodiments can detect very small amounts of fluids that can emanate from in or around components on flow controls, typically valves. This feature can reduce costs and improve safety because it forecloses the need for “manual” examination of these devices that often require technicians to approach individual valves with hand-held equipment. One benefit of the proposed approach is to reduce costs of labor because of operators can extend regular maintenance cycles in lieu of alerts (or other indicators) to problems on their devices. Another benefit is that it takes advantage of existing communication infrastructure at an operator's facility. This feature can allow data, like measurements of fugitive emissions, to exchange with a central control network to further analysis and diagnostics.
This specification refers to the following drawings:
These drawings and any description herein represent examples that may disclose or explain the invention. The examples include the best mode and enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The drawings are not to scale unless the discussion indicates otherwise. Elements in the examples may appear in one or more of the several views or in combinations of the several views. The drawings may use like reference characters to designate identical or corresponding elements. Methods are exemplary only and may be modified by, for example, reordering, adding, removing, and/or altering individual steps or stages. The specification may identify such stages, as well as any parts, components, elements, or functions, in the singular with the word “a” or “an;” however, this should not exclude plural of any such designation, unless the specification explicitly recites or explains such exclusion. Likewise, any references to “one embodiment” or “one implementation” should does not exclude the existence of additional embodiments or implementations that also incorporate the recited features.
The discussion now turns to describe features of the examples shown in drawings noted above. These features address leaks or release of fluids that may occur on process lines. Often, the release is at such small quantities that it is difficult to detect or to provide accurate measure. The leak, though, can manifest over time to account for much greater volumes that exceed standards or specifications. As noted herein, the proposed design may address operator concerns about these “fugitive” emissions on their process lines. The designs also propose a cost-effective solution that can leverage existing computing hardware to give operators pre-emptive notice of fugitive gasses (or other fluids) that may percolate or escape from process devices. Other embodiments are within the scope of this disclosure.
Broadly, the valve positioner 100 may be configured to perform analysis or diagnostics. These configurations may embody devices that can alert operators to problems on their process lines. These devices might detect fugitive emissions that arise in proximity to process devices found in industrial settings. This feature can alert operators to release of harmful fluids, like chlorine gas. The feature can also reduce greenhouse gas emission in hydrocarbon plants because the device can alert operators to slow leaks that occur in valves or like process devices. The operators can then perform pre-emptive maintenance to fix issues that would avoid any protracted emissions from the device.
The distribution system 102 may be configured to deliver or move these fluids. These configurations may embody vast infrastructure. Material 104 may comprise gases, liquids, solid-liquid mixes, or liquid-gas mixes, as well. The conduit 106 may include pipes or pipelines, often that connect to pumps, boilers, and the like. The pipes may also connect to tanks or reservoirs. In many facilities, this equipment forms complex networks to execute a process, like refining raw materials or manufacturing an end product.
The flow control 108 may be configured to regulate flow of material 104 through the conduit 106 in these complex networks. These configurations may include control valves and like devices. The actuator 110 may use pressurized fluid (like air or natural gas) to generate a load. Often, the device may include a piston, spring (or springs), or a flexible diaphragm for this purpose. The valve stem 112 may direct this load to the closure member 116, typically a ball, a plug, or a disc. The load may counter pressure of material 104 on an opposite side of the closure member 116. This feature can maintain the closure member 116 in a desired position relative to the seat 118. In one implementation, the desired position or “set point” may correspond with flow parameters for the material 104 to meet process requirements or parameters.
The control unit 120 may be configured to process and generate signals. These configurations may connect to a control network (or “distributed control system” or “DCS”), which maintains operation of all devices on process lines to ensure that materials flow in accordance with a process. The DCS may generate control signals with operating parameters that describe or define operation of the flow control 108 for this purpose. The control unit 120 may have operating hardware, like electrical and computing components (e.g., processors, memory, executable instructions, etc.). These components may also include electro-pneumatic devices that operate on incoming pneumatic supply signal. These components ensure that the outgoing actuator control signal to the actuator 112 is appropriate for the flow control 108 to supply material 104 downstream according to process parameters.
The sensor unit 122 may be configured to detect fugitive emissions. These configurations may include devices that are sensitive to various fluids, often in limited or finite amounts or quantities. The device(s) may embody various types of detection technology, including LIDAR, infrared, optical, chemical, and the like. Technology may prevail to accommodate distance or spacing between the device and the source of emissions, for example, packing material that is found on the flow control 108. This technology may generate a signal that quantifies the amount or, for example, presence or absence of the fluid(s) in vicinity of the device. This signal may transit to the control unit 120. Operating hardware may be configured with software (or like executable instructions) to process the signals as part of its analysis or diagnostics processes.
The examples below include certain elements or clauses to describe embodiments contemplated within the scope of this specification. These elements may be combined with other elements and clauses to also describe embodiments. This specification may include and contemplate other examples that occur to those skilled in the art. These other examples fall within the scope of the claims, for example, if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
