The disclosed subject matter is in the field of fluidic system health monitoring. In particular, the disclosed subject matter is directed to systems and methods for measuring total dissolved gases in fluid streams contained within fluidic systems, for the purpose of monitoring fluidic system health and purity of fluid streams.
Fluidic systems consist of conduits that contain liquids for diverse purposes including the transmission of fluidic volume or mass or fluidic pressure. A hydraulic actuation system is an example of a fluidic system that efficiently transfers force from one location to another. A hydraulic system may actuate control surfaces in an aircraft or ship, or may actuate a digging implement or lift bed in a piece of machinery, or may provide the propulsive force for a rotating motor actuator. Fluidic systems also include manifolds or radiators which circulate various liquids for cooling different type of industrial machinery.
An undersea or over-land crude oil pipeline is an example of a fluidic system that transfers volume of a material from one location to another. Volume-transfer fluidic systems are used in petroleum refining, chemical manufacture, water transfer, and food beverage and industrial applications
Common features to fluidic systems include pipes, valves, pistons, actuators, servos, turbines, pumps, flow capacitors, reservoirs, unions and the like. Proper function and integrity of such fluidic components are crucial to the safe and efficient operation of a force- or volume-transfer fluidic system. The phenomenon of cavitation in fluidic systems can accelerate wear and failure of such components. Cavitation is the process where free bubbles of fluid or contaminants rapidly evolve and redissolve in the fluid when subjected to sufficiently large and varying negative pressures. Cavitation causes rapid erosion and wear of fluidic components, rises in temperature and stress that contribute to early or unexpected failure of fluidic components. It is therefore desirable to operate the fluidic systems under conditions of fluid purity, flow rate and pressure that prevent cavitation.
Contamination of hydraulic fluid, for example, affects the health of a force-transfer fluidic system. Generally hydraulic fluid is assumed to be an incompressible medium capable of transmitting force through large positive or negative pressures. Air and water may enter hydraulic fluid either through normal use, as a result of servicing the fluidic system, or by recharging a system with hydraulic fluid contaminated with air and water. The air and water dissolved in hydraulic fluid increase the susceptibility to cavitation and also result in slow, erratic, unpredictable or spongy behavior during actuation. In an aircraft this behavior leads to loss of performance, decreased safety, and increased maintenance costs as fluidic components must be replaced more often than desired.
Similarly, water and air dissolved in the fluid of a volume-transfer fluidic system will reduce the maximum practical flow rates and pressures, and will reduce fluidic component service life. In order to avoid fluidic component failure due to cavitation caused by evolution of contaminant gases, the flow rate and pressures of a volume-transfer fluidic system must be set conservatively low. This results in a lower system efficiency which does not maximize the economic potential of a volume-transfer process.
A known and contemporary apparatus for measuring dissolved gas contaminants in hydraulic and other fluids uses a gas chromatograph to determine dissolved gas concentration in volume percent units. A small sample, for example 100 ul, is taken from a fluidic system in a gas impermeable syringe. The 100 ul sample from the syringe is introduced into a gas chromatograph provisioned with a pre-treatment column that traps the fluid and allows the dissolved gases to evolve. The evolved gases travel through the chromatograph and are detected with a thermal conductivity or other detector system. The area of the peak from the injected fluid is compared to the peak are produced by a standard, typically a 100 ul, volume of air injected in a similar manner. Such a method has been described in the open literature and in the US publication Military Aerospace Fluids and Lubricant Workshop Proceedings, November 2004.
The contemporary apparatus using gas chromatography exhibits serious drawbacks; its accuracy is limited, it does not provide real time measurements, it is difficult and expensive to implement on-line or in-line, and requires a human operator. The contemporary apparatus cannot be incorporated into a fluidic component, therefore cannot provide real-time TDG concentration for optimization of flow and pressure in force- or volume transfer fluidic systems.
The apparatus (systems and/or devices) and methods of the disclosed subject matter improve on the contemporary apparatus, as the disclosed subject matter allows for; detection of total dissolved air in fluids contained in fluidic systems, indication of need for purification, and purity measurement for optimization of fluidic system operational parameters. Additionally the disclosed subject matter provides real-time, unattended, on line or in-line measurements of total dissolved gas using inexpensive and robust devices.
