Detection of escaping emissions using valve positioner

Abstract

A valve positioner is configured to detect escape emissions on a valve. The valve positioner is configured to detect the escape emissions on the valve. The construction may include a sensor located proximate to the device. The sensor may be connected to a control unit, preferably with operational hardware that may process signals. This arrangement may be secured to the structure of the valve. In one embodiment, a sensor may be connected to a connection present on a circuit board. This feature allows for upgrading of the device, including those in the group with minimal impact on design or performance or those in the field.

Description

Background Art

[0001] Flow control devices play an important role in many industrial facilities. For example, power plants and industrial process facilities use different types of flow control devices to manage the flow of materials (usually fluids) throughout a vast network of pipes, tanks, generators, and other equipment. In some applications, such as those transporting hydrocarbons or fossil fuels, the performance of flow control is affected by important regulatory or operating parameters to meet contractors, purchasers, or end-users, which includes the allowable amount of emissions that can be released from the device. Summary of the Invention

[0002] The subject matter of the present disclosure relates to improvements in addressing emissions in or around devices on a process line. Particular interest lies in embodiments sensitive to "fugitive" emissions. Embodiments can detect very small amounts of fluid that may emanate from or around components on a flow control device, typically a valve. This feature can reduce costs and improve safety as it obviates the need for "manual" inspections of these devices, which typically require technicians to approach individual valves with handheld equipment. One beneficial effect of the proposed method is to reduce labor costs as operators can extend the regular maintenance cycle in lieu of alarms (or other indication markings) of problems on their devices. Another beneficial effect is that it utilizes the existing communication infrastructure at the operator's facility. This feature can allow data, such as measurements of fugitive emissions, to be exchanged with a central control network for further analysis and diagnosis. Brief Description of the Drawings

[0003] This specification refers to the following drawings:

[0004] Figure 1 A schematic diagram showing an exemplary embodiment of a valve controller;

[0005] Figure 2 Showing Figure 1 a schematic diagram of a controller;

[0006] Figure 3 Showing Figure 1 a front view of an example of a controller;

[0007] Figure 4 Showing Figure 1 a perspective view of an example of a controller; and

[0008] Figure 5 a perspective view of an example of a flow control device.

[0009] These figures and any description in this document represent examples that can disclose or interpret the present invention. These examples include the best mode and also enable any person skilled in the art to practice the present invention, including manufacturing and using any device or system and performing any combined method. Unless otherwise stated in the discussion, the figures are not drawn to scale. Elements in the examples may appear in one or more of several views or in a combination of several views. The figures may use similar reference numerals to represent the same or corresponding elements. The methods are merely exemplary and may be modified, for example, by reordering, adding, deleting, and / or changing the individual steps or stages. This specification may use the singular words "a" or "an" to identify such stages and any parts, components, elements, or functions; however, this should not exclude the plural form of any such name, unless the specification explicitly states or describes such an exclusion. Similarly, any reference to "an embodiment" or "a particular implementation" does not exclude the existence of other embodiments or particular implementations that also incorporate the described features. Detailed Description

[0010] The features of the examples shown in the above figures will now be discussed. These features address fluid leakage or release that may occur in a process pipeline. Typically, the release is such a small amount that it is difficult to detect or provide an accurate measurement. However, the leakage may occur over time, resulting in a larger volume that exceeds the standard or specification. As described herein, the proposed designs can address an operator's concerns about these "fugitive" emissions on their process pipelines. These designs also present a cost-effective solution that can utilize existing computing hardware to provide the operator with advance notice of fugitive gases (or other fluids) that may permeate or escape from a process plant. Other embodiments are within the scope of this disclosure.

[0011] Figure 1 A schematic diagram of an exemplary valve positioner 100 is shown. This example exists in a distribution network 102 that is generally designed to transport a substance 104 through a network of conduits 106. The network 102 may include a flow control 108 as part of the network 102. The flow control 108 may have an actuator 110 and a valve stem or valve shaft 112, one end of which is coupled to a valve mechanism 114 that may include a closure member 116 and a seat 118. In one particular implementation, the valve positioner 100 may include a control unit 120 coupled to a sensor unit 122.

[0012] Broadly, the valve positioner 100 can be configured to perform analysis or diagnostics. These configurations can be embodied as devices capable of warning an operator of problems in their process pipelines. These devices can detect fugitive emissions that occur near process equipment found in industrial environments. This feature can warn the operator of the release of harmful fluids, such as chlorine gas. This feature can also reduce greenhouse gas emissions in hydrocarbon plants, as the device can warn the operator to slow down leaks that occur in valves or similar process equipment. The operator can then perform preemptive maintenance to address the problem, which will avoid any extended emissions from the equipment.

