Patent Application
20190003917
The field of the disclosure relates generally to containment vessels and, more particularly, to a method and system for verifying leak tightness of a containment vessel boundary.
At least some known hydrogen or hydrogen and water cooled generators are maintained to be gas tight to prevent uncontrolled loss of hydrogen to ambient. During outages, the generator casing and/or stator cooling water cycle is checked to avoid hydrogen leaks when the generator is brought back online.
Known leak test procedures include filling the containment vessel to be tested, such as, but not limited to the hydrogen cooled generator, with a testing fluid, for example, a gas, such as air or nitrogen (N2) or a liquid such as water. After reaching a predetermined test pressure, the filling is stopped and the hydrogen cooled generator system is permitted to stabilize, however the testing gas pressure may oscillate due to temperatures in the system stabilizing over time, and may only reach an equilibrium value after several hours. The testing phase is started after a suitable equilibrium is reached, typically by determining that the internal pressure level has been stabilize for a period of time. During the testing phase, various temperatures and pressures are recorded and an algorithm is used to determine a system leakage rate. In various instances, the duration of stabilization of the system parameters is between approximately three and twenty-four hours and the entire test duration is therefore greater than twenty-four hours. Checking the generator and associated piping for leakage typically lies on the critical path of maintenance activities during the outage. Accordingly, any time that is able to be eliminated from the testing procedure directly impacts the length of the outage.
In one embodiment, a leakage tightness testing system for checking a tightness of a test vessel having a test vessel internal volume and a test vessel thermal inertia characteristic includes an external reference vessel coupled in flow communication to the test vessel. The external reference vessel includes an external reference vessel volume that includes an insulative material layer at least partially covering the external reference vessel. The insulative material layer is configured to approximately match a thermal inertia characteristic of the external reference vessel to the thermal inertia characteristic of the test vessel. The leakage tightness testing system also includes a leakage testing device coupled in flow communication to the test vessel and the external reference vessel. The leakage testing device includes a leakage sensor.
In another embodiment, a method of performing a leakage tightness test of a test vessel includes coupling an external reference vessel in flow communication with the test vessel and charging the test vessel and external reference vessel, with a test gas, to a predetermined initial test pressure during a filling phase of the leakage tightness test. The method also includes monitoring a pressure of at least one of the test vessel and the external reference vessel for a stabilization of the test pressure and beginning the leakage tightness test of the test vessel when the monitored pressure is stable within a predetermined pressure range.
In yet another embodiment, a leakage tightness testing system for measuring a leakage rate of a test vessel having a test vessel volume includes an external reference vessel coupled in flow communication to the test vessel. The external reference vessel includes an external reference vessel volume and an insulative material layer at least partially covering the external reference vessel. The insulative material layer is configured to approximately match a thermal inertia characteristic of the external reference vessel to the thermal inertia characteristic of the test vessel.
Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced and/or claimed in combination with any feature of any other drawing.
Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems includes one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.
The following detailed description illustrates embodiments of the disclosure by way of example and not by way of limitation. It is contemplated that the disclosure has general application to analytical and methodical embodiments of testing leakage in vessels in industrial and commercial applications.
Embodiments of a leakage tightness testing method and system that uses a relatively large external reference vessel than is used in the current art are described herein. A leakage tightness test is a procedure performed to verify an integrity of a pressure boundary. The leakage tightness testing of a large pressure vessel, also referred to herein as a “test vessel,” such as a utility electrical generator, is influenced by ambient parameters like temperature and atmospheric pressure. The test for tightness uses test equipment including a leakage sensor, such as, but not limited to a pressure measurement device, a differential pressure sensor, a flow measurement device, and the like. As used herein, the leakage sensor refers to any sensor or suite of sensors configured to detect a leakage of the pressurized fluid from the leakage tightness testing system. Other test equipment used during the leakage tightness test may include valves, temperature sensors, pressure sensors, and an external reference vessel. After pressurization of the test vessel and the external reference vessel, the pressures in both vessels will stabilize after a period of time. After the pressures in both vessels maintain steady state values, monitoring of the test equipment is started. Any change of ambient temperature surrounding the test vessel and the external reference vessel has an impact on the pressure inside of the vessels. The smaller a volume of the vessel, the faster is the impact. The external reference vessel has a smaller thermal capacity than the test vessel, so the pressure inside external reference vessel changes more rapidly than the pressure in the test vessel. Because of the different time constants for the reaction of the pressure changes in the test vessel and the external reference vessel and the goal to test the test vessel in as short a period of time as possible, the measurement results could show false results, leading to discarding the measurement. In order to avoid or to mitigate the thermal impact on the external reference vessel, the external reference vessel is insulated to match the thermal behavior of the test vessel. Therefore, the thermal behavior of the test vessel to a change of internal temperature of the test vessel is similar to the thermal behavior of the external reference vessel to a change in its internal temperature. By insulating the external reference vessel, the thermal inertia of the test vessel and the external reference vessel can be made comparable. The influence of ambient temperature on both the test vessel and the external reference vessel on the inner temperature and pressure of both vessels are made similar. Thus, eliminating or mitigating the ambient temperature influence, which can reduce the testing time.
The following description refers to the accompanying drawings, in which, in the absence of a contrary representation, the same numbers in different drawings represent similar elements.
