Erosion probe

Abstract

A sensor 106 that measures erosion in a flow of fluid includes a casing 108 defining an inner space, a sensor end 306, and a signal end 308. A penetrator 202 is positioned within the signal end. A mai

Description

BACKGROUND

[0001] Fluids, such as resource fluids like oil and natural gas are often moved using pipes, valves, tanks, and other flow members. In some cases, the resources may include foreign materials such as sand that can be very abrasive when flowing though this pipeline equipment. Erosion sensors may be used to measure a level of erosion to help predict when repair or replacement of pipeline equipment may be necessary. SUMMARY

[0002] In one aspect, a sensor that measures erosion in a flow of fluid includes a casing defining an inner space, an open sensor end, and an open signal end. A penetrator is positioned within the signal end and a main sensing element is positioned in the sensor end. The casing, the penetrator, and the main sensing element cooperating to form a water-tight enclosure around the inner space and a reference sensing element is positioned fully within the inner space. A temperature sensing element is positioned within the inner space. A first connector is connected to the main sensing element and extends out of the inner space, a second connector is connected to the reference sensing element and extends out of the inner space, and a filler is formed within the inner space to completely fill the inner space.

[0003] In another aspect, a sensor that measures erosion in a flow of fluid includes a casing having a cylindrical wall that defines an open sensor end, an open signal end, and a sensor axis extending therebetween. The sensor end is arranged at an oblique angle with respect to the sensor axis and a main sensing element is positioned in the sensor end and arranged at the oblique angle. The main sensing element has a sensing face that defines a normal direction. The main sensing element cooperates with the casing to define an inner space. A reference sensing element is positioned fully within the inner space, and a filler is formed within the inner space to completely fill the inner space. The main sensing element is arranged within the flow of fluid such that the normal direction extends from the sensing face and away from the main sensing element in an upstream direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number m which that element is first introduced.

[0005] FIG. 1 schematically illustrates a sensor positioned within a pipe that conducts a flow of fluid.

[0006] FIG. 2 is a perspective view of a portion of the sensor of FIG. 1.

[0007] FIG. 3 is a section view of the sensor of FIG. 1 taken along a centerline or sensor axis of the sensor and including a main sensing element and a reference sensing element.

[0008] FIG. 4 is a perspective view of the main sensing element of FIG. 3.

[0009] FIG. 5 is a perspective view of the reference sensing element of FIG. 3.

[0010] FIG. 6 is a plan view of the reference sensing element of FIG. 5. DETAILED DESCRIPTION

[0011] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in this description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0012] Various technologies that pertain to systems and methods will now be described with reference to the drawings, where like reference numerals represent like elements throughout. The drawings discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled m the art will understand that the principles of the present disclosure may be implemented in any suitably arranged apparatus. It is to be understood that functionality that is described as being carried out by certain system elements may be performed by multiple elements. Similarly, for instance, an element may be configured to perform functionality that is described as being carried out by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

[0013] It should be understood that the words or phrases used herein should be construed broadly, unless expressly limited in some examples. For example, the terms “including,” “having,” and “comprising,” as well as derivatives thereof, mean inclusion without limitation. The singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, the term “and / or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. The term “or” is inclusive, meaning and / or, unless the context clearly indicates otherwise. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. Furthermore, while multiple embodiments or constructions may be described herein, any features, methods, steps, components, etc. described with regard to one embodiment are equally applicable to other embodiments absent a specific statement to the contrary.

[0014] Also, terms such as “first”, “second”, “third” and so forth may be used herein to refer to various elements, information, functions, or acts, but should not be considered as limiting in any way. Rather these numeral adjectives are used to distinguish different elements, information, functions or acts from each other. For example, a first element, information, function, or act could be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act could be termed a first element, information, function, or act, without departing from the scope of the present disclosure.

[0015] In addition, the term “adjacent to” may mean that an element is relatively near to but not in contact with a further element or that the element is in contact with the further portion unless the context clearly indicates otherwise. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Terms “about” or “substantially” or like terms are intended to cover variations in a value that are within normal industry manufacturing tolerances for that dimension. If no industry standard is available, a variation of twenty percent would fall within the meaning of these terms unless otherwise stated.

[0016] FIG. 1 schematically illustrates a piece of pipeline equipment such as a pipe 102 in which a flow of fluid 104 may pass. A sensor 106 is positioned within the pipe 102 and in contact with the flow of fluid 104 to measure a particular parameter of the flow of fluid 104. In one arrangement, the sensor 106 is an erosion sensor that operates to estimate the level of erosion within the pipe 102 or other component. In other arrangements, the sensor 106 could operate to measure other parameters or additional parameters (e.g., temperature, pressure, etc.) in place of, or in addition to erosion. While the particular fluid, fluids, or other substances flowing within the pipe 102 is not critical to the arrangement of the sensor 106, one particular sensor 106 is useful when the flow of fluid 104 includes a mixture of hydrocarbons and sand. This flow is particularly effective at eroding components, making the prediction of the level of erosion or a rate of erosion important.

