WO2018156313A1 - Leak detection system and related methods - Google Patents

Leak detection system and related methods Download PDF

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Publication number
WO2018156313A1
WO2018156313A1 PCT/US2018/015728 US2018015728W WO2018156313A1 WO 2018156313 A1 WO2018156313 A1 WO 2018156313A1 US 2018015728 W US2018015728 W US 2018015728W WO 2018156313 A1 WO2018156313 A1 WO 2018156313A1
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WO
WIPO (PCT)
Prior art keywords
jacket
pipe
equipment
detector
section
Prior art date
Application number
PCT/US2018/015728
Other languages
French (fr)
Inventor
Ralph G. Whitten
Charles A. Miller
Original Assignee
Nevada Nanotech Systems Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nevada Nanotech Systems Inc. filed Critical Nevada Nanotech Systems Inc.
Publication of WO2018156313A1 publication Critical patent/WO2018156313A1/en

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Classifications

    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00Investigating fluid-tightness of structures
    • G01M3/02Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/04Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00Investigating fluid-tightness of structures
    • G01M3/002Investigating fluid-tightness of structures by using thermal means
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00Investigating fluid-tightness of structures
    • G01M3/02Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/04Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
    • G01M3/16Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using electric detection means
    • G01M3/18Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using electric detection means for pipes, cables or tubes; for pipe joints or seals; for valves; for welds; for containers, e.g. radiators
    • G01M3/183Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using electric detection means for pipes, cables or tubes; for pipe joints or seals; for valves; for welds; for containers, e.g. radiators for pipe joints or seals
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00Investigating fluid-tightness of structures
    • G01M3/02Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/04Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
    • G01M3/20Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using special tracer materials, e.g. dye, fluorescent material, radioactive material
    • G01M3/22Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using special tracer materials, e.g. dye, fluorescent material, radioactive material for pipes, cables or tubes; for pipe joints or seals; for valves; for welds; for containers, e.g. radiators
    • G01M3/223Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using special tracer materials, e.g. dye, fluorescent material, radioactive material for pipes, cables or tubes; for pipe joints or seals; for valves; for welds; for containers, e.g. radiators for pipe joints or seals
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00Investigating fluid-tightness of structures
    • G01M3/02Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/26Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors
    • G01M3/28Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds
    • G01M3/2853Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds for pipe joints or seals

Definitions

  • Embodiments of the disclosure relate generally to systems for detecting a leak in section of piping, process equipment, or other structure, and to related methods. More particularly, embodiments of the disclosure relate to systems for leak detection configured to wrap around a portion of a system and having one or more detectors configured to detect a presence of one or more analytes, and to related methods.
  • BACKGROUND BACKGROUND
  • Leak detection is of particular importance in industrial facilities including factories, mining facilities, processing plants, refineries (e.g., oil refineries), or other chemical processing plants.
  • industrial facilities often include several hundred, if not thousands, of linear feet of process piping and associated equipment.
  • the piping may include many flanged connections, threaded connections, welded connections, and other connections between different sections of piping or equipment. Each connection between adjacent portions of piping and equipment provides a location with an increased likelihood of a leak.
  • process equipment and piping may be subject to corrosion, erosion, or other forms of degradation.
  • piping and equipment may be subject to corrosion from one or more of acids, gases (e.g., such as carbon monoxide, ammonia, chlorine, sulfur dioxide, hydrogen sulfide, etc.), or other materials carried by the piping.
  • gases e.g., such as carbon monoxide, ammonia, chlorine, sulfur dioxide, hydrogen sulfide, etc.
  • the piping may also be subject to corrosion due to the environment external to the piping.
  • a system for detecting a leak comprises a jacket disposed around an outer surface of a section of pipe or equipment and defining a volume between an inner surface of the jacket and the outer surface of the section of pipe or equipment, a connection means for connecting ends of the jacket to the outer surface of the section of pipe or equipment, a structure separating the outer surface of the section of pipe or equipment from the inner surface of the jacket, and a detector disposed between the outer surface of the section of pipe or equipment and the inner surface of the jacket.
  • a leak detection system comprises a jacket disposed around a circumference of a section of pipe or equipment, the jacket comprising a material impermeable or semi-permeable to a vapor carried by the pipe, a connection means for attaching the jacket around the circumference of the section of pipe or equipment, a material separating an inner surface of the jacket from an outer surface of the section of pipe or equipment, and at least one of at least one detector or at least one detector probe disposed within a space between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
  • a leak detection system comprises a jacket disposed around an outer surface of a section of pipe or equipment, the jacket comprising an exposed outer surface and a corrugated surface, at least some of the corrugated surface in contact with the outer surface of the section of pipe or equipment, a connection means for attaching the jacket around a circumference of the section of pipe or equipment, and at least one detector disposed within a space between the jacket and the outer surface of the section of pipe or equipment.
  • a method of detecting a leak comprises disposing a jacket around a section of pipe or equipment, providing one of a porous material and a spacer in a volume between an inner surface of the jacket and an outer surface of the section of pipe or equipment, providing at least one gas detector in the volume, and monitoring the volume for one or more analytes indicative of a leak in the section of pipe or equipment.
  • FIG. 1 A is a cross-sectional view of a leak detection system, in accordance with embodiments of the disclosure
  • FIG. IB is another cross-sectional view of the leak detection system of FIG. 1A taken along sectional line B-B of FIG. 1A;
  • FIG. 2A and FIG. 2B are cross-sectional views of material systems, in accordance with embodiments of the disclosure.
  • FIG. 3 is a simplified block diagram illustrating leak detection system comprising a plurality of detectors
  • FIG. 4A is a cross-sectional view of a leak detection system, in accordance with embodiments of the disclosure.
  • FIG. 4B is another cross-sectional view of the leak detection system of FIG. 4A taken along sectional line B-B in FIG. 4A;
  • FIG. 4C is a yet another cross-sectional view of the leak detection system of FIG. 4A taken along sectional line C-C in FIG. 4A;
  • FIG. 4D is a plan view of a spacer, in accordance with embodiments of the disclosure.
  • FIG. 4E is a plan view of another spacer, in accordance with other embodiments of the disclosure.
  • FIG. 5A is a cross-sectional view of a leak detection system, in accordance with other embodiments of the disclosure.
  • FIG. 5B is another cross-sectional view of the leak detection system of FIG. 5 A taken along sectional line B-B in FIG. 5A;
  • FIG. 5C is a view of a jacket showing the contacting surface, in accordance with embodiments of the disclosure;
  • FIG. 5D is a cross-sectional view of the jacket of FIG. 5C taken along sectional line C-C;
  • FIG. 5E is a view of another jacket showing the contacting surface, in accordance with other embodiments of the disclosure.
  • FIG. 5F is a cross-sectional view of the jacket of FIG. 5E taken along sectional line D-D;
  • FIG. 6A is a cross-sectional view of a system for detecting a leak in a pipe, in accordance with embodiments of the disclosure
  • FIG. 6B is another cross-sectional view of the system of FIG. 6A.
  • FIG. 7 is a simplified schematic illustrating a system configured for detecting a leak in at least one section of equipment, in accordance with embodiments of the disclosure.
  • a system for detecting a leak is configured to continuously monitor connection structures (e.g., flanged connections, welded connections, threaded connections, etc.), pipe fixtures, sections of pipe, portions of equipment, or entire equipment assemblies for leaks.
  • the system may include ajacket, which may confine any materials that may have leaked (e.g., a vapor), be impermeable or semi-permeable to the leaked materials, or both.
  • the jacket is vapor impermeable.
  • the jacket may be configured to wrap around a section of piping or process equipment.
  • the jacket may be attached to a portion of the piping system (e.g., to a pipe) or equipment in an air-tight manner or with a non-airtight seal, such as with hook-and-loop (e.g., Velcro), tape, rubber bands, clamps, an adhesive, etc.
  • the system may further include a porous material between the jacket and an outer surface of the piping system or equipment, the porous material configured to provide a space between an inner surface of the jacket and the outer surface of the piping system or equipment.
  • the porous material may reduce or prevent formation of an impediment to a flow of material between the jacket and the pipe or equipment.
  • the porous material is permeable to liquids, vapors, or both, such that any liquid or vapors leaking from the piping system or equipment may pass therethrough.
  • the porous material may maintain a distance between the jacket and the outer surface of the piping system.
  • An annular space between the jacket and the outer surface of the piping system may receive (e.g., collect) materials leaking from the piping system or equipment and surrounded by the leak detection system. The leaking material may accumulate in the annular space.
  • One or more detectors e.g., gas detectors
  • detector probes may be coupled to an inside surface of the jacket, to the outer surface of the pipe or equipment, or both.
  • the detectors may include one or more types of sensors for increasing a sensitivity or a selectivity of detection of one or more analytes.
  • the detectors may be operably coupled to a central processing system configured to continuously monitor and record an output of the sensors.
  • a controller may be coupled to the one or more detectors or detector probes and to one or more valves configured to control a flow through the piping system or equipment.
  • the controller may be configured to send instructions to the one or more valves to close responsive to detection of a leak.
  • the leak detection system may comprise a network comprising a plurality of piping sections, pieces of equipment, or both, each piping section and piece of equipment including at least one wrapped detector coupled to a central processing unit for monitoring leaks of an entire system.
  • the central processing unit may be coupled to a controller configured to control (e.g., reduce or stop) a flow through one or more sections of piping or equipment responsive to detection of a leak.
  • FIG. 1 A is a cross-sectional view of a piping system 100 including a system 101 for detecting a leak in the piping system 100, according to an embodiment of the disclosure.
  • the piping system 100 may include, for example, sections of pipe 110. Adjacent sections of pipe 110 may be coupled together through, for example, flanges 116.
  • the flanges 116 may include bolt holes 1 18 configured to receive a bolt to operably couple the sections of the pipe 110 together.
  • FIG. 1 A illustrates that the sections of pipe 110 are coupled via flanges 116, the disclosure is not so limited. For example, other coupling methods such as welds, compression fittings, threaded fittings, etc. may be used to couple the sections of pipe 1 10 to each other.
  • the pipe 110 may be defined by outer surfaces 1 12 and inner surfaces 114.
  • the pipe 1 10 may carry (e.g., transport) one or more materials such as one or more liquids or one or more gases.
  • the pipe 1 10 may carry acids, oil, refinery cuts, (e.g., gasoline, jet fuel, diesel fuel, etc.), carbon dioxide, carbon monoxide, hydrogen sulfide, sulfur dioxide, ammonia, nitric oxide, hydrogen, methane, natural gas, other materials, etc.
  • a gasket material 120 may be disposed between the flanges 1 16 and configured to form a seal between the piping sections 110 to prevent materials from passing from an inside of the piping system 100 to an outside thereof (e.g., leaking therefrom).
  • the gasket material 120 may not form an ideal seal around an entire face of the flanges 116 and materials may leak therethrough, such as after a useful life of the gasket material 120 has passed.
  • different materials that may be carried by the pipe 1 10 may be prone to leaking (e.g., gases with relatively smaller molecular sizes than other gases, such as hydrogen) or may be corrosive (e.g., hydrogen sulfide, hydrogen, various acids, etc.).
  • the system 101 may be configured to detect a leak in the piping system 100.
  • the system 101 may include aj acket 130 substantially surrounding the outer surface 1 12 of the pipe 1 10.
  • the jacket 130 may confine or at least partially confine materials that may leak from the piping system 100 to a volume between the jacket 130 and the outer surface 1 12 of the pipe 110.
  • the j acket 130 may at least slow a rate at which material that has leaked from the piping system 100 exits the volume.