In the example embodiment, the insulative qualities of insulative material 324 facilitate making external reference vessel 206 a better reference for pressure decay testing of test vessel 100. For example, insulative material 324 is configured to permit external reference vessel 206 to approximate a similar thermal behavior as test vessel 100. As used herein, thickness 322 may refer to a physical dimension of insulative material 324 or may refer to a thermal dimension of insulative material 324 wherein the thermal dimension relates to a thermal conductivity of insulative material 324 and may include a thermal storage capability of insulative material 324. Additionally, external reference vessel 206 is of a greater volume than typical reference vessels. In one embodiment, internal volume 314 of external reference vessel 206 is approximately one-twentieth the internal volume 304 of test vessel 100. In another embodiment, internal volume 314 of external reference vessel 206 is approximately one-tenth the internal volume 304 of test vessel 100. In still another embodiment, internal volume 314 of external reference vessel 206 is approximately one-fifth the internal volume 304 of test vessel 100.
In the example embodiment, leakage testing device 202 includes a computing device or processor 330 coupled to a memory device 332. Processor 330 may receive inputs from for example, first pressure sensor 316, first temperature sensor 318, second temperature sensor 320, an ambient pressure sensor 334, and/or an ambient temperature sensor 336. Processor 330 may generate output to control various valves 218 in leakage tightness testing system 200 configured to, for example, isolate test vessel 100, external reference vessel 206, leakage sensor 216, and test fluid 212. Any of valves 218 may controlled by modulating its position between fully open and fully closed using any of the parameters received by leakage tightness testing system 200 including parameters stored in memory device 332, such as, in a look-up table or model of leakage testing device 202, external reference vessel 206, and test vessel 100.
The term processor, as used herein, refers to central processing units, microprocessors, microcontrollers, reduced instruction set circuits (RISC), application specific integrated circuits (ASIC), logic circuits, and any other circuit or processor capable of executing the functions described herein.
As used herein, the term “computer” and related terms, e.g., “computing device”, are not limited to integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein.
As used herein, the terms “software” and “firmware” are interchangeable, and include any computer program stored in a memory device for execution by mobile devices, clusters, personal computers, workstations, clients, servers, and processor 330 wherein the memory includes random access memory (RAM) memory, read only memory (ROM) memory, erasable programmable read-only memory (EPROM) memory, electrically erasable programmable read-only memory (EEPROM) memory, and non-volatile RAM (NVRAM) memory. The above memory types are examples only, and are thus not limiting as to the types of memory usable for storage of a computer program.
Memory device 332 may include, but is not limited to, random access memory (RAM) such as dynamic RAM (DRAM) or static RAM (SRAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), and non-volatile RAM (NVRAM). The above memory types are examples only, and are thus not limiting as to the types of memory usable for storage of a computer program and data.
In one embodiment, the pressure drop in, for example, mm Hg during the test duration may be determined using equations and/or algorithms programmed for use by processor 330. The pressure decay within leakage tightness testing system 200 over time is related to the leakage from test vessel 100. In one embodiment, a verification that insulative material 324 provides approximately the same thermal inertia characteristic to shell 312 of test vessel 100 is performed. If not, insulative material 324 may be changed to another material, or thickness 322 may be adjusted until the thermal inertia characteristic of external reference vessel 206 approximates the thermal inertia characteristic of test vessel 100. In one embodiment, the pressure drop in mm Hg during the test duration is determined from a difference between an initial gauge pressure of leakage tightness testing system 200 and the final gauge pressure of leakage tightness testing system 200, a difference between an initial barometric pressure proximate leakage tightness testing system 200 and the final barometric pressure proximate leakage tightness testing system 200 corrected for a change in average gas temperature of proximate leakage tightness testing system 200 during the test.
The above-described leakage tightness testing system provides an efficient method for determining a leakage in a test vessel, such as, but not limited to an electrical generator casing. Specifically, the above-described leakage tightness testing system includes an external reference vessel that is sized and insulated to approximately match the thermal behavior of the test vessel. This matching provides an ability to stabilize the pressures and temperatures in the test vessel and leakage tightness testing system faster than previously possible.
As will be appreciated based on the foregoing specification, the above-discussed embodiments of the disclosure may be implemented using computer programming or engineering techniques including computer software, firmware, hardware or any combination or subset thereof. Any such resulting program, having computer-readable and/or computer-executable instructions, may be embodied or provided within one or more computer-readable media, thereby making a computer program product, i.e., an article of manufacture, according to the discussed embodiments of the disclosure. The computer readable media may be, for instance, a fixed (hard) drive, diskette, optical disk, magnetic tape, semiconductor memory such as read-only memory (ROM) or flash memory, etc., or any transmitting/receiving medium such as the Internet or other communication network or link. The article of manufacture containing the computer code may be made and/or used by executing the instructions directly from one medium, by copying the code from one medium to another medium, or by transmitting the code over a network. The technical effect of the methods and systems may be achieved by performing at least one of the following steps: (a) coupling an external reference vessel in flow communication with the test vessel, a volume of the external reference vessel being greater than one-twentieth the volume of the test vessel, (b) charging the test vessel, and external reference vessel, with a test gas to a predetermined initial test pressure during a filling phase of the leakage tightness test, (c) monitoring a pressure of at least one of the test vessel and the external reference vessel for a stabilization of the pressure, and (e) beginning the leakage tightness test of the test vessel when the monitored pressure is stable within a predetermined pressure range.
The above-described embodiments of a method and system of leakage tightness testing provide a cost-effective and reliable means for providing determining a tightness of a pressure vessel. More specifically, the methods and systems described herein facilitate reducing a time to stabilization of the leakage tightness testing system, which directly impacts the length of the leakage tightness test. As a result, the methods and systems described herein facilitate reducing the time it takes to perform the leakage tightness test in a cost-effective and reliable manner.
Exemplary embodiments of leakage tightness testing systems are described above in detail. The leakage tightness testing systems, and methods of operating such systems and component devices are not limited to the specific embodiments described herein, but rather, components of the systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other systems using an insulated and relatively larger volume external reference vessel, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other pressure vessel applications and other non-pressure vessel applications.
Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include 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.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1756086 | Jun 2017 | FR | national |
