Patent Application
20200278042
Not applicable
Not applicable
The present invention relates to an improved method and apparatus for underwater device leak detection in a hydraulic system or device that includes a hydraulic ram. More particularly, the present invention relates to a method of detecting leaks (e.g. broken or cut hose or leaking seal or fitting) in an underwater hydraulic system that uses an underwater hydraulic cylinder.
In the offshore oil and gas industry, there are certain hydraulic devices that are needed in order to complete jobs in an underwater environment. A hydraulic shear is employed to conduct salvage operations. Such a hydraulic shear is lowered to a seabed area, for example several hundred feet (meters) deep. In this offshore environment, leakage of hydraulic oil has a profoundly disastrous effect on the environment.
Therefore, there exists a need for a simple and straightforward yet workable solution to the problem of leakage of hydraulic fluid from devices that are used in a marine environment.
It is not only important that a leak of hydraulic fluid be detected. It is further important that the hydraulic device be immediately disabled so that leakage is limited to a very minimal quantity.
Patents have issued that relate generally to the detection of leakage. One example is the Brandt patent (U.S. Pat. No. 5,748,077). The Brandt patent (U.S. Pat. No. 5,748,077) shuts down the hydraulic system if the leak is detected and notifies individuals in the area that a leak has occurred. The leak detection system has sensors for measuring hydraulic system parameters and a computer for detecting abnormalities in the system based on values returned by the sensors. Sensors used include an rpm pickup, a pressure transducer, a flow meter and a hydraulic fluid level and temperature switch. Outputs of the sensors are analyzed by the computer to determine if the hydraulic system has a leak. If a leak is detected, the computer sends response signals to a device for engaging or disengaging the prime mover from the hydraulic pump and to another device for actuating a valve to stop hydraulic fluid flow from the reservoir. The computer may also send indicator signals to a display console for activating a warning light, a buzzer or a display.
The Cass patent (U.S. Pat. No. 4,471,797) provides a hydraulic circuit breaker reset device. The system includes a pump, reservoir and an actuator system. The hydraulic circuit breaker is arranged to compare fluid flow to and from the actuator system and to shut off this flow in the event the flow to the actuator system is greater than the flow returning from the actuator system by more than a predetermined differential, thereby indicating a leakage condition. A hydraulic circuit breaker reset device is hydraulically connected to the actuator system and to the circuit breaker. When the circuit breaker is in a shut off condition, the reset device continuously pressure tests the actuator system. If the pressure in the actuator system increases to indicate the absence of fluid leakage, the reset device responds to the pressure increase in the actuator system to provide a reset signal to the circuit breaker. After the circuit breaker is reset to its normal operating position, a timing piston returns the reset device to its normal operating condition.
The present invention provides a method and apparatus for detecting a leak in a severed or broken hydraulic hose (or from a leaking seal or leaking fitting) in an underwater marine application. The system employs a hydraulic power unit that can be shut off if a breach or leak is detected. An indicator such as a red light can be activated to show an operator that the leak has occurred and that it has been curtailed.
The apparatus of the present invention provides a portable system that can be easily interfaced with a control hose reel of a hydraulic power unit.
The hydraulic leak detection system of the present invention is important for protection of equipment and for protection of the environment. Leakage of hydraulic fluid in a marine environment is a serious and potentially very costly problem.
The method and apparatus of the present invention measures both pressure and return flow rates. These parameters are then transmitted to a computer that can determine if there is an inconsistent flow ratio. If so, a signal is sent to a suitable switch such as a solenoid that discontinues power to a prime mover such as an engine.
The method and apparatus of the present invention can provide a selector switch that can have multiple, preset parameters as settings. The selector switch can be used to reset depending upon a particular piece of equipment that is being used. A number of settings such as eight settings can be reset or kept as default settings.
The method and apparatus of the present invention give the operator an ability to set exactly how sensitive the system must be in order to react to fluid loss. The system can be programmed to shut off the prime mover or other active part of the hydraulic power unit depending upon how much fluid has to be lost before shut down occurs.