  • the jacket 130 may shield or at least partially shield the volume from wind or other extemal conditions that may disburse material confined within the volume.
  • the jacket 130 may comprise an impermeable material through which materials carried by the pipe 110 may be impermeable.
  • the impermeable material of the jacket 130 may comprise a plastic material, a
  • thermoplastic material a rubber material, a metal material, a metal sheet, a metal foil, a second pipe having a larger diameter than the sections of pipe 1 10, or other material impermeable or semi -impermeable to materials carried by the pipe 1 10.
  • the jacket 130 may be permeable or semi-permeable to the materials carried by the pipe 110.
  • the jacket 130 may be substantially flexible. In some such embodiments, the jacket 130 exhibits a suitable flexibility such that it may be wrapped around the pipe 1 10, such as at the flanges 116.
  • the shape of the jacket 130 may be changed by an operator to conform to a shape of pipe 110 (e.g., a diameter of the pipe 1 10 or a diameter of the flanges 116) or equipment.
  • the jacket 130 may be configured to conform to an outer surface of piping at an elbow or at other shapes or contours.
  • the jacket 130 may be coupled to the outer surface 1 12 with one or more connection structures 132.
  • the connection structure 132 may comprise an elastic material (e.g., a rubber band), a hook-and-loop fastener (e.g., Velcro), a hose clamp, an adhesive, or other material or structure for securing the j acket 130 to the outer surface 1 10 pipe 1 10.
  • a seal between the outer surface 112 and the connection structure 132 may not be air-tight.
  • the seal between the outer surface 1 12 and the connection structure 132 may be hermetic (i.e., air-tight).
  • the system 101 may include a material structure separating an inner surface of the j acket 130 from the outer surface 112 of the pipe 1 10 to provide a space or volume for any materials that have leaked from the pipe 110 to accumulate.
  • the material structure may comprise a porous material 134 permeable or semi -permeable to any materials (e.g., liquids, vapors, etc.) that have leaked from the piping system 100.
  • the jacket 130 may be disposed around the pipe 110 such that there are substantially no pinch points that would impede a flow or circulation of any material that has leaked in the volume.
  • the jacket 130 may be separated from the outer surface 1 12 such that a volume between the jacket 130 and the outer surface 1 12 is substantially continuous and does not include any divided (e.g., separated) volumes.
  • any material that has leaked may circulate within the system 101 and a composition within the system 101 may be substantially uniform.
  • the porous material 134 may exhibit a substantial rigidity such that a space between an inner surface of the jacket 130 and the outer surface 1 12 of the pipe 1 10 is maintained along a length of the jacket 130.
  • the porous material 134 may be configured to provide a space between outermost portions of the flange 116 and the inner surface of the jacket 130 such that a volume on one side of a flange 1 16 of the pair of flanges 1 16 is not separated from a volume on an opposing side of the flanges 116.
  • the jacket 130 may cover long sections of pipe that may include a plurality of joints (e.g., flanges 1 16, welded connections, threaded connections, etc.) and a plurality of ancillary fixtures and equipment.
  • the jacket 130 may cover sections of pipe as long as about 10 feet (3.04 m), as long as about 20 feet (6.09 m), as long as about 50 feet (15.24 m), as long as about 100 feet (30.4 m), or as long as about 500 feet (152.4 m), although the disclosure is not so limited.
  • the porous material 134 may comprise a material that is permeable to materials that may leak from the pipe 1 10.
  • the porous material 134 may comprise a filter material permeable to the materials that may leak from the pipe 1 10, a foam material (e.g., open-cell foam), a porous ceramic material, a rigid wire screen, a metal mesh, a perforated metal material, a corrugated sheet (e.g., corrugated metal, corrugated cardboard, etc.).
  • the porous material 134 may comprise a filter comprising polyester, a porous fiber material (e.g., cotton, such as cotton paper), fiberglass (e.g., spun fiberglass), or combinations thereof.
  • the filter material may be pleated.
  • the filter material may be reinforced with a metal wire or metal mesh to provide rigidity to the structure thereof.
  • the system 101 may further include at least one detector 150 configured to detect one or more analytes of interest disposed within the system 101.
  • the detector 150 may comprise a detector probe.
  • the detector 150 may be located outside the jacket 130 and the detector probe may be inserted into the jacket 130.
  • the detector 150 may be coupled to the inner surface of the jacket 130.
  • the detector 150 may be coupled to the outer surface 1 12 of the pipe 1 10.
  • the system 101 includes a plurality of detectors 150 and may include, for example, at least one detector 150 coupled to the inner surface of the jacket 130 and at least one detector 150 coupled to the outer surface 112 of the pipe 1 10.
  • the detector 150 may be positioned at a location where materials that have leaked may accumulate.
  • the detector 150 may be located at a bottom of the system 101.
  • the detector 150 may be located at a top of the system 101 , where such lighter vapors may accumulate.
  • the detector 150 may be powered with one or more batteries. In some embodiments,
  • the battery may comprise a solar powered battery. In some such
  • the system 101 may include a solar panel operably coupled to a battery that is operably coupled to the detector 150 to provide power thereto.
  • the detector 150 may be fully powered or at least partially powered by vibrations, such as vibrations in the equipment or system 101.
  • the detector 150 may be coupled to a vibration-powered generator or a micro- electromechanical system vibrational micro power generator.
  • the system 101 may be disposed on piping sections that are remote (e.g., located away from a power source) from other areas of a processing facility.
  • FIG. IB is a cross-sectional view of the system 101.
  • the porous material 134 may extend from the inner surface of the j acket 130 to the outer surface 112 of the pipe 1 10 or to the outer surface of the flanges 116.
  • the porous material 134 may be substantially continuous and may fill substantially all of an annular space between the inner surface of the jacket 130 to the outer surfaces 1 12 of the pipe 1 10 and flanges 1 16.
  • the system 101 may comprise a detector 150 on the outer surface 112 of the pipe 1 10, a detector 150 on an inside surface of the jacket 130, or both.
  • the system 101 includes a plurality of detectors 150.
  • FIG. 2A is a cross-sectional view of a material system 200 used to form the system 101 (FIG. 1A, FIG. IB).
  • the material system 200 may include the jacket 130 and the porous material 134 attached to the jacket 130, such as at an inner, unexposed surface of the jacket 130.
  • the porous material 134 may be attached to the jacket 130 with an adhesive, hook-and-loop fasteners, snap connectors, stitching, other suitable method, or combinations thereof.
  • an inner surface of the jacket 130 may comprise hook-and-loop fasteners configured to correspond to corresponding
  • the inner surface of the jacket 130 may comprise a snap-type connector configured to operate with a corresponding one or more corresponding snap-type connectors on the porous material 134.
  • the porous material 134 is integral with the jacket 130.
  • FIG. 2B is a cross-sectional view of another material system 200' that may be used to form the system 101 (FIG. 1A, FIG. IB).
  • the material system 200' may be substantially similar to the material system 200 of FIG. 2A, except that the system 200' may include a porous material 134' having a surface having indents 135 and ridges 137 configured to contact the outer surface 112 (FIG. 1 A) of the pipe 110 (FIG. 1 A). In some such embodiments, only a portion of the outer surface 112 of the pipe 110 may be contacted by the porous material 134'.
  • the material systems 200, 200' may be prepared as rolls of material having a predetermined width, (e.g., 12 inches (30.48 cm), 18 inches (45.72 cm), 24 inches (60.96 cm), 30 inches (76.2 cm), 36 inches (91.44 cm), etc.) and may be cut to a desired length, depending on a length or diameter of pipe 100 to be monitored for leaks.
  • the system 101 may be formed on site according to needs of a particular processing plant.
  • the material system 200, 200' may be wrapped around a section of piping and the jacket 130 may be punctured to insert one or more detectors 150 (FIG. 1A) or detector probes between the jacket 130 and a section of pipe.
  • FIG. 3 is a simplified block diagram illustrating a leak detection system 300 including at least one detector 150.
  • the detector 150 may comprise a gas detector and may include a detector probe.
  • the detector 150 may include one or more of reference sensors 152, a catalytic sensor 154, one or more metal oxide semiconductor (MOS) sensors 156, one or more resonant sensors 158 (e.g., microcantilever resonant sensors), and one or more environmental sensors 160 as described in, for example, United States Provisional Patent Application Serial Number 62/376,675, entitled "A SYSTEM AND METHOD FOR DETECTING, IDENTIFYING, AND/OR QUANTIFYING GASES,” filed August 18, 2016, the entire disclosure of which is hereby incorporated herein in its entirety by this reference.
  • MOS metal oxide semiconductor
  • each of the reference sensors 152, the catalytic microhotplate sensor 154, the MOS sensors 156, the resonant sensors 158, and the environmental sensors 160 may be in communication with a central processing unit 162.
  • the central processing unit 162 may be configured to communicate with each of the sensors.
  • the central processing unit 162 may be in communication with a memory 164 configured to store data (e.g., historic data) measured by one or more of the sensors and may also contain calibration and stored response data used in analysis of sensor responses.
  • the central processing unit 162 may also be in communication with a user interface 166.
  • the detector 150 may be coupled to a power source 174.
  • the power source 174 may comprise one or more batteries, a wired connection, or one or more solar panels operably coupled to a rechargeable battery. In some embodiments, the power source 174 comprises one or more batteries. In other embodiments, the power source 174 comprises one or more solar panels. In yet other embodiments, the power source 174 may include a vibrational energy harvesting device (e.g., a vibration-powered generator or a micro- electromechanical system vibrational micro power generator).
  • a vibrational energy harvesting device e.g., a vibration-powered generator or a micro- electromechanical system vibrational micro power generator.
  • the detector 150 may be in communication with a system controller 168, such as through an antenna 170.
  • the system controller 168 may be coupled to an antenna 172 configured to wirelessly communicate with the antenna 170 of the detector 150.
  • the detector 150 may be wirelessly coupled to the system
  • the leak detection system 300 comprises a wireless network comprising a mesh network wherein a plurality of detectors 150 and associated antennas 170 are operably coupled to each other (i.e., an antenna 170 of a detector 150 is configured to wirelessly communicate with an antenna 170 of at least another detector 150) and with the antenna 172 of the system controller 168. Accordingly, in some embodiments, at least one detector 150 of the leak detection system 300 may communicate with the system controller 168 via one or more other detectors 150 in the leak detection system 300.
  • the detector 150 may communicate with the system controller 168 via a wired connection.
  • the system controller 168 may be configured to take corrective action such as reducing or stopping flow through a section of pipe 110 in which a leak has been detected by the detector 150.
  • many flammable and nonflammable gases may be identified and quantified by measuring a thermal conductivity and a viscous damping of a sample.
  • the thermal conductivity may be measured with the reference sensor 152 and a viscous damping may be measured by sensing a shift in a resonant frequency of the resonant sensor 158 or another resonant sensor.
  • the detector 150 may be configured to detect in a leak in the pipe 110 (FIG. 1 A) around which the system 101 (FIG. 1 A) is disposed, such as by detecting one or more flammable or nonflammable gases (e.g., such as gases carried by the pipe 110) with one or more of the sensors.
  • the detector 150 may further comprise one or more environmental sensors 160 such as a temperature sensor, a pressure sensor, a humidity sensor, or combinations thereof.
  • the detector 150 may be configured to compensate measured values for changes in one or more of the temperature, the pressure, the viscosity, and the humidity of a sample analyzed by the detector 150.
  • the central processing unit 162 may
  • the system controller 168 may be configured to decrease a flow (e.g., substantially stop a flow) of material through the piping system responsive to receiving an indication from the central processing unit 162 of a leak.