[0017] FIG. 2 illustrates a portion of the sensor 106 with the casing 108 removed. As shown, the sensor 106 includes a penetrator 202, a main sensing element 204, and a reference sensing element 206. As discussed, the sensing elements are selected to operate as erosion sensors with the main sensing element 204 positioned to be exposed to the flow of fluid 104 and the reference sensing element 206 positioned in a way that protects it or isolates it from contact with the flow of fluid 104.

[0018] The penetrator 202 includes a body 208 that defines a plurality of apertures 210 that pass therethrough. As will be discussed in greater detail, the apertures 210 provide for the passage from outside of the sensor 106 to an interior of the sensor for a tube 212 and a plurality of connectors including a first connector 214 and a second connector 216.

[0019] The reference sensing element 206 includes a wall 218 that is curved to fit within the casing 108 as is better illustrated in FIG. 3. A reference slot 220 is formed in the wall 218 and extends along a continuous path between a first end 222 and a second end 224. A reference conductor (not shown) is positioned within the reference sensing element 206 and in particular is positioned in the center of the continuous path between the first end 222 and the second end 224. The reference sensing element 206 is disposed between the main sensing element 204 and the penetrator 202, thereby protecting it from contact with the flow of fluid 104.

[0020] FIG. 3 is a cross sectional view of the sensor 106 better illustrating the arrangement of the internal components. The sensor 106 includes the casing 108 which contains or supports the penetrator 202, the main sensing element 204, the reference sensing element 206, and a filler 326 that fills up any empty space within the casing 108 and interlocks the various components.

[0021] The casing 108 includes a cylindrical wall that defines an open sensor end 306, an open signal end 308, and a sensor axis 318 that is parallel to the cylindrical wall and extends between the sensor end 306 and the signal end 308. The sensor end 306 is arranged at an oblique angle 322 with respect to the sensor axis 318. In the illustrated construction, the oblique angle 322 is forty-five degrees. However, most arrangements select an oblique angle 322 that is between thirty degrees and sixty degrees with other angles, including zero degrees (parallel with the piping) being possible.

[0022] The penetrator 202 includes a body 208 that defines several apertures 210. The body 208 is sized to fit within the open signal end 308 to form a water-tight seal between the body 208 and the casing 108.

[0023] A tube 212 extends through one of the apertures 210 of the body 208 to the main sensing element 204. An O-ring 304 or seal element is placed or formed between the tube 212 and the body 208 to form a water-tight seal. In one construction, the O-ring 304 is formed from a glass material that forms a metal-to-glass seal. The tube 212 is hollow for at least a portion of its length to allow for the placement of a thermocouple 324 or other temperature sensing element within the tube 212. Wires for the thermocouple 324 extend out of the sensor 106 via the hollow tube 212. The tube 212 is also connected to a power supply so that the tube 212 is able to provide power to the main sensing element 204 and the reference sensing element 206 as required for operation.

[0024] In the illustrated construction, five connectors 302 (shown best in FIG. 2) extend through the body 208 to provide connections between the various sensing elements and the exterior of the sensor 106. Each of the connectors 302 includes a strain relief loop to reduce the likelihood of unwanted movement of the connectors 302. While the illustrated construction includes five connectors 302 other constructions could use fewer or more connectors 302 as may be required by whatever sensor elements are employed.

[0025] As with the pipe 102, each of the connectors 302 extends through an aperture 210 and is surrounded by an O-ring 304 or other seal element (e.g., metal-to-glass seal) to form a watertight seal between each connector 302 and its respective O-ring 304 and each O-ring 304 and the body 208.

[0026] The main sensing element 204 includes an inner face 312 and a sensing face 314 opposite the inner face 312. The sensing face 314 is arranged at the oblique angle 322 and defines a normal direction 320 that extends away from the sensing face 314 and the sensor 106 in a direction normal to the sensing face 314. In the illustrated construction, the inner face 312 is parallel to the sensing face 314. However, this is not required for proper performance of the main sensing element 204.

[0027] A main slot 316 is formed in the main sensing element 204 and extends between the inner face 312 and the sensing face 314. As illustrated in FIG. 4, the main slot 316 is formed in a spiral shape that extends from a first end 402 to a second end 404.

[0028] When the components of the sensor 106 are assembled, the casing 108, the penetrator 202, and the main sensing element 204 cooperate to fully enclose an inner space 310 with the reference sensing element 206 disposed fully within that inner space 310. A filler 326 is placed or formed within the inner space 310 to fully fill the inner space 310 and to fix the positions of the various components. In addition to filling the inner space 310, the filler 326 fills the reference slot 220 and the main slot 316 to couple the main sensing element 204 and the reference sensing element 206 to one another via the filler 326. Once the filler 326 is in place, it seals the main slot 316 such that the casing 108, the main sensing element 204, and the penetrator 202 form a water-tight enclosure. The filler 326 further acts as an electrical insulator to fully isolate the connectors 302 from one another.