[0013] The distribution system 102 can be configured to deliver or move these fluids. These configurations can be embodied as vast infrastructure. The substance 104 can also include gases, liquids, solid-liquid mixtures, or liquid-gas mixtures. The conduit 106 can include pipes or pipelines that are typically connected to pumps, boilers, etc. The pipeline can also be connected to tanks or reservoirs. In many facilities, this equipment forms a complex network to perform processes, such as refining raw materials or manufacturing final products.

[0014] The flow control 108 can be configured to regulate the flow of the substance 104 through the conduit 106 in these complex networks. These configurations can include control valves and similar devices. The actuator 110 can use pressurized fluids, such as air or natural gas, to generate a load. Typically, the device can include a piston, spring (or springs), or flexible diaphragm for this purpose. The valve stem 112 can direct this load to the closure member 116, typically a ball, plug, or disk. This load can resist the pressure of the material 104 on the opposite side of the closure member 116. This feature can hold the closure member 116 in a desired position relative to the seat 118. In one specific implementation, the desired position or "set point" can correspond to the flow parameters of the material 104 to meet process requirements or parameters.

[0015] The control unit 120 can be configured to process and generate signals. These configurations can be connected to a control network (or "distributed control system" or "DCS") that maintains the operation of all devices on the process pipeline to ensure that materials flow according to the process. The DCS can generate control signals with operating parameters that describe or define the operation of the flow control 108 for this purpose. The control unit 120 can have operating hardware, such as electrical components and computing components (e.g., processors, memory, executable instructions, etc.). These components can also include electro-pneumatic devices that operate on incoming pneumatic supply signals. These components ensure that the actuator control signals sent to the actuator 112 are suitable for the flow control 108 to supply the material 104 downstream according to the process parameters.

[0016] The sensor unit 122 may be configured to detect fugitive emissions. These configurations may include devices that are sensitive to various fluids, which are typically in limited or finite amounts or quantities. The device may embody various types of detection technology, including LIDAR, infrared, optical, chemical, etc. The technology may be primarily adapted to the distance or spacing between the device and the emission source (e.g., the fill material found on the flow control 108). The technology may generate a signal that quantifies the amount of fluid near the device or, for example, the presence or absence of the fluid. The signal may be transmitted to the control unit 120. The operating hardware may be configured with software (or similar executable instructions) to process the signal as part of its analysis or diagnostic process.

[0017] Figure 2 Shows Figure 1 100 is a front view of an example of the structure of the controller 100. The sensor unit 122 may include a sensor 124 that is sensitive to various types of emissions. In one specific implementation, an interface 126 may be used to connect the sensor unit 124 to the control unit 120. The interface 126 may have an electrical conduit 128 having an end 130 for receiving the sensor 124. The other end 132 may be connected to a connection 134 on the control unit 120. The ends 130, 132 may have suitable threads or similar adapters to secure them in place at their desired locations. The conduit 128 itself may accept or receive the wiring required to connect the sensor 124 to the electronics of the control unit 120. The present disclosure also contemplates the use of wireless technology (such as ).

[0018] Figure 3 and Figure 4A view showing an example of the structure of control unit 120. Connection 134 may form part of housing 136, which encapsulates and protects various components, including the electronic or electro-pneumatic components of the device. The housing 136 may include a manifold 138 having a manifold body 140, which is typically machined or formed from metal, plastic, or composite material. The manifold body 140 may include openings 142 for the entry or exit of fluid, which is typically "instrument air" in the form of compressed air or sometimes pressurized natural gas (or more generally, material 104). Threaded openings 144 may receive electrical connections, e.g., similar to the threaded conduits found at the ends 132 of conduit 128. These openings 144 may provide access to the control components found on circuit board 146. These components work together with current-pressure converter 148 and relay 150 to operate flow control 108. Cover 152 may be coupled to manifold body 140 to encapsulate the electro-pneumatic components 148, 150. Another cover 154 may encapsulate and protect circuit board 146. The cover 154 may include a display 156 and button input device 158, which operate as the primary local user interface to allow the end user to interact with controller 100. In one particular implementation, gauges 160, 162 may provide an indication of the flow conditions (such as pressure or flow rate) of the instrument air used by valve positioner 100 to operate valve 106 in valve assembly 102.