One embodiment of the disclosed subject matter provides for the measurement of total dissolved gas by using measurements of oxygen in hydraulic fluid as a proxy for total dissolved gas in hydraulic fluid. It is assumed that the total dissolved gas is proportional to the total dissolved oxygen. A reading of total dissolved oxygen is obtained using an oxygen sensing device, and the result is and scaled to represent total dissolved gas as would be reported by contemporary gas chromatography analysis.
Another embodiment of the disclosed subject matter provides for the measurement of total dissolved gas by using measurements of oxygen in coolant oil as a proxy for total dissolved gas in coolant oil. Such a coolant oil measurement could be used in real-time for aerospace or industrial coolant systems to optimize process efficiency and alert users of system problems.
Another embodiment of the disclosed subject matter provides for the measurement of total dissolved gas by using measurements of oxygen in transformer oil as a proxy for total dissolved gas in transformer oil. Such a transformer oil measurement could be used in real-time for commercial and industrial transformers to optimize process efficiency and alert users of system failure.
Another embodiment of the disclosed subject matter uses an enclosed chamber of which at least a portion of the enclosing wall consists of a gas-permeable, liquid impermeable membrane. When the membrane is put in contact with the fluid, a pressure change occurs in the chamber, the equilibrium pressure being proportional to the amount of total dissolved gas in the fluid contacting the gas permeable membrane. A pressure measurement is made on the sealed chamber and related to total dissolved gas of the fluid.
Another embodiment of the disclosed subject matter consists of a fluidic component comprising a flow through chamber and a total dissolved gas sensor. The fluidic component is used to make a total dissolved gas measurement, in real time, on the fluid within a force- or volume-transfer fluidic system. The reading of the total dissolved gas sensor indicates when the fluid requires purification, or can be used to adjust operating parameters to minimize cavitation and other deleterious phenomena. Such a fluidic component and methods could be used on aircraft, in ships, in petroleum refining, and in other industrial fluidic systems to optimize in real time process efficiency and alert for system deficiencies.
Another embodiment of the disclosed subject matter provides for a feedback signal for use during purification of fluid. In this embodiment a TDG sensor makes a measurement on the fluid entering a purification system and reports purity based on TDG reading. When the reading of TDG is acceptably low, the purification process is stopped. The use of the TDG reading can be with an automated device that shuts off the process at a certain purity, or can be read by an operator to determine when to stop purification.
The advantages of the disclosed subject matter compared to the contemporary art are numerous. Contemporary art requires expensive instrumentation and dedicated operator personnel to measure TDG. It would be impractical to put the contemporary gas chromatographic measurements on-line in an aircraft hydraulic system, or in a fluid purification system. A TDG sensor used with a purification system will indicate when the optimum purification level, or extraction of TDG, has been reached, thereby reducing expense due to time and energy expenditures. When used in an industrial automation application, the TDG sensor will indicate the health of the fluidic system, and operating speed and pressures may be adjusted accordingly to maximize efficiency, effectiveness, and safety of a fluidic system. When the TDG sensor indicates that purity falls below a certain level, a system alarm can be triggered indicating the need for fluid purification.
Attention is now directed to the drawing Figures, where like or corresponding numerals indicate like or corresponding components. In the drawings:
a-2c are schematic diagrams of one embodiment of a TDG sensor.
The subject matter disclosed herein is directed to apparatus and methods that use sensors to measure total dissolved gas (TDG) in force-transfer, or volume-transfer fluidic systems. One embodiment of a TDG sensor measures dissolved oxygen as a proxy to indicate TDG. Another embodiment of a TDG sensor measures the pressure of gas that diffuses across a membrane forming a portion of the wall of a sealed chamber in contact with the fluid. Apparatus and methods that employ the TDG sensors in fluidic components are disclosed. Apparatus and methods that use the output of TDG sensors to improve efficiency and operational cost of purification processes and systems, and performance and efficiency of force- or volume-transfer fluidic systems are disclosed. The disclosed subject matter will greatly improve the safety, efficiency and cost effectiveness of fluidic systems commonly in use in aircraft, ships, and a variety of industrial processes.
