Patent Application
20170185093
This invention relates to a unique method and system for delivery of acetylene from any multiple trailer combination, or primary trailer-reserve bank configuration, to a point of use at a constant delivery pressure without significant interruption in supply.
There are many operations that utilize large amounts of acetylene, making the use of a single cylinder at a time impractical. In these instances, as an alternative, several cylinders can be interconnected and used in combination with a manifold to provide a constant source of acetylene to an operation. A conventional arrangement involves cylinders that are delivered to the worksite or customer point of use where they are interconnected together with a manifold. Equipment may be utilized to regulate the delivery of acetylene to a point of use. However, such a manifold of cylinders contains numerous drawbacks. For example, the supply of acetylene can be interrupted due to delays in switching from an empty acetylene source to a fresh acetylene source. Additionally, there is generally a lack of proper monitoring means for ensuring when the acetylene supply system has deviated from preset operational limits. Still further, the cylinders generally have to be transported to a refilling station when the delivery pressure drops below a predetermined set point.
More recently, in an attempt to more effectively supply larger amounts of acetylene in comparison to cylinders which are interconnected by a manifold, multiple cylinders have been arranged on a trailer and then used at a site while remaining on the trailer. Such an approach eliminates the unloading and reloading of the cylinders at the point of use, thereby making it easier to replace empty cylinders with filled cylinders. However, such acetylene trailer arrangements still suffer numerous drawbacks, including interruptions in supply of acetylene to the point of use as a result of delays occurring during switchover from an empty trailer to a new trailer. Additionally, conventional acetylene trailer systems continue to lack proper monitoring means for ensuring when the acetylene supply system has deviated from preset operational limits.
Interrupted supply of acetylene typically leads to significant downtime, production costs and unacceptable reduction in throughput. In view of such drawbacks, there is a need for improved acetylene supply systems.
This invention in one aspect relates to a portable skid-mounted apparatus that includes valving, conduit, pressure regulators, transmitters, status indicators and other equipment specifically tailored for safe and controlled acetylene flow at controlled delivery pressures not exceeding a predetermined level. The apparatus is compact and modular in design so that it can be readily transported to a customer site where it can then be installed to the customer acetylene sources. When one of the acetylene sources is detected to reach a minimum pressure state, a controller that is assembled onto the skid-mounted apparatus is configured to automatically switch to the other acetylene source to resume flow. The acetylene source is allowed to increase in temperature until the partial pressure of acetylene increases to a level that is sufficient to resume flow therefrom at the required delivery pressure. Flow resumes from the original acetylene source until the pressure in the source is reduced to a final value at which point the source is removed from operation. Remote alert notifications are provided to indicate a change in status of the acetylene sources. In this manner, increased utilization is provided form the acetylene sources and supply to a customer is substantially uninterrupted. method for preparing a pressure vessel for receiving high purity acetylene at elevated pressure, said method comprising:
In one aspect, a system for maximizing utilization of supply of acetylene at a substantially constant delivery pressure to a point of use, comprising: a first acetylene source and a second acetylene source; the first acetylene source characterized by an initial source pressure comprising a first set of cylinders manifolded together to provide the supply of acetylene at the substantially constant delivery pressure; the second acetylene source comprising a second set of cylinders manifolded together to provide the supply of acetylene at the substantially constant pressure; each of the first set and the second set of cylinders comprising a porous filler with solvent selected from the group consisting of dimethylformaldehyde (DMF), acetone and N-methylpyrrolidone (NMP) into which pressurized acetylene is absorbed; the first acetylene source and the second acetylene source operably connected to a portable apparatus, said portable apparatus, comprising: a discharge manifold in fluid communication to the first acetylene source and the second acetylene source; and a controller to maximize the supply of acetylene from the first acetylene source, the controller having as an input, the delivery pressure of the acetylene, and the controller configured to switch supply to the second acetylene source when the controller determines the initial source pressure from the first acetylene source decreases by no more than 80% of the initial source pressure, and further wherein the controller is configured to divert from the second acetylene source back to the first acetylene source to resume supply of acetylene from the first acetylene source when determining the pressure of the first acetylene source is greater than the delivery pressure.