The present invention is an improvement over other leak detection systems such as velocity checks or fuses which cannot be trusted. Additionally, fuses can only be tested if they are destroyed. Thus, a fuse may or may not work.
Another prior art system involves the use of tank level alarms. With large hydraulic cylinders that can hold 15 to 20 gallons (57 to 76 liters) of fluid, a huge amount of fluid must be lost before a level can be reached that can be detected.
Some systems employ a measurement of pump rpm and return flow. Such a parameter as pump rpm cannot be used reliably because some pumps are pressure compensated pumps. A pressure compensating pump varies in efficiency and would result in a high loss of fluid due to a need to set all parameters very high in order to account for fluid bypass within the pump that cannot be accounted for nor noticed without a flow meter on the pressure side.
The present invention thus provides a simple, straightforward, yet effective method and apparatus for quickly halting leakage from a hydraulic system where leakage has occurred in a hose, seal, fitting or other component of such system.
In one embodiment is provided a method and apparatus for leak detection having a microprocessor operably connected to a plurality of flow meters which flow meters are connected to input and output lines connected to one or more hydraulically powered systems.
In one embodiment the method and apparatus can receive flow rate signals from the plurality of flow meters; use the received signals in comparing against predefined values to determine if a leaking exception condition has occurred in one or more of the connected hydraulically powered systems.
In one embodiment the method and apparatus senses and detects the presence of abnormalities in fluid flow to and from one or more of the connected hydraulicly powered systems. These abnormalities, when detected, indicate a possible leak has occurred in a particular hydraulic system. Once a leak is identified, the method and apparatus can shut down one or more of the hydraulic systems, overall hydraulic power to the method and apparatus such as the hydraulic pump and/or its prime mover, and/or issue a warning signal.
In one embodiment the method and apparatus can shut down and/or stop hydraulic fluid flow in the method and apparatus by shutting off the hydraulic pump and/or its prime mover. In another embodiment hydraulic fluid flow to one or more of the connected hydraulic systems can be stopped by closing a valve from the hydraulic pump.
In one embodiment, in response to an identified leaking event, the method and apparatus can shut down the hydraulic pump and/or its prime mover, and/or close a valve in the inlet line to the pump and/or stop fluid flow from leaving a hydraulic reservoir.
In one embodiment, if a leaking event is identified, the method and apparatus can send signals for shutting down the particular hydraulic system for which such leaking event was identified, and furthermore issue a warning indicating that a leak has occurred.
In one embodiment, the method and apparatus can be user programmed to enter one or more predefined quantities and one or more predefined time periods in determining a leaking exception and/or a leaking event. In one embodiment the method and apparatus can be user programmed regarding predefined quantities and/or predefined ranges which are to be considered as leaking exceptions.
Leaking conditions monitored in one embodiment can include predetermined combinations of flow ratios between the plurality of flow meters. In one embodiment, one or more predefined quantities and one or more predefined time periods can be compared to real time measurements from the plurality of flow meters. If the values measured from the flow meters exceed a predefined quantity (e.g., predefined flow ratios between the plurality of flow meters) for at least a predefined time period, the method and apparatus can shut down the hydraulic system and issue a warning signal.
In one embodiment the method and apparatus can be user programmed allowing a user to specify the predefined quantity or quantities regarding measurements made by the plurality of flow meters which are considered to be leaking exceptions, along with programming the predefined quantity or quantities of time for which the flow meter measurements must exceed the predefined quantity before being considered a confirmed leaking event.
In one embodiment the method and apparatus can be user programmed regarding the frequency of sampling for which the method and apparatus accepts signals from the plurality of flow meters.
In one embodiment the method and apparatus can intermittently sample the plurality of flow meters, and obtain measured flow meter parameters and then compare such measured parameters against predefined parameters to determine if a leaking condition has occurred.
In one embodiment the method and apparatus can be user programmed regarding predefined time periods for which leaking exceptions are to exist before the method and apparatus identifies a leaking event as occurring and takes remedial action.