  • the central processing unit 162 may be in communication with the user
  • the user interface 166 may comprise a graphical user interface (e.g., a screen, a touchscreen, etc.), an audible sound configured to alarm when a leak is detected, or other system.
  • a graphical user interface e.g., a screen, a touchscreen, etc.
  • an audible sound configured to alarm when a leak is detected, or other system.
  • the leak detection system 300 may include a plurality of detectors 150 coupled to the system controller 168 for detecting leaks in one or more locations throughout a piping system. Accordingly, the system controller 168 may be in communication with a plurality of detectors 150. In some embodiments, each detector 150 is substantially the same. In other embodiments, at least some of the detectors 150 are different than at least other of the detectors 150. By way of nonlimiting example, at least some of the detectors 150 may comprise different types of sensors than at least some other of the detectors 150 in the leak detection system 300.
  • the detector 150 has been described as including the reference sensor 152, the catalytic microhotplate sensor 154, the MOS sensors 156, the resonant sensors 158, and the environmental sensors 160, the disclosure is not so limited. In other embodiments, the detector 150 may include fewer components. By way of nonlimiting example, the detector 150 may not include the central processing unit 162, and sensors other than the catalytic microhotplate sensor 154, the MOS sensors 156, the resonant sensors 158, and the environmental sensors 160 may be used.
  • FIG. 4A is a piping system 100' including a system 101 ' for detecting a leak in the piping system 100', according to another embodiment of the disclosure.
  • the system 10 ⁇ may be substantially similar to the system 101, except that the system 10 ⁇ may not include the porous material 134.
  • the system 10 ⁇ may include spacers 140 disposed between the inner surface of the jacket 130 and the outer surface 112 of the pipe 110 to define a volume 136 in the annular space between the inner surface of the jacket 130 and the outer surface 112 of the pipe 110 for the fluid or fumes to permeate volume 136.
  • the spacers 140 may also be referred to herein as "stand-off" structures or "legs.”
  • At least some spacers 140 are positioned on portions of the piping system 100 such that the volume 136 is substantially continuous.
  • the spacers 140 may be positioned such that the volume 136 forms a substantially continuous and undivided volume along a length of the system 10 ⁇ .
  • the spacers 140 may be sized and positioned such that the volume 136 on one side of the flanges 116 is in fluid communication with the volume 136 on an opposing side of the flanges 116 and the volume 136 exhibits a substantially uniform composition throughout.
  • a detector 150 in the volume 136 may detect a presence of materials leaking into the volume 136 at an opposing side of the volume 136.
  • At least some spacers 140 may be located in positions where the jacket 130 may otherwise contact the outer surface 112 of the pipe 110 and separate the volume 136 into isolated portions. As one example, at least some spacers 140 may be positioned on at least one surface of the piping system 100' that is located closer to the inside surface of the jacket 130 than other surfaces of the piping system 100'. As another example, at least some spacers 140 may be positioned on a surface of the flanges 116 and may be configured to maintain a space between the inner surface of the jacket 130 and an outermost surface of the flanges 116. In some embodiments, the system 10 ⁇ may include spacers 140 extending between the outer surface 112 of the pipe 110 and the inner surface of the jacket 130.
  • the spacers 140 may have different lengths than at least other spacers 140.
  • spacers 140 on the flanges 116 may be shorter than spacers 140 in contact with the outer surface 112 of the pipe 110.
  • Spacers 140 located proximate the connection structures 132 may have a shorter length than other spacers 140 in contact with the outer surface 112 of the pipe 110.
  • the spacers 140 may be coupled (e.g., attached) to the inner surface of the jacket 130 by any suitable means for securing the spacers 140 to the jacket 130.
  • the spacers 140 are coupled to the inner surface of the jacket 130 with an adhesive, hook-and-loop fasteners, snap connectors, stitching, or other method.
  • at least some portions of the inner surface of the jacket 130 may comprise hook-and-loop fasteners configured to couple to corresponding hook-and-loop fasteners of the spacers 140.
  • at least some portions of the inner surface of the jacket 130 may comprise snap connectors configured to couple with corresponding snap connectors of the spacers 140.
  • the spacers 140 are integral with the inner surface of the j acket 130.
  • the spacers 140 may comprise a substantially rigid material. In some embodiments,
  • the spacers 140 comprise a metal material (e.g., steel (e.g., carbon steel), stainless steel, aluminum, brass, copper, etc.), a galvanized metal, a plastic material, an elastic material (e.g., rubber), a thermoplastic material, a thermosetting material, or combinations thereof.
  • the spacers 140 comprise a substantially porous material permeable to any material that may leak from the piping system 100.
  • the spacers 140 may comprise the same materials as the porous material 134 described above with reference to FIG. 1A and FIG. IB.
  • FIG. 4B is a cross-sectional view of the system 10 ⁇ taken along sectional line B-B in FIG. 4A.
  • the spacers 140 may be disposed around the circumference of the pipe 110 at a plurality of locations across a circumference thereof.
  • the spacers 140 may be disposed along the circumference of the pipe 110 every about 90°.
  • the disclosure is not so limited and the spacers 140 may be disposed around the pipe 110 every about 30°, every about 45°, every about 60°, every about 180°, or at different angular distances along the circumference.
  • FIG. 4C is a cross-sectional view of the system 10 ⁇ taken along sectional line C-C in FIG. 4A.
  • the spacers 140 may be angularly offset from other spacers 140.
  • the spacers 140 may extend from the outer surface 112 of the pipe 110 to the inner wall of the jacket 130 but may not isolate any portions of the volume 136 from other portions thereof. Accordingly, any material (e.g., gas) leaking from the piping system 100' may accumulate in the entire volume 136 and the volume 136 may comprise a substantially uniform composition (and concentration of the leaked material).
  • FIG. 4D is a plan view of the spacer 140 according to some embodiments of the disclosure.
  • the spacer 140 may comprise a checkered pattern with a plurality of openings 142 defined between walls 144.
  • the openings 142 may be square-shaped.
  • the openings 142 may facilitate permeation of materials through the spacer 140 such that the composition of the material in the volume 136 has a substantially uniform composition between the inner surface of the j acket 130 and the outer surface 112 of the pipe 110 along a length of the system 101.
  • FIG. 4E is a plan view of another spacer 140' according to other embodiments of the disclosure.
  • the spacer 140' may include openings 142 with a different shape than the openings 142 of the spacer 140.
  • the openings 142 may be diamond-shaped.
  • the openings 142 may be circular, oval, rectangular, triangular, or another shape.
  • FIG. 5 A and FIG. 5B are cross-sectional views illustrating a system 101", according to another embodiment of the disclosure.
  • the system 101" may include pipes 110 welded together at weld 190 and a jacket 130' disposed around a section of pipe 110.
  • the jacket 130' may comprise a material having a corrugated surface 131 such that portions of the corrugated surface 131 contact the outer surface 112 of the pipe 110 and other portions of the corrugated surface 131 are spaced from the outer surface 112.
  • the corrugated surface 131 may facilitate distribution and flow of material in the space between the jacket 130' and the outer surface 112 of the pipe 110.
  • FIG. 5C is a plan view of the inner surface of the jacket 130'.
  • FIG. 5D is a cross- sectional view of the jacket 130' taken along sectional line D-D in FIG. 5C.
  • the jacket 130' may be defined by a checkered pattern.
  • the jacket 130' comprises adjacent material structures 137 separated by gaps 139.
  • the gaps 139 may be interconnected such that any materials that have leaked from the pipe 110 (FIG. 5 A) permeate through the interior of the jacket 130'. Accordingly, a composition of the material in a space between the jacket 130' and the outer surface 112 of the pipe 110 may be substantially uniform since the material may permeate through the jacket 130' via the gaps 139. Accordingly, the jacket 130' may not form any impediments to the distribution of material in the space between the jacket 130' and the outer surface 112 of the pipe 110.
  • FIG. 5E is a plan view of the inner surface of another jacket 130".
  • FIG. 5F is a cross-sectional view of the jacket 130" taken along sectional line F-F in FIG. 5E.
  • the jacket 130" may include a network of interconnected gaps 139 separating a plurality of adjacent material structures 137.
  • the material structures 137 may comprise a metal, a thermoplastic material, a thermosetting material, a rubber material, a plastic material, or other material configured to provide sufficient rigidity to the jacket 130".
  • the material structures 137 comprise bubbles or pockets of material, such as a "bubble-wrap" material, wherein a gas or liquid may flow between the material structures 137 in the gaps 139.
  • the interconnected gaps 139 may allow for any materials that have leaked through the pipe 110 to mix in the space between the jacket 130" such that the space exhibits a substantially uniform concentration and an analyte sampled by the detectors 150 may be representative of the composition within the space.
  • the jacket may comprise a second pipe disposed around a section of pipe to be monitored for a leak.
  • FIG. 6A is a cross-sectional view of a system 200 for detecting a leak in a pipe 210.
  • FIG. 6B is another cross-sectional view of the system 200 taken along sectional line B-B in FIG. 6A.
  • the system 200 may include a pipe 210 carrying a material.
  • the system 200 may include a jacket 230 disposed around the pipe 210.
  • the jacket 230 may comprise another pipe having a larger diameter than a diameter of the pipe 210.
  • the pipe 210 and the jacket 230 may comprise a double-walled pipe.
  • a volume 236 between an outer wall of the pipe 210 and an inner wall of the jacket 230 may be configured to receive any materials that may leak from the pipe 210.
  • a porous material substantially similar to the porous material 134 described above with reference to FIG. 1A or substantially similar to the porous material 134' described above with reference to FIG. 2B may be disposed in the volume 236 between outer wall of the pipe 210 and the inner wall of the jacket 230.
  • the volume 236 includes one or more spacers substantially similar to the spacers 140 described above with reference to FIG. 4A.
  • One or more detectors 250 may be located within the volume 236 and may be located on the outer wall 212 of the pipe 210, an inner wall of the jacket 230, or both. The detector 250 may be substantially similar to the detectors 150 described above with reference to FIG. 1A through FIG. 5B.
  • FIG. 7 is a simplified schematic illustrating a system 700 configured for detecting a leak in at least one section of equipment 302.
  • the system 700 may include a section of equipment 302 enclosed by a housing 304.
  • the section of equipment 302 may include one or more of a compressor, a valve, a pump, a heat exchanger, a pressure vessel, a tank, or another piece of equipment.
  • the system 700 may include at least one detector 350 coupled to an outer portion of the equipment, at least one detector 350 coupled to an inner surface of the housing 304, or both.
  • the detector 350 may be substantially similar to the detectors 150 described above with reference to FIG. 1A through FIG. 5B.
  • the housing 304 may comprise a plastic material, a thermoplastic material, a rubber material, a metal material, a metal sheet, a metal foil, another material, or combinations thereof.
  • providing the systems 101, 10 ⁇ , 101", 200, 700 including the detector 150, 250, 350 with one or more of the sensors may provide advantages compared to prior art methods of detecting a leak in a piping system.
  • the detector 150, 250, 350 may exhibit an increased sensitivity to more analytes than prior art systems that use, for example, mass spectrometers.
  • the detector 150, 250, 350 may be configured to detect more than one type of leaking gas and may be exhibit an increased cross-sensitivity relative to other detectors in prior art leak detection systems.
  • the systems 101, 10 ⁇ , 101", 200, 700 may be configured to conform to piping systems with different shapes and diameters.