In a second aspect, a method for remotely monitoring an acetylene source which attains a change in status to a remote unit, comprising: providing a controller configured to monitor process variable information of a first acetylene source and a second acetylene source, said process variable information selected from the group consisting of valve position status, initial source pressure, source pressure, flow rate, manifold pressure, pipeline pressure at the point of use, and temperature; said controller detecting when the first acetylene source has undergone the change in status between a minimum pressure state, a permanent or temporary depleted state and an online state; and transmitting in response to said change in the status an alert notification to a remote unit over a cellular network or cyber secure internet link.
In a third aspect, a process for optimizing acetylene supply to a point of use, comprising the steps of: directing a flow of acetylene from a first acetylene source at a predetermined delivery pressure, said first acetylene source characterized by a first initial source pressure; switching to the second acetylene source when a pressure of the first acetylene source has decreased by no greater than 80% of the first initial source pressure; directing flow from the second acetylene source; designating the first acetylene source in standby mode and allowing the pressure of the first acetylene source to increase to greater than 20% of the first initial source pressure; and diverting supply of acetylene to the first acetylene source when the pressure of the first acetylene source increases to greater than 20% of the first initial source pressure.
In a fourth aspect, a portable on-site apparatus configured for automatically controlling supply of acetylene from multiple acetylene trailers, said portable-onsite apparatus comprising: a discharge manifold, said manifold adapted to interconnect to at least a first acetylene source and a second acetylene source to allow the supply of acetylene at a substantially constant delivery pressure to a point of use from either the first acetylene source or the second acetylene source; a controller to maximize the supply of the acetylene from the first acetylene source, the controller having as an input, the delivery pressure of the acetylene, and the controller configured to switch supply from the first acetylene source to the second acetylene source when the controller determines a pressure of the first acetylene source decreases by no greater than 80% of an initial source pressure of the first acetylene source, and further wherein the controller is configured to divert from the second acetylene source to the first acetylene source to resume supply of acetylene from the first acetylene source when determining the pressure of the first acetylene source is sufficient to supply the acetylene at the substantially constant delivery pressure; a modular platform characterized by a footprint having an area of no more than about 50 ft2, said modular platform configured to receive said controller and said discharge manifold.
As will be described, the present invention offers a transportable skid-mounted apparatus 50 that is designed to offer substantially uninterrupted acetylene supply to a point of use 40 while increasing acetylene utilization from the sources. The process 1 that incorporates the transportable skid-mounted apparatus 50 is flexible and eliminates the need to assemble acetylene supply systems at a point of use. Additionally, the process 1 optimizes the use of large amounts of compressed acetylene sources at the point of use 40.
In one aspect, and as will now be described with reference to
Referring to
Because acetylene can decompose explosively into carbon and hydrogen under conditions of high pressure and temperature, even in the absence of air or oxygen, the acetylene cylinders as used herein are specifically prepared to avoid decomposition of acetylene. In particular, each of the first set and second set of cylinders 11 and 21, respectively, are prepared to contain porous filler with solvent distributed into the porous material. Solvent such as acetone, dimethylformamide (DMF) or N-methylpyrrolidone (NMP) can be employed. The porous filler is a porous mass generally having a certain porosity, such as, by way of example, a porosity of about 10-90% by volume; preferably about 30-90% by volume; and more preferably about 50-90% by volume. The porous filler allows the acetylene to be separated into small units in the pores that help to inhibit the decomposition of acetylene when stored within the first set and second set of cylinders 11 and 21, respectively. The solvent absorbs a sufficient amount of acetylene to enable high cylinder loading in the cylinders. DMF is preferably used as the solvent. One method for possible cylinder preparation for charging high purity acetylene is descried in U.S. Pat. No. 8,322,383, the contents of which are hereby incorporated by reference in their entirety. Other suitable methods for acetylene cylinder preparation as known in the art may also be employed.