In one embodiment the method and apparatus can be user programmed regarding a predefined start up period before the method and apparatus reviews signals from the plurality of flow meters.
In one embodiment, the method and apparatus can monitor the plurality of flow meters only after certain pre-monitoring conditions are satisfied such as expiration of a predefined initial start up period. However, once the required pre-monitoring conditions are satisfied, the method and apparatus can begin checking the plurality of flow meters, obtaining measured parameters, and comparing these against set-up values to determine if a leak has occurred. In various embodiments the checking can be intermittently. In various embodiments the checking can be substantially continuously.
In one embodiment, the system works by monitoring and comparing flow from two flow meters as a ratio. The system has the ability to have volumes put in manually for this comparison. By linking a computer, controller, or laptop to the system and using a service tool to change and add data, the system responds to sensitivity and other variations such as time delay, percentage of leak allowance, and rod and bore size for ratio or motor which is one to one ratio.
In one embodiment the system can employ a “learn” button which is more user friendly. With this function, the user can set this system up without a laptop or service tool. The user simply turns on the system in bypass mode operates the unit when the user has the unit flowing at normal operation. He or she simply switches to the first position on the selector switch and presses the learn button for 5 seconds and the system automatically reads the ratio and stores that data as its setting.
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
In
Deck area 3 on vessel 1 has a crane 4 with lifting line 5 and rigging 6 to enable lifting and lowering of hydraulic device 11. The hydraulic device shown in
The hydraulic device 11 provides a body 13 that supports the moving jaw 14. Hydraulic cylinder 12 has a pushrod 15 that moves between extended (
Hydraulic power is provided with a hydraulic power unit or HPU which is designated generally by the numeral 28 in
From control station 30, the line 31 which supplies pressurized hydraulic fluid to hose reel 40. A first flow meter 45 is placed in flow line 31 or at the junction of flow lines 25, 31 as shown in
Line 32 also receives flow from control station 30. Return flow line 32 communicates with hose reel 40. The flow line 32 carries a second flow meter 46. Return flow is able to travel from the hose reel 40 to the flow line 32 through the flow meter 46 and then to the control station 30. From the control station 30, the flow in line 32 communicates with the return line 26 for returning fluid to hydraulic tank or reservoir 22. Flow meters 45, 46 can be commercially available CT Series flow meters from Webster Instruments of Milwaukee, Wis.
The hose reel 40 provides flow lines 41, 42 which enable the hydraulic cylinder 12 to either open jaw 14 or close jaw 14 by either extending pushrod 15 or retracting the pushrod 15 (see
In
A start button 56 can be provided for enabling use of control station 30. Lamps 57, 58 can be provided to indicate whether or not the control station 30 has been activated or is deactivated. For the diesel engine 20, a solenoid operated valve 64 is provided in flow line 65 which supplies diesel fuel from tank 23 to engine 20. (See
In one embodiment, the method and apparatus can be provided with a display which may include a leak detection visual and/or audible alarm. A display console can be provided for controller 33 which can include a selector switch 55, on off button 56, indicator lamps 57 and 58, along with default program button. Controller 33 can be operatively connected to a computer (e.g., a notebook computer) for programming operating values into controller regarding its operations.
A plurality of flow meters 45 and 46 can be used to measure flow to and from the monitored hydraulic systems (e.g., shears 11 and reel drive motor 38). The flow meter 45 sends a signal to controller 33 which is proportional to the rate of fluid flow in flow line 31. The flow meter 46 sends a signal to controller 33 which is proportional to the rate of fluid flow in flow line 32.
Leak detection 10 system can go through various pre-leak detection monitoring checks which are designed to ensure that the connected hydraulic systems (e.g., shears 11 and reel drive motor 38) are operating correctly. In one embodiment leak detection system 10 will shut off hydraulic power to the hydraulic pump 21 if one or more pre-monitoring exceptions are found.
