Patent Application
20230213115
Flow controls play a large role in many industrial facilities. Power plants and industrial process facilities, for example, use different types of flow controls to manage flow of a material, typically fluids, throughout vast networks of pipes, tanks, generators, and other equipment. These devices may include control valves, which provide active control of flow, typically through an exchange of control signals with a central control network. Pressure relief valves are another type of flow control. These valves can open and close in response to overpressure conditions in the network or system.
Operators may install equipment to monitor performance of these devices. This equipment may detect and generate data that corresponds with conditions on or around the devices, for example, vibrations or like anomalies. This data is valuable to operators because it can indicate that a device might fail or, at least, may provide signs of degrading performance over time. Operators can use this knowledge to implement pre-emptive measures to avoid failure of the device in the field, which can cost considerably in labor or process downtime. A slow deterioration of performance, for example, can degrade output of the process line, possibly leaving valuable product unmarketable or unsellable. On the other hand, outright failure of one or more flow controls can shut down process lines indefinitely until technicians can repair or replace the disabled device.
The subject matter of this disclosure relates to improvements that can gather data that relates to performance of flow controls. Of particular interest are embodiments that can detect sound vibrations. These embodiments do not, however, use sensors that require power or that are otherwise sensitive to the environment around the device. For control valves, the embodiments can provide operators with clues to indicate operating anomalies in the device. This feature can help operators diagnose problems or problematic devices before complete failure leads to extensive process downtime that can cost operators substantially in labor and lost output. The embodiments can also generate data that can indicate or detect leaks from relief valves. Operators can, in turn, take these faulty devices offline to prevent fugitive emissions or prevent unnecessary flaring that can emit greenhouse gases, for example, methane or carbon dioxide.
Reference is now made briefly to the accompanying drawings, in which:
Where applicable, like reference characters designate identical or corresponding components and units throughout the several views, which are not to scale unless otherwise indicated. The embodiments disclosed herein may include elements that appear in one or more of the several views or in combinations of the several views. Moreover, methods are exemplary only and may be modified by, for example, reordering, adding, removing, and/or altering the individual stages.
The drawings and any description herein use examples to disclose the invention. These 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. An element or function recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or functions, unless such exclusion is explicitly recited. References to “one embodiment” or “one implementation” should not be interpreted as excluding the existence of additional embodiments or implementations that also incorporate the recited features.
The discussion now turns to describe features of the embodiments shown in drawings noted above. These embodiments implement passive devices to pick-up anomalies that may occur during operation of an industrial device, for example, control valves, pressure relief valves, and like flow control devices. These anomalies may correspond with performance issues that can frustrate operation of the device. Other embodiments are within the scope of this disclosure.
Broadly, the device monitor 100 is configured to inform operators of health and operation of industrial devices. These configuration can generate data and information that operators may use to make maintenance and repair decisions. One benefit of the proposed design, however, is that it does not require power at its sensing or sensitive end. This feature avoids use of active or “live” devices and wiring in potentially hazardous environments. Moreover, the design can take advantage of safety measures that already exist on the industrial device, like explosion-proof housings or intrinsically-safe circuitry. This feature results in a cost-effective technique to monitor performance, for example, by picking up on vibrations that may correspond with issues (or potential issues) on the target industrial device.
The distribution system 102 may be configured to deliver or move resources. These configurations may embody vast infrastructure. Material 104 may comprise gases, liquids, solids, or 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.
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; however, the concepts can also apply to relief valves, as well. In one implementation, the valve body 110 consist of cast or machined metals. This structure may form a flange at the openings I, O. Adjacent pipes 106 may connect to these flanges to allow material 104 to flow through the device, for example, through an opening in the seat 112. The closure member 114 may embody a metal disc or metal “plug.” The actuator 116 may use pneumatics or hydraulics to regulate the position of the plug 114, which in turn manages flow of material 104 through the seat 112 into the pipes 106 downstream of the device.
The controller 118 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 control valve 108 for this purpose. The operating hardware 120 may employ 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 S1. These components ensure that the outgoing actuator control signal S2 to the actuator 116 is appropriate for the control valve 108 to supply material 104 downstream according to process parameters.
The sensor 122 may be configured to generate a signal. These configurations may include devices that can convert energy into a current or voltage. These devices may embody a vibration sensor, for example, a microphone; however, other mechanisms may work as well. In one implementation, the vibration sensor can connect to the operating hardware 118 to exchange various signals. For example, the operating hardware 118 may provide power to the vibration sensor. The computing components of the operating hardware 118 may also process the signal from the vibration sensor to determine, for example, whether vibrations reach or exceed a threshold level that is cause for concern. This threshold level may trigger an alarm or other indication to alert the operator to attend to the flow control 108.
The conduit 124 may be configured to direct energy onto the vibration sensor. These configurations may include tubing or hoses, preferably made of flexible materials, e.g., rubber or like composites. The flexible tubing may provide a pathway for energy to transit to the vibration sensor. In one implementation, pressure waves may reflect or bounce off inner walls or surfaces of the flexible tubing. This feature can amplify any sounds coming from the flow control 108.
The powerless device 126 may be configured to generate the a non-electrical signal. These configurations may embody passive devices that deflect or change position in response to vibrations. This feature can create pressure waves that, in turn, travel through the flexible tubing to the vibration sensor. The passive design makes it easier to implement because the powerless device does not pose a risk when in use in hazardous areas or with flammable or caustic materials that flow through the flow control 108.
In view of the foregoing, the improvements here provide a safe, effective way to monitor health of flow controls and like industrial devices. The embodiments foreclose the need to expose active or powered sensors to hazardous environments. As a result, the proposed design can find wide use, while at the same time offering operators valuable data that describes performance of devices throughout their process lines.
Examples appear below that include certain elements or clauses one or more of which may be combined with other elements and clauses to describe embodiments contemplated within the scope and spirit of this disclosure. The scope may include and contemplate other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims 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.