After preparation of the first set of cylinders 11 and the second set of cylinders 21, acetylene may be charged therein. Methods for filling the first set of acetylene trailers 10 and the second set of acetylene cylinders 20 are described in U.S. Patent Publication Application Nos. 20130213521 and 20140290791, the contents of both which are hereby incorporated by reference in their entirety. Other suitable methods may also be utilized. Having filled the first set of cylinders 11 and the second set of cylinders 21, they can be loaded onto their first trailer 10 and second trailer 20, respectively, and thereafter transported to the customer point of use 40. The point of use 40 can also be a manufacturing process, a reservoir for storage, point of consumption, a gas transport infrastructure, a pipeline or any other location that requires compressed acetylene.
The first of set of cylinders 11 are loaded onto the first trailer 10, and the second set of cylinders 21 are loaded onto the second trailer 20. It should be understood that the loading of cylinders 11 and 21 onto trailers 10 and 20, respectively, can occur before or after acetylene charging into the first set of cylinders 11 and the second set of cylinders 21. The first set of cylinders 11 are preferably manifolded together in a parallel arrangement so that each of the first set of cylinders 11 is supplying acetylene during operation of the first trailer 10. Similarly, the second set of cylinders 21 are preferably manifolded together in a parallel arrangement so that each of the second set of cylinders 21 is supplying acetylene during operation of the second trailer 20. In a preferred embodiment, each of the first and second trailers 10 and 20 can hold approximately 200 cylinders that are manifolded together to give a total available volume of approximately 75,000 cubic ft. It should be understood that the first and second trailers 10 and 20 can be modified as known in the art to hold a higher number or lower number of cylinders as needed for a particular application.
In accordance with one aspect of the present invention,
The skid mounted apparatus 50 acts as a fluid conduit between the trailers 10 and 20 and the customer point of use 40 that is able to activate flow from either the first trailer 10 (labelled Acetylene Trailer A in
Referring to
The PLC 60 preferably receives the delivery pressure as a user input. The PLC 60 sends a signal to activate control valve 53 to an open position; sends another signal to activate control valve 99 to an open position to enable acetylene flow from the skid mounted platform 50 to the customer point of use 40; and checks to ensure that control valve 54 is set in the closed position so that acetylene is not inadvertently flowing from the second set of cylinders 21 loaded on the acetylene trailer 20 into the second flow leg 91. If control valve 54 is in the open position, the PLC 60 sends a signal to activate control valve 54 into the closed position. Any suitable method can be employed by which the PLC activates the various control valves 53, 54 and 99 into either the open or closed position. One example is as follows. Nitrogen is withdrawn from cylinders 77 and is directed to a pressure regulator 78 which regulates the pressure of the nitrogen to 90 psi. Thereafter, the nitrogen is directed to one of the solenoid valves 61, 62 or 63 which are in parallel arrangement with one another. The exact solenoid valve 61, 62 or 63 to which nitrogen is directed depends on which control valve 53, 54 or 99 is to be activated. Solenoid valve 61 is in communication with control valve 53; solenoid valve 62 is in communication with control valve 54; and solenoid valve 63 is in communication with control valve 99. Each of the solenoid valves 61, 62 and 63 is controlled by the PLC 60; and each of the solenoid valves 61, 62 and 63 is energized, as nitrogen is supplied to a pneumatic positioner (not shown) corresponding to the control valve 53, 44 and 99. For example, when solenoid valve 61 is energized by a 4-20 mA signal, nitrogen from the cylinders 77 is directed to the pneumatic positioner of the control valve 53, thereby causing the control valve 53 to open and close. Control valves 54 and 99 in
Valves 68 and 59 are shown in
At least control valve 54 is set in the closed position along the second flow leg 91 to prevent flow from the second set of cylinders 21 of the second trailer 20 when the primary acetylene trailer 10 is on-line.