  • the systems 101, 10 ⁇ , 101", 200, 700 may be configured to continuously determine a presence of a leak in real time and may minimize a need for an operator to manually inspect piping connections for leaks.
  • Embodiment 1 A system for detecting a leak, the system comprising: a jacket disposed around an outer surface of a section of pipe or equipment and defining a volume between an inner surface of the jacket and the outer surface of the section of pipe or equipment; a connection means for connecting ends of the jacket to the outer surface of the section of pipe or equipment; a structure separating the outer surface of the section of pipe or equipment from the inner surface of the jacket; and a detector disposed between the outer surface of the section of pipe or equipment and the inner surface of the jacket.
  • Embodiment 2 The system of Embodiment 1, wherein the jacket comprises a plastic material, a thermoplastic material, a rubber material, a metal material, or combinations thereof.
  • Embodiment 3 The system of Embodiment 1 or Embodiment 2, wherein the jacket comprises a housing surrounding the section of pipe or equipment.
  • Embodiment 4 The system of any one of Embodiments 1 through 3, wherein the structure comprises a gas permeable material.
  • Embodiment 5 The system of any one of Embodiments 1 through 4, wherein the structure comprises a plurality of legs separating the inner surface of the jacket from the outer surface of the section of pipe or equipment.
  • Embodiment 6 The system of Embodiment 5, wherein at least some legs of the plurality of legs have a different length than other legs of the plurality of legs.
  • Embodiment 7 The system of any one of Embodiments 1 through 6, wherein the structure is coupled to the inner surface of the jacket with an adhesive, hook-and-loop fasteners, snap connectors, or combinations thereof.
  • Embodiment 8 The system of any one of Embodiments 1 through 7, wherein the structure is integral with the jacket.
  • Embodiment 9 The system of any one of Embodiments 1 through 7, wherein the jacket comprises another pipe disposed around the section of pipe, the jacket and the section of pipe comprising a double-walled pipe.
  • Embodiment 10 The system of any one of Embodiments 1 through 9, wherein the structure substantially fills the volume between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
  • Embodiments 11 The system of any one of Embodiments 1 through 10, wherein the connection means comprises an adhesive, an elastic member, or a retaining member.
  • Embodiment 12 The system of any one of Embodiments 1 through 11, wherein the detector is disposed on the inner surface of the jacket.
  • Embodiment 13 The system of any one of Embodiments 1 through 11, wherein the detector is disposed on the outer surface of the section of pipe or equipment.
  • Embodiment 14 The system of any one of Embodiments 1 through 13, wherein the detector comprises a gas detector.
  • Embodiment 15 The system of any one of Embodiments 1 through 14, wherein the detector is wired to a system monitor.
  • Embodiment 16 The system of any one of Embodiments 1 through 14, wherein the detector is configured to wirelessly communicate with a system monitor.
  • Embodiment 17 The system of any one of Embodiments 1 through 16, further comprising a mesh network of a plurality of detectors, wherein at least one detector is configured to wirelessly communicate with at least another detector
  • Embodiment 18 The system of any one of Embodiments 1 through 17, further comprising a controller configured to stop a flow through the section of pipe or equipment responsive to a detected leak.
  • Embodiment 19 The system of any one of Embodiments 1 through 18, wherein the detector is battery powered, vibration powered, or solar powered.
  • Embodiment 20 A leak detection system, comprising: a jacket disposed around a circumference of a section of pipe or equipment, the jacket comprising a material impermeable or semi-permeable to a vapor carried by the pipe; a connection means for attaching the jacket around the circumference of the section of pipe or equipment; a material separating an inner surface of the jacket from an outer surface of the section of pipe or equipment; and at least one of at least one detector or at least one detector probe disposed within a space between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
  • Embodiment 21 The leak detection system of Embodiment 20, wherein the at least one of the at least one detector or at least one detector probe is configured to detect multiple gases.
  • Embodiment 22 The leak detection system of Embodiment 20 or Embodiment 21, wherein the jacket comprises a housing surrounding the section of pipe or equipment.
  • Embodiment 23 The leak detection system of any one of Embodiments 20 through 22, wherein the at least one detector or at least one detector probe comprises a microcantilever sensor.
  • Embodiment 24 The leak detection system of Embodiment 23, wherein the at least one detector further comprises at least one reference microcantilever sensor.
  • Embodiment 25 The leak detection system of any one of Embodiments 20 through 24, wherein the at least one of the at least one detector or at least one detector probe comprises at least one reference sensor and one or more microcantilever sensors.
  • Embodiment 26 The leak detection system of Embodiment 25, wherein the at least one of the at least one detector or at least one detector probe further comprises at least one catalytic sensor and at least one metal oxide semiconductor sensor.
  • Embodiment 27 The leak detection system of any one of Embodiments 20 through 26, wherein the at least one of at least one detector or at least one detector probe comprises at least one detector coupled to the inner surface of the jacket.
  • Embodiment 28 The leak detection system of any one of Embodiments 20 through
  • the at least one of at least one detector or at least one detector probe comprises at least one detector coupled to the outer surface of the section of pipe or equipment.
  • Embodiment 29 The leak detection system of any one of Embodiments 20 through
  • the material separating the inner surface of the jacket from the outer surface of the section of pipe or equipment comprises a porous material.
  • Embodiment 30 The leak detection system of any one of Embodiments 20 through 39, wherein the material separating the inner surface of the jacket from the outer surface of the section of pipe or equipment comprises a porous material and substantially fills the space between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
  • Embodiment 31 The leak detection system of any one of Embodiments 20 through 30, wherein the material comprises a metal material, a plastic material, an elastic material, a thermoplastic material, or a thermosetting material.
  • Embodiment 32 A leak detection system, comprising: a jacket disposed around an outer surface of a section of pipe or equipment, the jacket comprising an exposed outer surface and a corrugated surface, at least some of the corrugated surface in contact with the outer surface of the section of pipe or equipment; a connection means for attaching the jacket around a circumference of the section of pipe or equipment; and at least one detector disposed within a space between the jacket and the outer surface of the section of pipe or equipment.
  • Embodiment 33 The leak detection system of Embodiment 32, wherein the jacket comprises a plurality of adjacent material structures separated by interconnected gaps, the interconnected gaps forming a continuous volume between the outer surface of the section of pipe or equipment and the exposed outer surface of the jacket.
  • Embodiment 34 The leak detection system of Embodiment 32 or Embodiment 33, wherein the jacket comprises a network of interconnected gaps separating a plurality of adjacent material structures.
  • Embodiment 35 A method of detecting a leak, the method comprising: disposing a jacket around a section of pipe or equipment; providing one of a porous material and a spacer in a volume between an inner surface of the jacket and an outer surface of the section of pipe or equipment; providing at least one gas detector in the volume; and monitoring the volume for one or more analytes indicative of a leak in the section of pipe or equipment.
  • Embodiment 36 The method of Embodiment 35, wherein providing one of a porous material and a spacer in a volume comprises substantially filling the volume with the porous material.
  • Embodiment 37 The method of Embodiment 35 or Embodiment 36, wherein providing at least one gas detector in the volume comprises providing at least one gas detector comprising at least one reference sensor and at least one microcantilever sensor in the volume.
  • Embodiment 38 The method of Embodiment 37, further comprising providing at least one catalytic sensor and at least one metal oxide semiconductor sensor in the volume.
  • Embodiment 39 The method of any one of Embodiments 35 through 38, wherein disposing a jacket around a section of pipe or equipment comprises disposing a jacket comprising an impermeable material to a material carried by the section of pipe or equipment.
  • Embodiment 40 The method of any one of Embodiments 35 through 39, wherein providing at least one gas detector in the volume comprises providing a gas detector probe in the volume through the jacket, the gas detector probe coupled to the at least one gas detector.

Abstract

A system for detecting a leak in one or more sections of piping. The system comprises a jacket disposed around an outer surface of a section of pipe or equipment and defining a volume between an inner surface of the jacket and the outer surface of the section of pipe or equipment, a connection means for connecting ends of the jacket to the outer surface of the section of pipe or equipment, a structure separating the outer surface of the section of pipe or equipment from the inner surface of the jacket, and a detector disposed between the outer surface of the section of pipe or equipment and the inner surface of the jacket. Related leak detection systems and methods of detecting a leak are also disclosed.

Description

LEAK DETECTION SYSTEM AND RELATED METHODS
PRIORITY CLAIM
This application claims the benefit of the filing date of United States Provisional Patent Application Serial No. 62/463,395, filed February 24, 2017, for "LEAK DETECTION SYSTEM AND RELATED METHODS."
TECHNICAL FIELD
Embodiments of the disclosure relate generally to systems for detecting a leak in section of piping, process equipment, or other structure, and to related methods. More particularly, embodiments of the disclosure relate to systems for leak detection configured to wrap around a portion of a system and having one or more detectors configured to detect a presence of one or more analytes, and to related methods. BACKGROUND
Leak detection is of particular importance in industrial facilities including factories, mining facilities, processing plants, refineries (e.g., oil refineries), or other chemical processing plants. Such industrial facilities often include several hundred, if not thousands, of linear feet of process piping and associated equipment. The piping may include many flanged connections, threaded connections, welded connections, and other connections between different sections of piping or equipment. Each connection between adjacent portions of piping and equipment provides a location with an increased likelihood of a leak.
In addition, process equipment and piping may be subject to corrosion, erosion, or other forms of degradation. By way of nonlimiting example, piping and equipment may be subject to corrosion from one or more of acids, gases (e.g., such as carbon monoxide, ammonia, chlorine, sulfur dioxide, hydrogen sulfide, etc.), or other materials carried by the piping. The piping may also be subject to corrosion due to the environment external to the piping.
Process piping and equipment having one or more leaks poses both environmental hazards and safety hazards. The United States Environmental Protection Agency (EPA) estimates that about 80,000 tons (72574.779 metric tons) of air pollutants escape from equipment leaks each year. In view of the dangers associated with a leak, many industrial facilities are subject to strict environmental regulations and are required to periodically monitor flanged connections and other piping connections for leaks. Such facilities often employ or contract individuals to monitor the piping system and equipment for leaks. The monitoring typically involves manual inspection of valves, fittings, flanges, compressors, or other equipment, for leaks by an operator. The operator conventionally places a handheld wand that measures gas concentrations in proximity to flanged connections or the portion of piping or equipment being monitored. However, many connection structures are located outdoors and are exposed to wind and other environmental conditions that may result in a false indication of an absence of one or more leaks.
Manual detection of leaks is time consuming and impractical. It may take an operator many days or even weeks to check every connection structure in a facility for leaks before a connection is rechecked again. However, fines for a leak may be based on the time (e.g., the number of days) that has elapsed since the connection was previously checked for a leak.
DISCLOSURE
Embodiments disclosed herein include systems for detecting a leak in a section of piping, process equipment or other structure and to related methods of detecting a leak. For example, in accordance with one embodiment, a system for detecting a leak comprises a jacket disposed around an outer surface of a section of pipe or equipment and defining a volume between an inner surface of the jacket and the outer surface of the section of pipe or equipment, a connection means for connecting ends of the jacket to the outer surface of the section of pipe or equipment, a structure separating the outer surface of the section of pipe or equipment from the inner surface of the jacket, and a detector disposed between the outer surface of the section of pipe or equipment and the inner surface of the jacket.