Pre-monitoring exceptions can include, but are not limited to:
If one or more of the above pre-monitoring exceptions are found, leak detection system 10 can turn off power to pump 21, and issue a warning signal indicating the identification of a pre-monitoring exception. The pressure exerted by the hydraulic fluid can be monitored by pressure transducers in flow lines 31, 32, 41, and 42.
If an exception condition is found, including satisfaction of the time periods for existence of such exception, the leak detection system 10 shuts down the identified leaking hydraulic system (e.g., shears 11 and/or reel drive motor 38). Shutting down a hydraulic system can include shutting off the flow of hydraulic fluid from the reservoir tank 22 to pump 21 and shutting off power to pump 21. The hydraulic fluid flow can be shut off at reservoir tank 22 by turning a valve in line 27 to a closed position.
If a leaking exception condition satisfying leaking parameters has been found, the leaking hydraulic system (e.g., shears 11 or reel drive motor 38) causing the leaking event to be identified may be shut down and the indicator or display signals are sent to console to warn that a leaking event has been identified. The leak detected light 58 can be turned on and optionally an auditory alarm can also be issued.
In one embodiment, following the completion of the various pre-leak detection monitoring checks, leak detection system 10 can monitor one or both connected hydraulic systems (shears 11 and/or reel drive motor 38) by monitoring flow though flow meters 45 and 46 and comparing such monitored flow to certain predefined flow amounts for the particular hydraulic system being monitored.
In one embodiment leak detection system 10 provides a predefined startup period of time from activation of a hydraulic system to beginning of monitoring operations of flow meters 45 and 46. Such predefined start up period of time allows the monitored hydraulic system time to stabilize before leak detection system 10 begins looking for leaking exceptions in monitoring conditions. In one embodiment such predefined start up period of time can be at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, and/or 50 seconds. In various embodiments such predefined period of time can be a range between any two of the specified time periods.
Exceptions for leak detection can be identified by leak detection system 10 where a measured parameter falls outside of the predefined allowed ranged for such measured parameter. Additionally, preferably leak detection system 10 requires that the exception be present for a predetermined period of time before considering that an identified leaking exception is considered a leaking event and acting accordingly, such as by shutting down pump 21 and/or the hydraulic system (e.g., shears 11 or reel drive motor 38) causing the identified leaking exception to be present.
In one embodiment leak detection system 10 can be user programmed regarding the frequency of sampling of which the system accepts signals from the plurality of flow meters 45 and 46. Although “continuous” is used in this specification it is anticipated that, in any given time period, only a finite number sampling of measurements can be taken by leak detection system 10.
In various embodiments embodiment sampling rates can be at least 1, 5, 10, 50, 100, 120, 150, 200, 300, 500, 1000, 2000, or 3000 Hertz. In various embodiments sampling rates can be a range between any two of the specified sampling rates.
In one embodiment leak detection system 10 responds or reacts rapidly to an identified leaking event, such as by shutting off power to pump 21 along with shutting off fluid flow from reservoir 22 to pump 21. With the occurrence of such an event, leak detection system 10 can also issue a warning signal such as be lighting lamp 57 or lamp 58, along with possibly issuing a audible warning signal such as a siren.
In one embodiment, after a leaking event is determined, leak detection system 10 will shut down the flagged hydraulic system (shears 11 or reel drive motor 38). This can occur after determining a leaking exception exists for a predetermined time. In one embodiment such predefined period of time that the leaking exception must exist before a leaking event can be identified, can be at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, 50, and/or 60 seconds. In various embodiments such predefined period of time can be a range between any two of the specified time periods. In various embodiments the user can program this predefined period of time and/or range into leak detection system 10.