Having configured the valving of the first flow leg 90 to the open position and the appropriate valving of second flow leg 91 to the closed position so as to prevent flow from the secondary acetylene trailer 20, acetylene can be supplied from the first set of cylinders 11 of the primary trailer 10. As acetylene flows from each of the first set of cylinders 11 contained in the primary trailer 10 into the inlet 81 of skid mounted apparatus 50, pressure regulating device 51 regulates the pressure of acetylene from the initial source pressure in the manifolded first set of cylinders 11 (e.g., about 250 psig at start-up) to a predefined delivery pressure. In a preferred embodiment, the predefined delivery pressure is set to about, 10-40 psig, preferably 10-25 psig and more preferably about 15 psig. It should be understood that the present invention can also supply acetylene at other delivery pressures. The exact delivery pressure may be dependent upon several factors, including the pressure required by the customer at the customer point of use 40 for the specific application for which the acetylene is utilized (e.g., welding gas, heat treating gas or carburization gas applications).
Acetylene continues to flow through a hose 71 connected to the pressure regulating device 51 and thereafter through check valve 74, and control valve 53 along the first flow leg 90. Acetylene from the first set of cylinders 11 enters one side of a discharge manifold 70, which is a conduit that unites the first flow leg 90 with the second flow leg 91. A pressure transducer/transmitter 87 measures the pressure of acetylene flowing into the discharge manifold 70; and then relays the signal as an input to the PLC 60. The PLC 60 may adjust the pressure if necessary by, for example, adjusting the pressure regulating device 51 to ensure the pressure of acetylene along the first flow leg 90 is within acceptable tolerance limits of the delivery pressure required at the customer point of use 40 (e.g., a delivery pressure of 15 psig, plus or minus 1 psig). Thereafter, the acetylene flows along a third flow leg 84 extending into the flash arrestors 80. The flash arrestors 80 are a safety device designed to stop an acetylene flash. The flash arrestors 80 as shown in
The acetylene emerges from the outlet of each of the flash arrestors 80, and then converges as a single stream that flows along the outlet flow leg 100. A pressure gauge 86 along the outlet flow leg 100 measures the pressure of the acetylene stream.
Acetylene at substantially constant delivery pressure continues to be supplied in this manner from the first set of cylinders 11 of the primary trailer 10 until the source pressure of acetylene from the first set of cylinders 11 in the primary trailer 10 has reduced to a predetermined minimum pressure. In particular, this predetermined minimum pressure is defined as the source pressure of acetylene decreasing by no more than about 70% of its initial source pressure, preferably no more than about 75% of its initial source pressure, and more preferably no more than about 80% of its initial source pressure. It should be understood that the source pressure may be measured with a pressure gauge (not shown) or pressure transducer, either of which is preferably located within the respective manifolded regions at which the first set 11 of cylinders are interconnected. Other suitable means for measuring the pressure are also contemplated. The process 1 of
A switchover from the first trailer 10 to the second trailer occurs 20 when the source pressure of the first trailer 10 has reduced to this predetermined minimum pressure level. Specifically, and in a preferred aspect of the present invention, the pressure transmitter 57 along the first flow leg 90 measures the source pressure of the acetylene from the first trailer 10 to decrease from an initial source pressure of 250 psig to no more than about 50 psig, which represents a 80% decrease in pressure. In response thereto, pressure transmitter 57 sends a signal to the PLC 60, which then directs control valve 53 to be set in the closed position along the first flow leg 90; and directs control valve 54 to be set in the open position along the second flow leg 91. The PLC 60 may direct the other valves on the second flow leg 91 to be set to the open position if previously in a closed position. Alternatively, such other valves may remain open to minimize the number of valves required to be opened and closed during switchover of acetylene supply between the first trailer 10 to second trailer 20 and vice versa. Valves 59 and 88 are manually configured in the open position. Alternatively, the valves 59 and 88 may be configured by signals relayed from the PLC 60 to the valves 59 and 88 if the valves 59 and 88 are control valves.