In additional embodiments, a leak detection system comprises a jacket disposed around a circumference of a section of pipe or equipment, the jacket comprising a material impermeable or semi-permeable to a vapor carried by the pipe, a connection means for attaching the jacket around the circumference of the section of pipe or equipment, a material separating an inner surface of the jacket from an outer surface of the section of pipe or equipment, and at least one of at least one detector or at least one detector probe disposed within a space between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
In other embodiments, a leak detection system comprises a jacket disposed around an outer surface of a section of pipe or equipment, the jacket comprising an exposed outer surface and a corrugated surface, at least some of the corrugated surface in contact with the outer surface of the section of pipe or equipment, a connection means for attaching the jacket around a circumference of the section of pipe or equipment, and at least one detector disposed within a space between the jacket and the outer surface of the section of pipe or equipment.
In further embodiments, a method of detecting a leak comprises disposing a jacket around a section of pipe or equipment, providing one of a porous material and a spacer in a volume between an inner surface of the jacket and an outer surface of the section of pipe or equipment, providing at least one gas detector in the volume, and monitoring the volume for one or more analytes indicative of a leak in the section of pipe or equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 A is a cross-sectional view of a leak detection system, in accordance with embodiments of the disclosure;
FIG. IB is another cross-sectional view of the leak detection system of FIG. 1A taken along sectional line B-B of FIG. 1A;
FIG. 2A and FIG. 2B are cross-sectional views of material systems, in accordance with embodiments of the disclosure;
FIG. 3 is a simplified block diagram illustrating leak detection system comprising a plurality of detectors;
FIG. 4A is a cross-sectional view of a leak detection system, in accordance with embodiments of the disclosure;
FIG. 4B is another cross-sectional view of the leak detection system of FIG. 4A taken along sectional line B-B in FIG. 4A;
FIG. 4C is a yet another cross-sectional view of the leak detection system of FIG. 4A taken along sectional line C-C in FIG. 4A;
FIG. 4D is a plan view of a spacer, in accordance with embodiments of the disclosure;
FIG. 4E is a plan view of another spacer, in accordance with other embodiments of the disclosure;
FIG. 5A is a cross-sectional view of a leak detection system, in accordance with other embodiments of the disclosure;
FIG. 5B is another cross-sectional view of the leak detection system of FIG. 5 A taken along sectional line B-B in FIG. 5A; FIG. 5C is a view of a jacket showing the contacting surface, in accordance with embodiments of the disclosure;
FIG. 5D is a cross-sectional view of the jacket of FIG. 5C taken along sectional line C-C;
FIG. 5E is a view of another jacket showing the contacting surface, in accordance with other embodiments of the disclosure;
FIG. 5F is a cross-sectional view of the jacket of FIG. 5E taken along sectional line D-D;
FIG. 6A is a cross-sectional view of a system for detecting a leak in a pipe, in accordance with embodiments of the disclosure
FIG. 6B is another cross-sectional view of the system of FIG. 6A; and
FIG. 7 is a simplified schematic illustrating a system configured for detecting a leak in at least one section of equipment, in accordance with embodiments of the disclosure. MODE(S) FOR CARRYING OUT THE INVENTION
Illustrations presented herein are not meant to be actual views of any particular material, component, or system, but are merely idealized representations that are employed to describe embodiments of the disclosure.
The following description provides specific details, such as material types, material thicknesses, and processing conditions in order to provide a thorough description of embodiments described herein. However, a person of ordinary skill in the art will understand that the embodiments disclosed herein may be practiced without employing these specific details. Indeed, the embodiments may be practiced in conjunction with conventional fabrication techniques employed in the industry. Only those process acts and structures necessary to understand the embodiments described herein are described in detail below. Additional acts to form a complete system for detecting a leak may be performed by conventional techniques.
According to embodiments described herein, a system for detecting a leak is configured to continuously monitor connection structures (e.g., flanged connections, welded connections, threaded connections, etc.), pipe fixtures, sections of pipe, portions of equipment, or entire equipment assemblies for leaks. The system may include ajacket, which may confine any materials that may have leaked (e.g., a vapor), be impermeable or semi-permeable to the leaked materials, or both. In some embodiments, the jacket is vapor impermeable. The jacket may be configured to wrap around a section of piping or process equipment. The jacket may be attached to a portion of the piping system (e.g., to a pipe) or equipment in an air-tight manner or with a non-airtight seal, such as with hook-and-loop (e.g., Velcro), tape, rubber bands, clamps, an adhesive, etc. The system may further include a porous material between the jacket and an outer surface of the piping system or equipment, the porous material configured to provide a space between an inner surface of the jacket and the outer surface of the piping system or equipment. The porous material may reduce or prevent formation of an impediment to a flow of material between the jacket and the pipe or equipment. In some embodiments, the porous material is permeable to liquids, vapors, or both, such that any liquid or vapors leaking from the piping system or equipment may pass therethrough. The porous material may maintain a distance between the jacket and the outer surface of the piping system. An annular space between the jacket and the outer surface of the piping system may receive (e.g., collect) materials leaking from the piping system or equipment and surrounded by the leak detection system. The leaking material may accumulate in the annular space.
One or more detectors (e.g., gas detectors) or detector probes may be coupled to an inside surface of the jacket, to the outer surface of the pipe or equipment, or both. The detectors may include one or more types of sensors for increasing a sensitivity or a selectivity of detection of one or more analytes. The detectors may be operably coupled to a central processing system configured to continuously monitor and record an output of the sensors. A controller may be coupled to the one or more detectors or detector probes and to one or more valves configured to control a flow through the piping system or equipment. The controller may be configured to send instructions to the one or more valves to close responsive to detection of a leak. The leak detection system may comprise a network comprising a plurality of piping sections, pieces of equipment, or both, each piping section and piece of equipment including at least one wrapped detector coupled to a central processing unit for monitoring leaks of an entire system. The central processing unit may be coupled to a controller configured to control (e.g., reduce or stop) a flow through one or more sections of piping or equipment responsive to detection of a leak.
FIG. 1 A is a cross-sectional view of a piping system 100 including a system 101 for detecting a leak in the piping system 100, according to an embodiment of the disclosure. The piping system 100 may include, for example, sections of pipe 110. Adjacent sections of pipe 110 may be coupled together through, for example, flanges 116. The flanges 116 may include bolt holes 1 18 configured to receive a bolt to operably couple the sections of the pipe 110 together. Although FIG. 1 A illustrates that the sections of pipe 110 are coupled via flanges 116, the disclosure is not so limited. For example, other coupling methods such as welds, compression fittings, threaded fittings, etc. may be used to couple the sections of pipe 1 10 to each other.
The pipe 110 may be defined by outer surfaces 1 12 and inner surfaces 114. The pipe 1 10 may carry (e.g., transport) one or more materials such as one or more liquids or one or more gases. By way of nonlimiting example, the pipe 1 10 may carry acids, oil, refinery cuts, (e.g., gasoline, jet fuel, diesel fuel, etc.), carbon dioxide, carbon monoxide, hydrogen sulfide, sulfur dioxide, ammonia, nitric oxide, hydrogen, methane, natural gas, other materials, etc.
A gasket material 120 may be disposed between the flanges 1 16 and configured to form a seal between the piping sections 110 to prevent materials from passing from an inside of the piping system 100 to an outside thereof (e.g., leaking therefrom). In some instances, the gasket material 120 may not form an ideal seal around an entire face of the flanges 116 and materials may leak therethrough, such as after a useful life of the gasket material 120 has passed. In addition, different materials that may be carried by the pipe 1 10 may be prone to leaking (e.g., gases with relatively smaller molecular sizes than other gases, such as hydrogen) or may be corrosive (e.g., hydrogen sulfide, hydrogen, various acids, etc.).
The system 101 may be configured to detect a leak in the piping system 100. The system 101 may include aj acket 130 substantially surrounding the outer surface 1 12 of the pipe 1 10. The jacket 130 may confine or at least partially confine materials that may leak from the piping system 100 to a volume between the jacket 130 and the outer surface 1 12 of the pipe 110. In some embodiments, the j acket 130 may at least slow a rate at which material that has leaked from the piping system 100 exits the volume. In some
embodiments, the jacket 130 may shield or at least partially shield the volume from wind or other extemal conditions that may disburse material confined within the volume. In some embodiments, the jacket 130 may comprise an impermeable material through which materials carried by the pipe 110 may be impermeable. By way of nonlimiting example, the impermeable material of the jacket 130 may comprise a plastic material, a
thermoplastic material, a rubber material, a metal material, a metal sheet, a metal foil, a second pipe having a larger diameter than the sections of pipe 1 10, or other material impermeable or semi -impermeable to materials carried by the pipe 1 10. In other embodiments, the jacket 130 may be permeable or semi-permeable to the materials carried by the pipe 110.
In some embodiments, the jacket 130 may be substantially flexible. In some such embodiments, the jacket 130 exhibits a suitable flexibility such that it may be wrapped around the pipe 1 10, such as at the flanges 116. The shape of the jacket 130 may be changed by an operator to conform to a shape of pipe 110 (e.g., a diameter of the pipe 1 10 or a diameter of the flanges 116) or equipment. By way of nonlimiting example, the jacket 130 may be configured to conform to an outer surface of piping at an elbow or at other shapes or contours.
The jacket 130 may be coupled to the outer surface 1 12 with one or more connection structures 132. The connection structure 132 may comprise an elastic material (e.g., a rubber band), a hook-and-loop fastener (e.g., Velcro), a hose clamp, an adhesive, or other material or structure for securing the j acket 130 to the outer surface 1 10 pipe 1 10. In some embodiments, a seal between the outer surface 112 and the connection structure 132 may not be air-tight. In other embodiments, the seal between the outer surface 1 12 and the connection structure 132 may be hermetic (i.e., air-tight).
In some embodiments, the system 101 may include a material structure separating an inner surface of the j acket 130 from the outer surface 112 of the pipe 1 10 to provide a space or volume for any materials that have leaked from the pipe 110 to accumulate. In some embodiments, the material structure may comprise a porous material 134 permeable or semi -permeable to any materials (e.g., liquids, vapors, etc.) that have leaked from the piping system 100. The jacket 130 may be disposed around the pipe 110 such that there are substantially no pinch points that would impede a flow or circulation of any material that has leaked in the volume. In other words, the jacket 130 may be separated from the outer surface 1 12 such that a volume between the jacket 130 and the outer surface 1 12 is substantially continuous and does not include any divided (e.g., separated) volumes. In some such embodiments, any material that has leaked may circulate within the system 101 and a composition within the system 101 may be substantially uniform.
The porous material 134 may exhibit a substantial rigidity such that a space between an inner surface of the jacket 130 and the outer surface 1 12 of the pipe 1 10 is maintained along a length of the jacket 130. In some embodiments, the porous material 134 may be configured to provide a space between outermost portions of the flange 116 and the inner surface of the jacket 130 such that a volume on one side of a flange 1 16 of the pair of flanges 1 16 is not separated from a volume on an opposing side of the flanges 116. In some embodiments, the jacket 130 may cover long sections of pipe that may include a plurality of joints (e.g., flanges 1 16, welded connections, threaded connections, etc.) and a plurality of ancillary fixtures and equipment. By way of nonlimiting example, the jacket 130 may cover sections of pipe as long as about 10 feet (3.04 m), as long as about 20 feet (6.09 m), as long as about 50 feet (15.24 m), as long as about 100 feet (30.4 m), or as long as about 500 feet (152.4 m), although the disclosure is not so limited.