In one embodiment benchmark conditions in a known non-leaking conditions to be expected when taking sampling measurements can be automatically programmed into the method and apparatus. In one embodiment predefined exception conditions can be programmed into leak detection system 10 based on actual operating conditions of the hydraulic system being monitored (e.g., shears 11 and/or reel drive motor 38). In one embodiment, the default predefined button can be provided in leak detection system 10, and a method of programming predefined conditions for flow meters 45 and 46 can be as follows:
With hydraulic shear system 11, hydraulic power can be suppled by pump 21 though lines 31 and 32 which respectively flow through lines 41 and 42. The ratio of flow measured by flow meter 45 to compared to flow meter 46 (or vice versa) can be calculated by controller 33 and such ratio be set in the method and apparatus as the ideal predefined ratio in a non-leaking condition.
As best can be seen in
For reel drive motor 38 hydraulic power can be suppled by pump 21 though lines 31 and 32 which power reel drive motor 38 to outlay or take up lines 41 and 42. The ratio of flow measured by flow meter 45 to 46 can be calculated by controller 33 and such ratio be set as a predefined ratio in a non-leaking condition. However, this ratio in a non-leaking situation is expected to be 1:1 and this step can be omitted for programming the leak detection parameters for reel drive motor 38.
Unlike shears 11, reel drive motor 38 operably connected to hose reel 40 (and rotating reel 40 to outlet and take up of flow lines 41 and 42) will have input and output lines which, in a non-leaking condition, are expected to have a 1:1 ratio of hydraulic fluid entering and exiting driving motor 38.
As best can be seen in
In one embodiment, where the push rod has a diameter Dr and the piston has a diameter DP the ratio between the two flow rates will be the same as the ratio of the cross sectional areas on either side of the piston, and can be calculated by the formula:
In this embodiment a user can enter the diameter of the rod “Dr”and the diameter of the piston “DP” and the method and apparatus can calculate the ideal predefined ratio in a non-leaking condition from which allowable variations can be looked for by the method and apparatus.
Customizing Allowable Variations from Predefined Non-Leaking Ratios
In various embodiments a user can custom program leak detection system 10 to allow a variation of a selected amount from the predefined ratio in a non-leaking condition for either the hydraulic shear system 11 and/or reel drive motor 38. In various embodiments such can be a symmetrical variation from the initial predefined ratio can be an allowable percentage variation from the initial predefined ratio. In various embodiments this allowable percentage can be at least about 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, and/or 50 percent. In various embodiments such exception variations can differ from variations above compared to variations below the user selected value in a non-leaking condition (e.g., the initial predefined ratio).
In various embodiments the lower limit can be one of the specified allowable variations, and the upper limit can be a different one of the specified allowable variations.
In various embodiments such user selected predefined parameters may be changed from time to time as the user desires.
At different points in time the user can use the default program button to calculate another predefined ratio for either hydraulic system (shear 11 or drive motor 38) as either hydraulic system's non-leaking characteristics may change over time. In one embodiment such predefined variations can be numerically entered into controller 33 by a computer.
As disclosed herein it is anticipated that leak detection system 10 can have programmed multiple sets of ratios for flow in flow meters 45 and 46 based on the different hydraulic systems which flow meters 45 and 46 are measuring flow in relation to. For example, when reel drive motor 38 is operating to lay out or take up hoses 41 and 42 (respectively lowering or raising shears 11), hydraulic shears 11 will not be operating. Accordingly, the values programmed for reel drive motor 38 are used by leak detection system 10.
During operations leak detection system 10 system can go through various checks for catastrophic leaking events which are designed to ensure that the connected hydraulic systems (e.g., shears 11 and reel drive motor 38) do not suffer a catastrophic leaking event. In one embodiment leak detection system 10 will shut off hydraulic power to the hydraulic pump 21 and/or hydraulic systems if one or more pre-monitoring exceptions are found.
Catastrophic monitoring exceptions can include, but are not limited to:
If one or more of the above catastrophic leak detection monitoring exceptions are found, leak detection system 10 can turn off power to pump 21, shut down the hydraulic systems, and issue a warning signal indicating the identification of a catastrophic leak detection event. The pressure exerted by the hydraulic fluid can be monitored by pressure transducers in flow lines 31, 32, 41, and 42.