The PLC 60 transmits a signal to status indicator 93 that changes the status indicator 93 for the first trailer 10 from “online” to “offline”; and the PLC 60 sends another signal to status indicator 94 that changes the status indicator 94 for the second trailer 20 from “offline” to “online”. Additionally, the PLC 60 detects when the first acetylene trailer 10 has undergone the change in status between a minimum pressure state and an online state; and subsequently transmits an alert notification to a main central location and/or remote unit (e.g., cell phone, pager, computer) over a cellular network or cyber secure internet link indicating the first trailer 10 has changed status from an “online’ mode to an “offline” or “minimum pressure” mode, as will be explained in greater detail with respect to the embodiment of
Second trailer 20 is shown in
The acetylene emerges from the outlet of each of the flash arrestors 80, and then converges as a single stream that flows along the outlet flow leg 100. A pressure gauge 86 along the outlet flow leg 100 measures the pressure of the acetylene stream.
As acetylene is supplied from the second set of cylinders 21 of the second trailer 20, the present invention maintains operable connection of the first trailer 10 to the process 1. This is contrary to conventional acetylene supply systems which disconnect the primary acetylene source from operational use for re-filling. Applicants have discovered that as acetylene is withdrawn from the first set of cylinders 11, there is a cooling effect whereby the temperature of the cylinders 11 is reduced. Without being bound by any theory, the cooling effect may occur to a degree where a portion of the acetylene liquefies. As a result of the liquefaction, the cylinder 11 pressure is reduced as hereinbefore described, and may be reduced further to a level that is below the predetermined minimum pressure limit (e.g., no more than about 80% decrease in initial source pressure of the first set of cylinders 11). Further, the present invention recognizes that as the temperature of the first set of cylinders 11 decreases, the solvent contained therewithin has a greater affinity for acetylene in the cylinder whereby it has a tendency to hold a larger volume of residual acetylene, thereby reducing the available capacity of acetylene vapor in the acetylene cylinder 11. Monitoring equipment and control systems will generally indicate to the user or operator a so-called “false positive” improperly indicating that the acetylene cylinders 11 are empty and need to be disengaged and removed from the process 1 and replaced with a new acetylene source. However, Applicants have discovered that the acetylene is not entirely depleted at this stage. In addition to this false positive, as mentioned hereinbefore, the continued supply of acetylene from the first set of cylinders 11 below a predetermined minimum pressure may cause undesirable entrainment of the solvent with the acetylene withdrawn from the cylinders 11, resulting in not only lower acetylene delivery pressure, but lower purity levels that may not meet applicable purity specifications at the customer point of use 40 for certain applications, thereby causing conventional supply systems to abort use of the primary trailer 10.
In accordance with the principles of the present invention, and contrary to conventional acetylene supply systems, the offline trailer 10 is not disengaged from the process 1; nor is the offline trailer 10 re-filled while in the “offline” or “standby” mode. Rather, the primary trailer 10 maintains operably connected to the skid-mounted apparatus 50 without re-filling for a certain duration, and with the status indicator 93 indicating an “offline” or “standby” mode. During this so-called temporary “offline” or “standby” mode, the first set of cylinders 11 will increase in temperature as a result of absorbing ambient heat and/or subject to other suitable heating means, thereby causing the residual liquefied acetylene to re-vaporize such that the partial pressure of acetylene in the first set of cylinders 11 is increased to a level sufficiently high enough to supply therefrom at the predetermined delivery pressure. The pressure in the first trailer 10 is greater than the delivery pressure. In one example, the pressure in the first trailer 10, while being temporarily offline, increases to greater than 50 psig, such as by way of example, about 59 to about 65 psig, preferably 60 to about 62 psig, and more preferably about 61 to about 65 psig, prior to the controller 60 switching from the second trailer 20 to the first trailer 10 and resuming supply from the first trailer 10. The pressure in the manifolded first set of cylinders 11 of the first trailer 10 is preferably monitored to determine when the pressure of acetylene has risen to above the delivery pressure, and in a more preferred embodiment, has risen to a pressure of at least 60 to about 62 psig. Depending on the heating means and number of cylinders 10, the duration that the first set of cylinders 11 may remain offline is approximately 1-75 hours or in another example 10-48 hours. In yet another example, the first set of cylinders is offline for 1-24 hours.