The porous material 134 may comprise a material that is permeable to materials that may leak from the pipe 1 10. By way of nonlimiting example, the porous material 134 may comprise a filter material permeable to the materials that may leak from the pipe 1 10, a foam material (e.g., open-cell foam), a porous ceramic material, a rigid wire screen, a metal mesh, a perforated metal material, a corrugated sheet (e.g., corrugated metal, corrugated cardboard, etc.). In some embodiments, the porous material 134 may comprise a filter comprising polyester, a porous fiber material (e.g., cotton, such as cotton paper), fiberglass (e.g., spun fiberglass), or combinations thereof. In some embodiments, the filter material may be pleated. In other embodiments, the filter material may be reinforced with a metal wire or metal mesh to provide rigidity to the structure thereof.
The system 101 may further include at least one detector 150 configured to detect one or more analytes of interest disposed within the system 101. In some embodiments, the detector 150 may comprise a detector probe. In some such embodiments, the detector 150 may be located outside the jacket 130 and the detector probe may be inserted into the jacket 130. The detector 150 may be coupled to the inner surface of the jacket 130. In other embodiments, the detector 150 may be coupled to the outer surface 1 12 of the pipe 1 10. In some embodiments, the system 101 includes a plurality of detectors 150 and may include, for example, at least one detector 150 coupled to the inner surface of the jacket 130 and at least one detector 150 coupled to the outer surface 112 of the pipe 1 10.
The detector 150 may be positioned at a location where materials that have leaked may accumulate. By way of nonlimiting example, where the pipe 1 10 contains gases with a specific gravity greater than a specific gravity of air, the detector 150 may be located at a bottom of the system 101. In embodiments where the pipe 1 10 contains vapors having a specific gravity less than a specific gravity of air, the detector 150 may be located at a top of the system 101 , where such lighter vapors may accumulate.
The detector 150 may be powered with one or more batteries. In some
embodiments, the battery may comprise a solar powered battery. In some such
embodiments, the system 101 may include a solar panel operably coupled to a battery that is operably coupled to the detector 150 to provide power thereto. In some embodiments, the detector 150 may be fully powered or at least partially powered by vibrations, such as vibrations in the equipment or system 101. By way of nonlimiting example, the detector 150 may be coupled to a vibration-powered generator or a micro- electromechanical system vibrational micro power generator. In some embodiments, the system 101 may be disposed on piping sections that are remote (e.g., located away from a power source) from other areas of a processing facility.
FIG. IB is a cross-sectional view of the system 101. As illustrated, the porous material 134 may extend from the inner surface of the j acket 130 to the outer surface 112 of the pipe 1 10 or to the outer surface of the flanges 116. The porous material 134 may be substantially continuous and may fill substantially all of an annular space between the inner surface of the jacket 130 to the outer surfaces 1 12 of the pipe 1 10 and flanges 1 16. As illustrated, the system 101 may comprise a detector 150 on the outer surface 112 of the pipe 1 10, a detector 150 on an inside surface of the jacket 130, or both. In some embodiments, the system 101 includes a plurality of detectors 150.
FIG. 2A is a cross-sectional view of a material system 200 used to form the system 101 (FIG. 1A, FIG. IB). The material system 200 may include the jacket 130 and the porous material 134 attached to the jacket 130, such as at an inner, unexposed surface of the jacket 130. The porous material 134 may be attached to the jacket 130 with an adhesive, hook-and-loop fasteners, snap connectors, stitching, other suitable method, or combinations thereof. In some embodiments, an inner surface of the jacket 130 may comprise hook-and-loop fasteners configured to correspond to corresponding
hook-and-loop fasteners of the porous material 134. In other embodiments, the inner surface of the jacket 130 may comprise a snap-type connector configured to operate with a corresponding one or more corresponding snap-type connectors on the porous material 134. In some embodiments, the porous material 134 is integral with the jacket 130.
FIG. 2B is a cross-sectional view of another material system 200' that may be used to form the system 101 (FIG. 1A, FIG. IB). The material system 200' may be substantially similar to the material system 200 of FIG. 2A, except that the system 200' may include a porous material 134' having a surface having indents 135 and ridges 137 configured to contact the outer surface 112 (FIG. 1 A) of the pipe 110 (FIG. 1 A). In some such embodiments, only a portion of the outer surface 112 of the pipe 110 may be contacted by the porous material 134'.
In some embodiments, the material systems 200, 200' may be prepared as rolls of material having a predetermined width, (e.g., 12 inches (30.48 cm), 18 inches (45.72 cm), 24 inches (60.96 cm), 30 inches (76.2 cm), 36 inches (91.44 cm), etc.) and may be cut to a desired length, depending on a length or diameter of pipe 100 to be monitored for leaks. In some embodiments, the system 101 may be formed on site according to needs of a particular processing plant. In some embodiments, the material system 200, 200' may be wrapped around a section of piping and the jacket 130 may be punctured to insert one or more detectors 150 (FIG. 1A) or detector probes between the jacket 130 and a section of pipe.
FIG. 3 is a simplified block diagram illustrating a leak detection system 300 including at least one detector 150. The detector 150 may comprise a gas detector and may include a detector probe. In some embodiments, the detector 150 may include one or more of reference sensors 152, a catalytic sensor 154, one or more metal oxide semiconductor (MOS) sensors 156, one or more resonant sensors 158 (e.g., microcantilever resonant sensors), and one or more environmental sensors 160 as described in, for example, United States Provisional Patent Application Serial Number 62/376,675, entitled "A SYSTEM AND METHOD FOR DETECTING, IDENTIFYING, AND/OR QUANTIFYING GASES," filed August 18, 2016, the entire disclosure of which is hereby incorporated herein in its entirety by this reference.
With continued reference to FIG. 3, each of the reference sensors 152, the catalytic microhotplate sensor 154, the MOS sensors 156, the resonant sensors 158, and the environmental sensors 160 may be in communication with a central processing unit 162. The central processing unit 162 may be configured to communicate with each of the sensors. The central processing unit 162 may be in communication with a memory 164 configured to store data (e.g., historic data) measured by one or more of the sensors and may also contain calibration and stored response data used in analysis of sensor responses. The central processing unit 162 may also be in communication with a user interface 166. The detector 150 may be coupled to a power source 174. The power source 174 may comprise one or more batteries, a wired connection, or one or more solar panels operably coupled to a rechargeable battery. In some embodiments, the power source 174 comprises one or more batteries. In other embodiments, the power source 174 comprises one or more solar panels. In yet other embodiments, the power source 174 may include a vibrational energy harvesting device (e.g., a vibration-powered generator or a micro- electromechanical system vibrational micro power generator).
The detector 150 may be in communication with a system controller 168, such as through an antenna 170. The system controller 168 may be coupled to an antenna 172 configured to wirelessly communicate with the antenna 170 of the detector 150. In some such embodiments, the detector 150 may be wirelessly coupled to the system
controller 168. Accordingly, conditions of the piping system 100 (FIG. 1A) may be monitored wirelessly and the system 101 (FIG. 1A) may be configured to monitor leak events from the piping system 100 remotely and may take corrective action responsive to detection of a leak in a section of pipe 110. In one embodiment, the leak detection system 300 comprises a wireless network comprising a mesh network wherein a plurality of detectors 150 and associated antennas 170 are operably coupled to each other (i.e., an antenna 170 of a detector 150 is configured to wirelessly communicate with an antenna 170 of at least another detector 150) and with the antenna 172 of the system controller 168. Accordingly, in some embodiments, at least one detector 150 of the leak detection system 300 may communicate with the system controller 168 via one or more other detectors 150 in the leak detection system 300.
In other embodiments, the detector 150 may communicate with the system controller 168 via a wired connection. The system controller 168 may be configured to take corrective action such as reducing or stopping flow through a section of pipe 110 in which a leak has been detected by the detector 150.
In some embodiments, many flammable and nonflammable gases may be identified and quantified by measuring a thermal conductivity and a viscous damping of a sample. By way of nonlimiting example, the thermal conductivity may be measured with the reference sensor 152 and a viscous damping may be measured by sensing a shift in a resonant frequency of the resonant sensor 158 or another resonant sensor. The
measurements may be augmented by responses (e.g., measurements) from the catalytic sensor 154, the MOS sensor 156, or both. Accordingly, the detector 150 may be configured to detect in a leak in the pipe 110 (FIG. 1 A) around which the system 101 (FIG. 1 A) is disposed, such as by detecting one or more flammable or nonflammable gases (e.g., such as gases carried by the pipe 110) with one or more of the sensors.
The detector 150 may further comprise one or more environmental sensors 160 such as a temperature sensor, a pressure sensor, a humidity sensor, or combinations thereof. The detector 150 may be configured to compensate measured values for changes in one or more of the temperature, the pressure, the viscosity, and the humidity of a sample analyzed by the detector 150.
Responsive to detection of the leak, the central processing unit 162 may
communicate with the system controller 168. The system controller 168 may be configured to decrease a flow (e.g., substantially stop a flow) of material through the piping system responsive to receiving an indication from the central processing unit 162 of a leak.
The central processing unit 162 may be in communication with the user
interface 166. The user interface 166 may comprise a graphical user interface (e.g., a screen, a touchscreen, etc.), an audible sound configured to alarm when a leak is detected, or other system.
In some embodiments, the leak detection system 300 may include a plurality of detectors 150 coupled to the system controller 168 for detecting leaks in one or more locations throughout a piping system. Accordingly, the system controller 168 may be in communication with a plurality of detectors 150. In some embodiments, each detector 150 is substantially the same. In other embodiments, at least some of the detectors 150 are different than at least other of the detectors 150. By way of nonlimiting example, at least some of the detectors 150 may comprise different types of sensors than at least some other of the detectors 150 in the leak detection system 300.
Although the detector 150 has been described as including the reference sensor 152, the catalytic microhotplate sensor 154, the MOS sensors 156, the resonant sensors 158, and the environmental sensors 160, the disclosure is not so limited. In other embodiments, the detector 150 may include fewer components. By way of nonlimiting example, the detector 150 may not include the central processing unit 162, and sensors other than the catalytic microhotplate sensor 154, the MOS sensors 156, the resonant sensors 158, and the environmental sensors 160 may be used.
Although the system 101 (FIG. 1A) has been described as including a porous material 134 substantially filling a volume between the inner surface of the jacket 130 and the outer surface 112 of the pipe 110, the disclosure is not so limited. FIG. 4A is a piping system 100' including a system 101 ' for detecting a leak in the piping system 100', according to another embodiment of the disclosure. The system 10Γ may be substantially similar to the system 101, except that the system 10Γ may not include the porous material 134. The system 10Γ may include spacers 140 disposed between the inner surface of the jacket 130 and the outer surface 112 of the pipe 110 to define a volume 136 in the annular space between the inner surface of the jacket 130 and the outer surface 112 of the pipe 110 for the fluid or fumes to permeate volume 136. The spacers 140 may also be referred to herein as "stand-off" structures or "legs."
In some embodiments, at least some spacers 140 are positioned on portions of the piping system 100 such that the volume 136 is substantially continuous. In other words, the spacers 140 may be positioned such that the volume 136 forms a substantially continuous and undivided volume along a length of the system 10Γ. Stated another way, the spacers 140 may be sized and positioned such that the volume 136 on one side of the flanges 116 is in fluid communication with the volume 136 on an opposing side of the flanges 116 and the volume 136 exhibits a substantially uniform composition throughout. In some such embodiments, a detector 150 in the volume 136 may detect a presence of materials leaking into the volume 136 at an opposing side of the volume 136.