Attention is now directed to
The TDG sensor comprises 1) a transducer 106 that is in contact with fluid, and that performs a measurement of a physical, chemical or electrical natures that can be related to TDG concentration in the fluid, and 2) a control logic 107 that translates the output of the TDG transducer 106 into a signal representing TDG concentration. The signal output of the control logic 107 may be, for example, an analog voltage or current with a pre-defined relationship to TDG concentration. Alternatively the control logic 107 may output a binary signal that changes state when a certain level of TDG concentration is reached. The binary signal may be an electrical, visual or mechanical actuation to indicate level of TDG or that is used by an operator or another apparatus to perform some function, for example, starting or stopping a purifier, or changing the flow and pressure parameters of a fluidic system. The signal output of the control logic 107 may be a digital signal that is sent to another device for display of reading or for control of some fluidic parameter or for starting or stopping a purifier.
Attention is now directed to
[TDG]=[O2]+[N2] Eq. 1
The following example shows how TDG in hydraulic fluid can be measured using a dissolved oxygen sensor, though this example in no way limits the disclosed subject matter to the measurement TDG in hydraulic fluid. In a typical hydraulic fluid, for example Royco 782, the TDG concentration at equilibrium with the atmosphere (at standard temperature and pressure) is 12% by volume as measured by the gas chromatographic method. When the dissolved gasses are removed from hydraulic fluid and enter a gaseous state, the gasses occupy 12% of the volume of hydraulic fluid (when the evolved gasses are measured at standard temperature and pressure):
V
TDG-STP
/V
HF=12% Eq. 2
where: VTDG is the volume of evolved gas at STP.
When converted to a mass ratio, accounting for the mass of VTDG and VHF, the concentration of TDG in hydraulic fluid is 160 parts per million (ppm).
Henry's law describes the proportionality of gas dissolved in a liquid with the partial pressure of that gas at the surface of the liquid, or for a system at equilibrium:
C=K*p Eq. 3
where: C=concentration of a gas in a liquid.
[TDG]=KO2ppO2+KN2ppN2 Eq. 4
where: KO2 and KN2 are the Henry's law constants for solution of oxygen and nitrogen respectively in hydraulic fluid.
It is assumed that when the hydraulic fluid is exposed to air outside of the fluidic system, that air consists of approximately 20% oxygen and 80% nitrogen and other gasses. Using this assumption with Eq. 4 yields:
[TDG]=KO2ppO2+5KN2ppO2 Eq. 5
Simplifying we find:
[TDG]=ppO2(KO2+5KN2) Eq. 6
Therefore the measurement of the equivalent partial pressure of oxygen in hydraulic fluid, and the knowledge of Henry's law constants for oxygen and nitrogen are known empirically or theoretically, is sufficient to give [MG]. In practice the quantity KO2+5KN2 is determined empirically by measuring the equivalent ppO2 in a sample of hydraulic fluid of known [TDG]. Equivalent ppO2 is defined as the partial pressure of oxygen at the surface of the fluid that is required to create the oxygen concentration [O2] of Eq. 1 that is dissolved in the fluid. Equivalent ppO2 can be measured using a dissolved oxygen sensor as discussed below that does not measure the actual concentration of oxygen in the fluid, but a value that is proportional to dissolved oxygen concentration and to ppO2.
It is not a requirement that the Henry's law constants of O2 and N2 be equal, that is the concentration of these gasses in the fluid do not need to be in the atmospheric ratio of 1 to 5, but the only requirement is the proportionality remains constant, and that neither the oxygen nor nitrogen in the fluid is not consumed over time by a chemical reaction or other process.
A membrane covered electrochemical oxygen sensor, or a quenched luminescent oxygen sensor may function as the sensor 200 that is used to measure the ppO2 of Eq. 6. A quenched luminescent oxygen sensor has the advantage that it does not consume oxygen and it does not show measurement dependence on rate of fluid flow across the surface of the sensor.
Attention is now directed to
It is important to note that the quenched luminescence oxygen sensor 203 indirectly measures the partial pressure, ppO2 of Equation 6. The actual quantity measured is a quantity that is related to the ppO2 that would exist at the surface of a sample of hydraulic fluid to create the present concentration of oxygen, and total dissolved gas according to Eq. 6. The quenched luminescence sensor 203 measures the concentration of oxygen in the sensor element, which has its own Henry's law constant. The composite of various Henry law constant's and proportionality constants are inherently determined by a calibration relating the output quantity of the quenched luminescent oxygen sensor 203 to samples containing known [TDG].