When the source pressure in the cylinders 11 of the first trailer 10 has risen to a sufficient level to generate the required delivery pressure, PLC 60 reactivates supply from the first trailer 10. In one example, supply of acetylene from the first trailer 10 increases to greater than 20% of an initial source pressure, which can be greater than 50 psig. In this regard, PLC 60 direct signals to activate control valve 53 along the first flow leg 90 to be set to an open position. Valve 68 is shown as a manual valve and is set to the open position if previously set to the close position. Alternatively, valve 68 may remain in the open position to simplify operation by reducing the number of valves that must be reconfigured between open and close positions. At minimum, control valve 54 along the second flow leg 92 is set in the closed position to prevent flow from the second set of cylinders 21 loaded on the second trailer 20. In this manner, the second trailer 20 is oriented to “standby” or “offline” mode, and the PLC 60 relays signals to change status indicator 94 of the second trailer 20 to standby/offline mode along with appropriate alert remote notifications (
With the appropriate valving for the first trailer 10 re-configured to the open position, supply of acetylene re-initiates from the first set of cylinders 11. Specifically, acetylene flows from each of the first set of cylinders 11 of the first trailer 10 and into the inlet 81 of skid mounted apparatus 50. Acetylene continues to flow through the apparatus 50 and to customer point of use 40 as previously described.
The process 1 recognizes that acetylene is being supplied a second time from the first trailer 10. As such, when the source pressure of the first set of cylinders 11 has reduced to a final pressure (e.g., less than delivery pressure of, by way of example, 15 psig), the cylinders 11 are considered depleted, at which point the PLC 60 send signals to abort supply from the first set of cylinders 11 and configure at least control valve 53 to the off position. Valves 68 and 88 can remain in the open position or also be set to the closed position.
Trailer 10 is disconnected from connection 102 to allow the trailer 10 to be removed from the inlet 81 of skid mounted apparatus 50. Status indicator 93 for the first trailer 10 may indicate “depleted” or “permanently depleted” and further indicate that a new trailer is required. Alert remote notifications to this effect are also relayed (
PLC 60 may reconfigure the valves along second flow leg 91 to allow flow to resume from the second trailer 20 such that it becomes the new primary trailer, while the previously depleted trailer 10 is disconnected from the skid mounted apparatus 50 and re-filled or replaced with a new trailer, to ensure uninterrupted flow is provided to the customer point of use 40 at substantially constant delivery pressure. Alternatively, PLC 60 may activate another trailer to serve as the primary trailer and the second trailer 20 continues to function as a secondary trailer as defined hereinbefore. Status indicators 93 and 94 are updated accordingly. Remote notifications can also be sent via a cellular network or secure internet connection to one or more remote units (e.g., cell phone, pager or computer) to alert customers, users and/or operators that the primary trailer 10 has been depleted and needs to be disconnected from the skid mounted apparatus 50 and replaced with a new acetylene source.
The present invention offers numerous benefits unprecedented within the context of acetylene supply systems. For example, the ability to regulate delivery pressure and monitor when switchover from a primary acetylene source to a second acetylene source occurs can prevent the temperature of the cylinder from reducing to a level where unacceptable amounts of solvent begin to be entrained with the withdrawn acetylene, thereby reducing the purity of the acetylene to the customer point of use 40. Applicants have discovered that lower temperature increases solvent affinity for acetylene and increases the tendency for solvent to be entrained with the acetylene that is withdrawn from its respective acetylene source. The present invention can minimize, reduce or eliminate the amount of solvent that is entrained with the acetylene that is withdrawn from the first set of cylinders 11, by switching to a secondary acetylene source when the pressure in the primary acetylene source is reduced to a predetermined minimum pressure. The predetermined minimum pressure defines the minimum pressure to be delivered to a customer point of use 40 before solvent impurities are introduced. In a preferred embodiment, the minimum pressure level is no more than 80% of the initial pressure. Specifically, when the pressure of the primary acetylene source is reduced from 250 psig to 50 psig, supply form the primary acetylene source stops, and the supply resumes from a secondary acetylene source, thereby avoiding solvent entrainment into the acetylene that is supplied to the customer point of use 40. As such, the purity level of acetylene is substantially maintained; the need to replenish the first set of cylinders 11 to the required solvent level is significantly reduced; and the utilization of the primary acetylene source 10 is increased in comparison to conventional acetylene supply systems.