In some embodiments, at least some spacers 140 may be located in positions where the jacket 130 may otherwise contact the outer surface 112 of the pipe 110 and separate the volume 136 into isolated portions. As one example, at least some spacers 140 may be positioned on at least one surface of the piping system 100' that is located closer to the inside surface of the jacket 130 than other surfaces of the piping system 100'. As another example, at least some spacers 140 may be positioned on a surface of the flanges 116 and may be configured to maintain a space between the inner surface of the jacket 130 and an outermost surface of the flanges 116. In some embodiments, the system 10Γ may include spacers 140 extending between the outer surface 112 of the pipe 110 and the inner surface of the jacket 130.
In some embodiments, at least some of the spacers 140 may have different lengths than at least other spacers 140. By way of nonlimiting example, spacers 140 on the flanges 116 may be shorter than spacers 140 in contact with the outer surface 112 of the pipe 110. Spacers 140 located proximate the connection structures 132 may have a shorter length than other spacers 140 in contact with the outer surface 112 of the pipe 110. The spacers 140 may be coupled (e.g., attached) to the inner surface of the jacket 130 by any suitable means for securing the spacers 140 to the jacket 130. In some embodiments, the spacers 140 are coupled to the inner surface of the jacket 130 with an adhesive, hook-and-loop fasteners, snap connectors, stitching, or other method. In some embodiments, at least some portions of the inner surface of the jacket 130 may comprise hook-and-loop fasteners configured to couple to corresponding hook-and-loop fasteners of the spacers 140. In other embodiments, at least some portions of the inner surface of the jacket 130 may comprise snap connectors configured to couple with corresponding snap connectors of the spacers 140. In other embodiments, the spacers 140 are integral with the inner surface of the j acket 130.
The spacers 140 may comprise a substantially rigid material. In some
embodiments, the spacers 140 comprise a metal material (e.g., steel (e.g., carbon steel), stainless steel, aluminum, brass, copper, etc.), a galvanized metal, a plastic material, an elastic material (e.g., rubber), a thermoplastic material, a thermosetting material, or combinations thereof. In other embodiments, the spacers 140 comprise a substantially porous material permeable to any material that may leak from the piping system 100. In some such embodiments, the spacers 140 may comprise the same materials as the porous material 134 described above with reference to FIG. 1A and FIG. IB.
FIG. 4B is a cross-sectional view of the system 10Γ taken along sectional line B-B in FIG. 4A. The spacers 140 may be disposed around the circumference of the pipe 110 at a plurality of locations across a circumference thereof. By way of nonlimiting example, the spacers 140 may be disposed along the circumference of the pipe 110 every about 90°. However, the disclosure is not so limited and the spacers 140 may be disposed around the pipe 110 every about 30°, every about 45°, every about 60°, every about 180°, or at different angular distances along the circumference.
FIG. 4C is a cross-sectional view of the system 10Γ taken along sectional line C-C in FIG. 4A. With reference to FIG. 4B and FIG. 4C, at least some of the spacers 140 may be angularly offset from other spacers 140. Stated another way, the spacers 140 may extend from the outer surface 112 of the pipe 110 to the inner wall of the jacket 130 but may not isolate any portions of the volume 136 from other portions thereof. Accordingly, any material (e.g., gas) leaking from the piping system 100' may accumulate in the entire volume 136 and the volume 136 may comprise a substantially uniform composition (and concentration of the leaked material). FIG. 4D is a plan view of the spacer 140 according to some embodiments of the disclosure. The spacer 140 may comprise a checkered pattern with a plurality of openings 142 defined between walls 144. The openings 142 may be square-shaped. The openings 142 may facilitate permeation of materials through the spacer 140 such that the composition of the material in the volume 136 has a substantially uniform composition between the inner surface of the j acket 130 and the outer surface 112 of the pipe 110 along a length of the system 101.
FIG. 4E is a plan view of another spacer 140' according to other embodiments of the disclosure. The spacer 140' may include openings 142 with a different shape than the openings 142 of the spacer 140. For example, the openings 142 may be diamond-shaped. In other embodiments, the openings 142 may be circular, oval, rectangular, triangular, or another shape.
FIG. 5 A and FIG. 5B are cross-sectional views illustrating a system 101", according to another embodiment of the disclosure. The system 101" may include pipes 110 welded together at weld 190 and a jacket 130' disposed around a section of pipe 110. The jacket 130' may comprise a material having a corrugated surface 131 such that portions of the corrugated surface 131 contact the outer surface 112 of the pipe 110 and other portions of the corrugated surface 131 are spaced from the outer surface 112. The corrugated surface 131 may facilitate distribution and flow of material in the space between the jacket 130' and the outer surface 112 of the pipe 110.
FIG. 5C is a plan view of the inner surface of the jacket 130'. FIG. 5D is a cross- sectional view of the jacket 130' taken along sectional line D-D in FIG. 5C. The jacket 130' may be defined by a checkered pattern. In some embodiments, the jacket 130' comprises adjacent material structures 137 separated by gaps 139. The gaps 139 may be interconnected such that any materials that have leaked from the pipe 110 (FIG. 5 A) permeate through the interior of the jacket 130'. Accordingly, a composition of the material in a space between the jacket 130' and the outer surface 112 of the pipe 110 may be substantially uniform since the material may permeate through the jacket 130' via the gaps 139. Accordingly, the jacket 130' may not form any impediments to the distribution of material in the space between the jacket 130' and the outer surface 112 of the pipe 110.
FIG. 5E is a plan view of the inner surface of another jacket 130". FIG. 5F is a cross-sectional view of the jacket 130" taken along sectional line F-F in FIG. 5E. The jacket 130" may include a network of interconnected gaps 139 separating a plurality of adjacent material structures 137. The material structures 137 may comprise a metal, a thermoplastic material, a thermosetting material, a rubber material, a plastic material, or other material configured to provide sufficient rigidity to the jacket 130". In other embodiments, the material structures 137 comprise bubbles or pockets of material, such as a "bubble-wrap" material, wherein a gas or liquid may flow between the material structures 137 in the gaps 139. The interconnected gaps 139 may allow for any materials that have leaked through the pipe 110 to mix in the space between the jacket 130" such that the space exhibits a substantially uniform concentration and an analyte sampled by the detectors 150 may be representative of the composition within the space.
In some embodiments, the jacket may comprise a second pipe disposed around a section of pipe to be monitored for a leak. FIG. 6A is a cross-sectional view of a system 200 for detecting a leak in a pipe 210. FIG. 6B is another cross-sectional view of the system 200 taken along sectional line B-B in FIG. 6A. The system 200 may include a pipe 210 carrying a material. The system 200 may include a jacket 230 disposed around the pipe 210. In some embodiments, the jacket 230 may comprise another pipe having a larger diameter than a diameter of the pipe 210. In some such embodiments, the pipe 210 and the jacket 230 may comprise a double-walled pipe. A volume 236 between an outer wall of the pipe 210 and an inner wall of the jacket 230 may be configured to receive any materials that may leak from the pipe 210. A porous material substantially similar to the porous material 134 described above with reference to FIG. 1A or substantially similar to the porous material 134' described above with reference to FIG. 2B may be disposed in the volume 236 between outer wall of the pipe 210 and the inner wall of the jacket 230. In other embodiments, the volume 236 includes one or more spacers substantially similar to the spacers 140 described above with reference to FIG. 4A. One or more detectors 250 may be located within the volume 236 and may be located on the outer wall 212 of the pipe 210, an inner wall of the jacket 230, or both. The detector 250 may be substantially similar to the detectors 150 described above with reference to FIG. 1A through FIG. 5B.
Although FIG. 1A, FIG. 4A, FIG. 5 A, and FIG. 6A illustrate the systems 101, 101', 101", 200 as disposed around the flanges 116 and pipe 100, the disclosure is not so limited. In other embodiments, the systems 101, 10Γ, 101", 200 may be disposed around any portion of piping or equipment having any desired size or shape. FIG. 7 is a simplified schematic illustrating a system 700 configured for detecting a leak in at least one section of equipment 302. The system 700 may include a section of equipment 302 enclosed by a housing 304. The section of equipment 302 may include one or more of a compressor, a valve, a pump, a heat exchanger, a pressure vessel, a tank, or another piece of equipment. Any material that has leaked from the equipment 302 may be disposed in a volume 306 between the housing 304 and the equipment 302. The system 700 may include at least one detector 350 coupled to an outer portion of the equipment, at least one detector 350 coupled to an inner surface of the housing 304, or both. The detector 350 may be substantially similar to the detectors 150 described above with reference to FIG. 1A through FIG. 5B. The housing 304 may comprise a plastic material, a thermoplastic material, a rubber material, a metal material, a metal sheet, a metal foil, another material, or combinations thereof.
In some embodiments, providing the systems 101, 10Γ, 101", 200, 700 including the detector 150, 250, 350 with one or more of the sensors (one or more reference sensors 152, one or more catalytic sensors 154, one or more MOS sensors 156, one or more resonant sensors 158, and one or more environmental sensors 160) may provide advantages compared to prior art methods of detecting a leak in a piping system. By way of nonlimiting example, the detector 150, 250, 350 may exhibit an increased sensitivity to more analytes than prior art systems that use, for example, mass spectrometers. The detector 150, 250, 350 may be configured to detect more than one type of leaking gas and may be exhibit an increased cross-sensitivity relative to other detectors in prior art leak detection systems. The systems 101, 10Γ, 101", 200, 700 may be configured to conform to piping systems with different shapes and diameters. The systems 101, 10Γ, 101", 200, 700 may be configured to continuously determine a presence of a leak in real time and may minimize a need for an operator to manually inspect piping connections for leaks.
Additional nonlimiting example embodiments of the disclosure are set forth below. Embodiment 1: A system for detecting a leak, the system comprising: a jacket disposed around an outer surface of a section of pipe or equipment and defining a volume between an inner surface of the jacket and the outer surface of the section of pipe or equipment; a connection means for connecting ends of the jacket to the outer surface of the section of pipe or equipment; a structure separating the outer surface of the section of pipe or equipment from the inner surface of the jacket; and a detector disposed between the outer surface of the section of pipe or equipment and the inner surface of the jacket. Embodiment 2: The system of Embodiment 1, wherein the jacket comprises a plastic material, a thermoplastic material, a rubber material, a metal material, or combinations thereof.
Embodiment 3: The system of Embodiment 1 or Embodiment 2, wherein the jacket comprises a housing surrounding the section of pipe or equipment.
Embodiment 4: The system of any one of Embodiments 1 through 3, wherein the structure comprises a gas permeable material.
Embodiment 5: The system of any one of Embodiments 1 through 4, wherein the structure comprises a plurality of legs separating the inner surface of the jacket from the outer surface of the section of pipe or equipment.
Embodiment 6: The system of Embodiment 5, wherein at least some legs of the plurality of legs have a different length than other legs of the plurality of legs.
Embodiment 7: The system of any one of Embodiments 1 through 6, wherein the structure is coupled to the inner surface of the jacket with an adhesive, hook-and-loop fasteners, snap connectors, or combinations thereof.
Embodiment 8: The system of any one of Embodiments 1 through 7, wherein the structure is integral with the jacket.
Embodiment 9: The system of any one of Embodiments 1 through 7, wherein the jacket comprises another pipe disposed around the section of pipe, the jacket and the section of pipe comprising a double-walled pipe.
Embodiment 10: The system of any one of Embodiments 1 through 9, wherein the structure substantially fills the volume between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
Embodiments 11 : The system of any one of Embodiments 1 through 10, wherein the connection means comprises an adhesive, an elastic member, or a retaining member.
Embodiment 12: The system of any one of Embodiments 1 through 11, wherein the detector is disposed on the inner surface of the jacket.
Embodiment 13: The system of any one of Embodiments 1 through 11, wherein the detector is disposed on the outer surface of the section of pipe or equipment.