[0019] Figure 5A perspective view depicting an exemplary structure of the flow control 108 is shown. This example reflects the structure of a typical glove control valve; however, the present disclosure contemplates the use of the proposed design in any industrial valve device, including rotary valves such as ball valves, butterfly valves, or globe valves. As shown, the valve body 110 may include a fluid connector 164 that forms a flow path 166 having a flanged open end 168. The fluid connector may encapsulate the valve mechanism 114 (and thus, they are hidden in this view). This structure may be used to regulate process fluids in an industrial production line, which are typical industries focused on chemical production, refining production, and resource extraction. The upper structure 170 may be fixed to the fluid connector 164. The upper structure 170 may support a pneumatic actuator 172, shown here as having a spherical housing 174, which is typically two components that are clamped around the edge to capture a diaphragm (not shown) around the perimeter. The control unit 120 may be mounted on a bracket 176, which itself is fixed to the upper structure 170 or incorporated as part of the upper structure. This arrangement may position the sensor unit 122 near the fluid connector 164, which may eventually vent fugitive gases, for example, from a packing material 178 located in the valve body 110. The packing material 178 may surround the valve stem 112. Also shown, the control unit 120 may deliver instrument air to the pneumatic actuator 172 at an appropriate pressure, which utilizes the pressurized fluid to generate a load. Typically, the device may include a piston, spring (or springs), or a flexible diaphragm for this purpose. The load may resist the pressure of the material 104 on the opposite side of the closure member 116 to hold the closure member 116 in a desired position relative to the seat 118. This desired position or "set point" may correspond to the flow parameters of the material 104 to meet the process requirements or parameters.

[0020] The following examples include certain elements or clauses that describe embodiments contemplated within the scope of this specification. These elements may be combined with other elements and clauses to further describe embodiments. This specification may include and contemplate other examples that occur to those skilled in the art. If these other examples have structural elements that are identical to the literal language of the claims, or if they include equivalent structural elements that are not materially different from the literal language of the claims, then these other examples fall within the scope of the claims.

Claims

1. A valve, the valve comprising: Actuator; A valve positioner coupled to the actuator, the valve positioner having operating hardware that generates a pneumatic signal to the actuator; and A sensor unit coupled to an open connector on the operating hardware, the sensor unit responsive to fugitive emissions.

2. The valve according to claim 1, the valve further comprising: A valve body coupled to the actuator, wherein the sensor unit is located near the valve body.

3. The valve according to claim 1, the valve further comprising: A valve body coupled to the actuator; and Packing material disposed in the valve body, wherein the sensor unit is located near the packing material.

4. The valve according to claim 1, the valve further comprising: A valve body coupled to the actuator, wherein the sensor unit is sensitive to emissions of gas from inside the valve body.

5. The valve according to claim 1, the valve further comprising: A valve stem coupled to the actuator, wherein the sensor unit is located near the valve stem.

6. The valve according to claim 1, wherein the sensor unit includes an electrical conduit connected to the valve positioner.

7. The valve according to claim 1, wherein the sensor unit includes a wire harness that extends into the valve positioner to reach the open connector.

8. A valve, the valve comprising: A valve positioner including operating hardware that generates a pneumatic signal and a housing enclosing the operating hardware, the housing having an opening for accessing the operating hardware; An electrical conduit connected to the opening; A wire harness extending through the electrical conduit and connected to the operating hardware; and A sensor coupled to the wire harness.

9. The valve according to claim 8, wherein the sensor is sensitive to natural gas.

10. The valve according to claim 8, wherein the electrical conduit is sized to position the sensor near a natural gas source.

11. The valve according to claim 8, the valve further comprising: A valve body and a superstructure coupled to the valve body, wherein the valve positioner is located on the superstructure, and wherein the electrical conduit is sized to position the sensor near the valve body.

12. The valve according to claim 8, the valve further comprising: A valve body, a superstructure coupled to the valve body, an actuator disposed on the superstructure, and a valve stem coupled to the actuator and extending into the valve body, wherein the valve positioner is located on the superstructure, and wherein the electrical conduit is sized to position the sensor near the valve stem.

13. The valve according to claim 8, wherein the valve further comprises: A valve body in which packing material is disposed, a superstructure coupled to the valve body, an actuator disposed on the superstructure, a valve stem coupled to the actuator and extending into the valve body, and packing material disposed in the valve body and surrounding the valve stem, wherein the valve positioner is located on the superstructure, and wherein the electrical conduit is sized to position the sensor near the packing material.

14. The valve according to claim 8, wherein the electrical conduit comprises a flexible portion.

15. The valve according to claim 8, wherein the electrical conduit comprises a portion that is threaded for connection to the opening in the housing.

16. A valve, the valve comprising: Actuator; A valve stem coupled to the actuator; A valve body having an opening for receiving the valve stem; A sensor disposed near the opening; A wire harness coupled to the sensor; and A valve positioner having a housing configured to receive the wire harness therein and hold the sensor in its position near the opening.

17. The valve according to claim 16, wherein the valve positioner has operating hardware inside the housing for processing signals from the sensor.

18. The valve according to claim 16, wherein the valve positioner has operating hardware inside the housing that transmits data to a location remote from the valve, the data including data related to signals from the sensor.

19. The valve according to claim 16, wherein the valve positioner has operating hardware inside the housing that exchanges data with a control system, the data including data related to signals from the sensor.

20. The valve according to claim 16, wherein the valve positioner has operating hardware inside the housing that generates a pneumatic signal to the actuator.

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