As an additional means to ensure purity of the supplied acetylene, the skid-mounted apparatus 50 includes a condensate leg 69 for removal of moisture and/or other contaminants that may inadvertently accumulate in the conduits. The present invention recognizes that moisture in particular can accumulate in the flow legs 90 and/or 91 despite the flow legs 90 and 91 being purged with nitrogen prior to acetylene supply, during acetylene supply; and after acetylene supply from one of the trailers 10 and 20. Alternatively or in addition thereto, the impurities can arise if the connections to the trailers 10 and 20 are not clean or when the connections 81 and 82 to the trailers 10 and 20, respectively, are disconnected and re-connected to the skid-mounted apparatus 50. As such, the condensate leg 69 can be periodically opened to remove any moisture or contaminants entrapped within the process 1 of
The portability of the skid-mounted apparatus 50 can be better appreciated by
When the new primary acetylene trailer 10 arrives to the customer site 40, it is connected as shown in
In an alternative embodiment, the depleted primary trailer 10 can remain connected to the process 2 and be allowed to absorb heat and increase in temperature as described hereinbefore in connection with the embodiment of
In accordance with another embodiment, the present invention is configured to provide remote alert and fault notifications to registered remote devices 517, as shown in the communication infrastructure and system 500 of
The PLC 115a at customer location “a” is programmed to look for an alarm or shutdown of its respective acetylene process 1 or 2. Similarly, the PLC 115b at customer location “b” looks for an alarm or shutdown of its respective acetylene process 1 or 2. When the PLC 115a and 115b finds a fault, the process of notification begins whereby the respective PLC's 115a and 115b send a signal via the internet or local area network (LAN) to a Supervisory Data Control and Data Acquisition (SCADA) Server 507. The SCADA server 507 is a supervisory control system that collects all the information, including all the alarms and shutdowns at each customer site “a” and “b” from the multiple different on-site acetylene supply processes 1 and 2. In order words, the SCADA server 507 is a warehouse of information and monitors all the alarms for all the different systems and processes 1 and 2 (
If there is a fault (for example, an overpressure situation during delivery where the delivery pressure is 5 psig or higher than set point; the flash arrestors absorb a flash; or a clog exists in the process 1 or 4 that creates a sudden pressure rise above a certain safety threshold level), the PLC 115a and/or 115b at that particular site where the fault occurs will register an alarm at the customer location 60a/b, such as by way of the status indicators 93 and 94 (
In addition to such faults, the communication infrastructure 500 of
While it has been shown and described what is considered to be certain embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail can readily be made without departing from the spirit and scope of the invention. It is, therefore, intended that this invention not be limited to the exact form and detail herein shown and described, nor to anything less than the whole of the invention herein disclosed and hereinafter claimed. For example, suitable modifications for carrying out the process 1 and 4 for delivery of acetylene are contemplated. In particular, although the various embodiments have been described with regards to cylinders, it should be understood that any type of container for acetylene source can used, including, by way of example and not intending to be limiting, bulk vessels and ISO containers. Further, although the modularity of the apparatus 50 has been defined as skid-mounted, it should be understood that any other suitable portable apparatus or platform 49 may be utilized, having modularity and compactness. Still further, various components may be assembled in close proximity to the skid-mounted apparatus 50. For example, although the PLC 60 has been shown and described in the embodiments as located onto the platform 49 of the skid-mounted apparatus 50 for purposes of conforming to certain regulatory approvals, the PLC 60 and associated control panel can be configured so as to be, one example, 5-15 ft away from the edge of platform 49 when deployed in a nonclassified area. Further, although the embodiments have utilized pressure as the basis for switching between a primary source and a secondary source, it should be understood that other manipulated variables may be employed to serve as the basis for switchover, including temperature and flow rate.