Embodiment 14: The system of any one of Embodiments 1 through 13, wherein the detector comprises a gas detector.
Embodiment 15: The system of any one of Embodiments 1 through 14, wherein the detector is wired to a system monitor. Embodiment 16: The system of any one of Embodiments 1 through 14, wherein the detector is configured to wirelessly communicate with a system monitor.
Embodiment 17: The system of any one of Embodiments 1 through 16, further comprising a mesh network of a plurality of detectors, wherein at least one detector is configured to wirelessly communicate with at least another detector
Embodiment 18: The system of any one of Embodiments 1 through 17, further comprising a controller configured to stop a flow through the section of pipe or equipment responsive to a detected leak.
Embodiment 19: The system of any one of Embodiments 1 through 18, wherein the detector is battery powered, vibration powered, or solar powered.
Embodiment 20: A leak detection system, comprising: a jacket disposed around a circumference of a section of pipe or equipment, the jacket comprising a material impermeable or semi-permeable to a vapor carried by the pipe; a connection means for attaching the jacket around the circumference of the section of pipe or equipment; a material separating an inner surface of the jacket from an outer surface of the section of pipe or equipment; and at least one of at least one detector or at least one detector probe disposed within a space between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
Embodiment 21 : The leak detection system of Embodiment 20, wherein the at least one of the at least one detector or at least one detector probe is configured to detect multiple gases.
Embodiment 22: The leak detection system of Embodiment 20 or Embodiment 21, wherein the jacket comprises a housing surrounding the section of pipe or equipment.
Embodiment 23: The leak detection system of any one of Embodiments 20 through 22, wherein the at least one detector or at least one detector probe comprises a microcantilever sensor.
Embodiment 24: The leak detection system of Embodiment 23, wherein the at least one detector further comprises at least one reference microcantilever sensor.
Embodiment 25: The leak detection system of any one of Embodiments 20 through 24, wherein the at least one of the at least one detector or at least one detector probe comprises at least one reference sensor and one or more microcantilever sensors. Embodiment 26: The leak detection system of Embodiment 25, wherein the at least one of the at least one detector or at least one detector probe further comprises at least one catalytic sensor and at least one metal oxide semiconductor sensor.
Embodiment 27: The leak detection system of any one of Embodiments 20 through 26, wherein the at least one of at least one detector or at least one detector probe comprises at least one detector coupled to the inner surface of the jacket.
Embodiment 28: The leak detection system of any one of Embodiments 20 through
27, wherein the at least one of at least one detector or at least one detector probe comprises at least one detector coupled to the outer surface of the section of pipe or equipment.
Embodiment 29: The leak detection system of any one of Embodiments 20 through
28, wherein the material separating the inner surface of the jacket from the outer surface of the section of pipe or equipment comprises a porous material.
Embodiment 30: The leak detection system of any one of Embodiments 20 through 39, wherein the material separating the inner surface of the jacket from the outer surface of the section of pipe or equipment comprises a porous material and substantially fills the space between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
Embodiment 31: The leak detection system of any one of Embodiments 20 through 30, wherein the material comprises a metal material, a plastic material, an elastic material, a thermoplastic material, or a thermosetting material.
Embodiment 32: A leak detection system, comprising: a jacket disposed around an outer surface of a section of pipe or equipment, the jacket comprising an exposed outer surface and a corrugated surface, at least some of the corrugated surface in contact with the outer surface of the section of pipe or equipment; a connection means for attaching the jacket around a circumference of the section of pipe or equipment; and at least one detector disposed within a space between the jacket and the outer surface of the section of pipe or equipment.
Embodiment 33: The leak detection system of Embodiment 32, wherein the jacket comprises a plurality of adjacent material structures separated by interconnected gaps, the interconnected gaps forming a continuous volume between the outer surface of the section of pipe or equipment and the exposed outer surface of the jacket.
Embodiment 34: The leak detection system of Embodiment 32 or Embodiment 33, wherein the jacket comprises a network of interconnected gaps separating a plurality of adjacent material structures. Embodiment 35: A method of detecting a leak, the method comprising: disposing a jacket around a section of pipe or equipment; providing one of a porous material and a spacer in a volume between an inner surface of the jacket and an outer surface of the section of pipe or equipment; providing at least one gas detector in the volume; and monitoring the volume for one or more analytes indicative of a leak in the section of pipe or equipment.
Embodiment 36: The method of Embodiment 35, wherein providing one of a porous material and a spacer in a volume comprises substantially filling the volume with the porous material.
Embodiment 37: The method of Embodiment 35 or Embodiment 36, wherein providing at least one gas detector in the volume comprises providing at least one gas detector comprising at least one reference sensor and at least one microcantilever sensor in the volume.
Embodiment 38: The method of Embodiment 37, further comprising providing at least one catalytic sensor and at least one metal oxide semiconductor sensor in the volume.
Embodiment 39: The method of any one of Embodiments 35 through 38, wherein disposing a jacket around a section of pipe or equipment comprises disposing a jacket comprising an impermeable material to a material carried by the section of pipe or equipment.
Embodiment 40: The method of any one of Embodiments 35 through 39, wherein providing at least one gas detector in the volume comprises providing a gas detector probe in the volume through the jacket, the gas detector probe coupled to the at least one gas detector.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure as defined by the following appended claims and their legal equivalents.

Claims

What is claimed is: 1. A system for detecting a leak, the system comprising:
a jacket disposed around an outer surface of a section of pipe or equipment and defining a volume between an inner surface of the jacket and the outer surface of the section of pipe or equipment;
a connection means for connecting ends of the jacket to the outer surface of the section of pipe or equipment;
a structure separating the outer surface of the section of pipe or equipment from the inner surface of the jacket; and
a detector disposed between the outer surface of the section of pipe or equipment and the inner surface of the jacket.
2. The system of claim 1, wherein the jacket comprises a plastic material, a thermoplastic material, a rubber material, a metal material, or combinations thereof.
3. The system of claim 1, wherein the jacket comprises a housing surrounding the section of pipe or equipment.
4. The system of claim 1, wherein the structure comprises a gas permeable material.
5. The system of claim 1, wherein the structure comprises a plurality of legs separating the inner surface of the jacket from the outer surface of the section of pipe or equipment.
6. The system of claim 5, wherein at least some legs of the plurality of legs have a different length than other legs of the plurality of legs.
7. The system of claim 1, wherein the structure is coupled to the inner surface of the jacket with an adhesive, hook-and-loop fasteners, snap connectors, or combinations thereof.
8. The system of claim 1, wherein the structure is integral with the jacket.
9. The system of claim 1, wherein the jacket comprises another pipe disposed around the section of pipe, the jacket and the section of pipe comprising a double-walled pipe.
10. The system of claim 1 , wherein the structure substantially fills the volume between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
11. The system of claim 1 , wherein the connection means comprises an adhesive, an elastic member, or a retaining member.
12. The system of claim 1, wherein the detector is disposed on the inner surface of the jacket.
13. The system of claim 1, wherein the detector is disposed on the outer surface of the section of pipe or equipment.
14. The system of claim 1, wherein the detector comprises a gas detector.
15. The system of claim 1, wherein the detector is wired to a system monitor.
16. The system of claim 1, wherein the detector is configured to wirelessly communicate with a system monitor.
17. The system of claim 16, further comprising a mesh network of a plurality of detectors, wherein at least one detector is configured to wirelessly communicate with at least another detector.
18. The system of claim 1, further comprising a controller configured to stop a flow through the section of pipe or equipment responsive to a detected leak.
19. The system of claim 1, wherein the detector is battery powered, vibration powered, or solar powered.
20. A leak detection system, comprising:
ajacket disposed around a circumference of a section of pipe or equipment, the jacket
comprising a material impermeable or semi-permeable to a vapor carried by the pipe; a connection means for attaching the jacket around the circumference of the section of pipe or equipment;
a material separating an inner surface of the jacket from an outer surface of the section of pipe or equipment; and
at least one of at least one detector or at least one detector probe disposed within a space between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
21. The leak detection system of claim 20, wherein the at least one of the at least one detector or at least one detector probe is configured to detect multiple gases.
22. The leak detection system of claim 20, wherein the jacket comprises a housing surrounding the section of pipe or equipment.
23. The leak detection system of claim 20, wherein the at least one detector or at least one detector probe comprises a microcantilever sensor.
24. The leak detection system of claim 23, wherein the at least one detector further comprises at least one reference microcantilever sensor.
25. The leak detection system of claim 20, wherein the at least one of the at least one detector or at least one detector probe comprises at least one reference sensor and one or more microcantilever sensors.
26. The leak detection system of claim 25, wherein the at least one of the at least one detector or at least one detector probe further comprises at least one catalytic sensor and at least one metal oxide semiconductor sensor.
27. The leak detection system of claim 20, wherein the at least one of at least one detector or at least one detector probe comprises at least one detector coupled to the inner surface of the jacket.
28. The leak detection system of claim 20, wherein the at least one of at least one detector or at least one detector probe comprises at least one detector coupled to the outer surface of the section of pipe or equipment.
29. The leak detection system of claim 20, wherein the material separating the inner surface of the jacket from the outer surface of the section of pipe or equipment comprises a porous material.
30. The leak detection system of claim 20, wherein the material separating the inner surface of the jacket from the outer surface of the section of pipe or equipment comprises a porous material and substantially fills the space between the inner surface of the jacket and the outer surface of the section of pipe or equipment.
31. The leak detection system of claim 20, wherein the material comprises a metal material, a plastic material, an elastic material, a thermoplastic material, or a thermosetting material.
32. A leak detection system, comprising:
a jacket disposed around an outer surface of a section of pipe or equipment, the jacket
comprising an exposed outer surface and a corrugated surface, at least some of the corrugated surface in contact with the outer surface of the section of pipe or equipment;
a connection means for attaching the jacket around a circumference of the section of pipe or equipment; and
at least one detector disposed within a space between the jacket and the outer surface of the section of pipe or equipment.
33. The leak detection system of claim 32, wherein the jacket comprises a plurality of adjacent material structures separated by interconnected gaps, the interconnected gaps forming a continuous volume between the outer surface of the section of pipe or equipment and the exposed outer surface of the jacket.
34. The leak detection system of claim 32, wherein the jacket comprises a network of interconnected gaps separating a plurality of adjacent material structures.
35. A method of detecting a leak, the method comprising:
disposing a jacket around a section of pipe or equipment;
providing one of a porous material and a spacer in a volume between an inner surface of the jacket and an outer surface of the section of pipe or equipment;
providing at least one gas detector in the volume; and
monitoring the volume for one or more analytes indicative of a leak in the section of pipe or equipment.
36. The method of claim 35, wherein providing one of a porous material and a spacer in a volume comprises substantially filling the volume with the porous material.
37. The method of claim 35, wherein providing at least one gas detector in the volume comprises providing at least one gas detector comprising at least one reference sensor and at least one microcantilever sensor in the volume.
38. The method of claim 37, further comprising providing at least one catalytic sensor and at least one metal oxide semiconductor sensor in the volume.
39. The method of claim 35, wherein disposing ajacket around a section of pipe equipment comprises disposing ajacket comprising an impermeable material to a material carried by the section of pipe or equipment.
40. The method of claim 35, wherein providing at least one gas detector in the volume comprises providing a gas detector probe in the volume through the jacket, the gas detector probe coupled to the at least one gas detector.
PCT/US2018/015728 2017-02-24 2018-01-29 Leak detection system and related methods WO2018156313A1 (en)

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