The following example illustrates the continuous calculation of a ratio of one chamber section 17 and the other chamber section 18. In the Example 1 below, the computer or controller 33 of control station 30 continuously calculates the ratio of fluid that enters or departs from the chamber 18 and compares that volume of fluid with the volume of fluid that enters or departs from the chamber section 17. The flow meters 45, 46 provide data to the controller or computer 33. If the computer 33 calculates that the ratio of the volume of fluid entering and exiting the cylinders differs from a ratio for example of 2.28:1 in the following example, the computer knows that a leak has occurred and it sends a signal to the solenoid valve 64 to shut off the flow of diesel fuel to the engine 20 thus deactiving the engine 20. In the case of an electric motor 50, the computer or controller 33 sends a signal to the solenoid operated switch 66 which deactivates the electric motor 50.
An exemplary hydraulic cylinder could have the following dimensions:
Cylinder bore=8 inches (20 cm), cylinder rod=6 inches (15 cm), cylinder stroke=20.5 inches (52 cm)
For this system, shutdown occurs when the difference in volume entering and exiting the cylinder is different from the ratio between the cylinder piston area and the cylinder annulus area. The annulus area is equal to the piston area minus the rod area. The computer or controller 33 which is part of the control system 30 compensates for this difference in volume, continuously calculating the ratio based upon input from the flow meters 45, 46. The computer or controller 33 can be a commercially available “Plus +1” controller available from Sauer-Danfoss (e.g. models MC024-010 or MC024-012).
The piston end volume is equal to the Cylinder Piston Area times the Cylinder Stroke
Cylinder piston area=Piston Diameter squared times a constant of (0.7845)
8″ (20 cm) squared (×) 0.7854=50.26 sq. in. (324.26 sq. cm)
Piston End Volume=50.26 sq. in. (324.26 sq. cm) (×) 20.5 in. (52 cm)=1030.33 cu. in.or 4.46 gallons (16,884.1 cu. cm)
The Rod end volume is equal to the Cylinder Annulus Area times the Cylinder Stroke
Rod Area=6″ (15 cm) squared (×) 0.7854=28.27 sq. in. (182.39 sq cm)
Cylinder Annulus=50.26 sq. in. (324.26 sq. cm) (−) 28.27 sq. in. (182.39 sq cm)=21.99 sq. in. (141.87 sq. cm)
Rod End Volume=21.99 sq. in. (141.87 sq. cm) (×) 20.5 in. (52 cm)=450.79 cu. in. or 1.95 gallons (7,381.6 cu. cm)
The ratio between the Piston End volume and the Rod End volume is (2.28:1)
Under normal operations with no leak present, the volume entering and exiting the cylinder will differ by the ratio of (2.28:1). If a leak occurs, the computer or controller 33 will then calculate a ratio that is not 2.28:1 and stop the prime mover, 20 or 50.
Thus, if at any time the ratio of volume entering and exiting the cylinder is a value that is different from the ratio of (2.28:1) the controller or computer 33 will send a signal to shut down the diesel engine or electric motor and thus the hydraulic device 11.
The following is a list of parts that correspond to
The following is a list of parts that correspond to
The following is a list of parts that correspond to
The following is a list of parts that correspond to
The following is a list of parts that correspond to
The following is a list of parts and materials suitable for use in the present invention:
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
This is a non provisional patent application of U.S. Provisional Patent Application Ser. No. 61/586,530, filed 13 Jan. 2012, and U.S. Provisional Patent Application Ser. No. 61/727,324, filed 16 Nov. 2012. Priority of U.S. Provisional Patent Application Ser. No. 61/586,530, filed 13 Jan. 2012, and U.S. Provisional Patent Application Ser. No. 61/727,324, filed 16 Nov. 2012, each of which is hereby incorporated herein by reference, is hereby claimed.
| Number | Date | Country | |
|---|---|---|---|
| 61727324 | Nov 2012 | US | |
| 61586530 | Jan 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13741074 | Jan 2013 | US |
| Child | 16786356 | US |