A sensor element 210 is shown in
Attention is now directed to
Once equilibrium is achieved, the pressure within the chamber 302 is measured by the pressure sensor 304 and related to the concentration of dissolved gas in the hydraulic fluid according to Henry's law, Eq. 3. For example if hydraulic fluid passing through the system of
In practice the equilibrium pressure condition may not always be reached for several reasons. Attaining the equilibrium condition requires a finite amount of time, and an effective infinite volume of hydraulic fluid. If the [TDG] of the hydraulic fluid in the fluidic component 306 of
Several methods can be used to address these potential inaccuracies. The temperature of the chamber 302 should be measured, and the measured pressure corrected to pressure at standard temperature. A support structure should be used to prevent the membrane from deforming and changing chamber volume. A membrane composition that discourages fouling or film formation should be used. For example the class of fluorine containing polymers generally known under the trade names Teflon, PFA, Tefzel, Teflon AF, Kynar, are suitable materials. The response time of the TDG sensor 300 may also be checked periodically to determine when the gas permeable membrane 301 has excessively fouled. The reading of the TDG sensor 300 should also be periodically checked against a sample of fluid with known TDG. The flow rate through the fluidic component 306 could be used to calculate the anticipated response time.
The control logic 305 acquires a reading from the pressure sensor 304, and the temperature sensor 303, applies corrections and calibrations as needed to determine [TDG]. In the pressure-based TDG sensor 300 described in
[TDG]=kP*Pchamb Eq. 7
where: k is a proportionality constant determined empirically or theoretically.
The ideal gas law can be used to correct for the pressure in the chamber 302 using the relationship:
P
Ts
=P
chamb
T
S
/T
chamb Eq. 8
where: PTs is the pressure of the chamber corrected to standard temperature TS.
In practice it is anticipated that an empirical calibration of sensor 300 response over temperature and pressure will be made since many of the proportionality constants, including Henry's law constants and k of Eq. 7 are temperature dependent.
The membrane assembly 400 of
Attention is now directed to
In example of use of the disclosed apparatus, the TDG sensor of
A small discrepancy exists between the first GC measurement, TDG=12%, and the maximum TDG reading from the disclosed apparatus, TDG=14%. The GC sample was taken from the top of the fluid reservoir immediately before purification began. The TDG sensor is in the inlet which receives its hydraulic fluid from the lower portion of the reservoir. It is believed that the saturation of air in the bottom of the reservoir is greater than at the top for the following reason; prior to purification compressed air was introduced into the reservoir using an air hose that was placed at the bottom of the reservoir. The air bubbles exiting the air hose at the bottom of the reservoir are at a higher pressure than the air bubbles at the top due to the static pressure of the fluid. Therefore a non-uniform, increasing TDG concentration with depth is expected. The GC sample was taken from the top of the reservoir, while the inlet fluid passing the TDG sensor was taken from the higher TDG concentration bottom portion of the barrel.
Alternative embodiments would use the control logic of the apparatus disclosed in
While preferred embodiments of the disclosed subject matter have been described, so as to enable one of skill in the art to practice the disclosed subject matter, the preceding description is intended to be exemplary only. It should not be used to limit the scope of the disclosure, which should be determined by reference to the following claims.
This application is a continuation of U.S. application Ser. No. 13/885,775 filed May 16, 2013, which is a 371 entry of International Application No. PCT/US2011/061087 filed Nov. 16, 2011, which claims the benefit of the filing date of U.S. Provisional Application No. 61/414,159, filed Nov. 16, 2010. All of the aforementioned applications are incorporated herein by reference in their entireties.
The disclosed subject matter was made with Government Support under a Phase I and Phase II SBIR Contract with the Department of Defense, Air Force contract FA8650-06-M-5031 and FA8650-07-C-5005, respectively. The US government has certain rights in this invention.
Number | Date | Country | |
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61414159 | Nov 2010 | US |
Number | Date | Country | |
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Parent | 13885775 | US | |
Child | 14148447 | US |