[0029] In the illustrated construction, a PEEK material is used as the filler 326. "PEEK" refers to polyetheretherketone which is a high-performance organic thermoplastic polymer with outstanding resistance to harsh chemicals, and excellent mechanical strength and dimensional stability. It offers hydrolysis resistance to steam, water, and sea water. Of course, other materials could be employed as the filler 326 as may be required for the particular application.

[0030] FIG. 5 and FIG. 6 better illustrate the reference sensing element 206 and in particular, the arrangement of the reference slot 220. As illustrated, the reference slot 220 follows a serpentine path between the first end 222 and the second end 224 to provide length to the reference slot 220. In addition, apertures or pins are illustrated between parallel portions of the reference slot 220 indicating points where the connectors 302 may connect to the reference sensing element 206 with similar pins or apertures being present on the main sensing element 204.

[0031] In operation, the sensor 106 is assembled with the filler 326 being molded into the inner space 310 to fix the position of the various components and provide a water-tight enclosure.

[0032] The sensor 106 in this construction is an erosion sensor and is positioned in a flow device such as a pipe 102 to expose the mam sensing element 204 directly to the flow of fluid 104 within the pipe 102. The sensor 106 is arranged such that the normal direction 320 points in the upstream direction of the flow of fluid 104 so that the oblique angle 322 provides a ramp arrangement that allows the flow of fluid 104 to directly contact the main sensing element 204 but also reduces the disturbance in the flow of fluid 104 caused by the sensor 106 as the flow of fluid 104 passes over the ramp.

[0033] Power is provided to the main sensing element 204 via the tube 212. Two of the connectors 302 connect to the main sensing element 204 and measure the electrical resistance between the two points of connection. The main slot 316 is arranged to produce a long electrical flow path in the main sensing element 204 to make the measurement of the electrical resistance more accurate. Specifically, the long electrical flow path spirals from the center of the main sensing element 204 to an outer portion of the main sensing element 204.

[0034] Similarly, the reference sensing element 206 receives power from the tube 212. In the illustrated construction, three connectors connect to the reference sensing element 206. This allows for two electrical resistance measurements, with a first being the resistance from a first connection point to a second connection point and the second being a measurement from the first connection point and a third connection point. Like the main slot 316, the reference slot 220 is provided to assure a long electrical flow path in the reference sensing element 206 to make the measurements of the electrical resistance more accurate. Specifically, the long electrical flow path of the reference sensing element 206 extends along a circuitous path between two parallel portions of the reference slot 220.

[0035] The measured resistance from the main sensing element 204 changes as the main sensing element 204 erodes. However, the measurements from the reference sensing element 206 should remain stable and are not affected by erosion as the reference sensing element 206 is shielded from any contact with the flow of fluid 104. Thus, a controller or a computer can be used to compare the differences between the measurement from the main sensing element 204 and the two measurements from the reference sensing element 206 to predict the rate of erosion of the main sensing element 204. This rate of erosion of the mam sensing element 204 is then used as a basis to predict the level of erosion for other components exposed to the same or a similar flow of fluid 104.

[0036] The thermocouple 324 can be used to measure the temperature within the sensor 106 which can then be used to calibrate or correct for differences caused by operating at different temperatures. In addition, the temperature measurement can be used to indirectly measure the temperature of the flow of fluid 104.

[0037] The arrangement of the sensor 106 fully protects the reference sensing element 206 from contact with the flow of fluid 104. As such, the reference sensing element 206 does not suffer any erosion. In addition, because the reference sensing element 206 is largely sealed within the filler 326 it is also not exposed to the atmosphere or the surrounding environment and is therefore also not likely to corrode. Thus, the reference sensing element 206 serves as a largely fixed reference measurement.

[0038] In addition, the complete sealing of the sensor 106 allows for its use in many different environments including subsea environments where it might be exposed to high-pressure seawater.

[0039] Although an exemplary embodiment of the present disclosure has been described in detail, those skilled in the art will understand that various changes, substitutions, variations, and improvements disclosed herein may be made without departing from the spirit and scope of the disclosure in its broadest form.

[0040] None of the description in the present application should be read as implying that any particular element, step, act, or function is an essential element, which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Moreover, none of these claims are intended to invoke a means plus function claim construction unless the exact words "means for" are followed by a participle.

Claims

What is claimed is:

1. A sensor that measures erosion in a flow of fluid, the sensor comprising:a casing defining an inner space, an open sensor end, and an open signal end;a penetrator positioned within the signal end;a main sensing element positioned in the sensor end, the casing, the penetrator, and the main sensing element cooperating to form a water-tight enclosure around the inner space;a reference sensing element positioned fully within the inner space;a temperature sensing element positioned within the inner space;a first connector connected to the main sensing element and extending out of the inner space;a second connector connected to the reference sensing element and extending out of the inner space; anda filler formed within the inner space to completely fill the inner space.

2. The sensor of claim 1, wherein the casing includes a cylindrical wall that defines a sensor axis that extends between the signal end and the sensor end, and wherein the sensor end is arranged at an oblique angle with respect to the sensor axis.

3. The sensor of claim 2, wherein the main sensing element includes a sensing face, and wherein the sensing face is arranged at the oblique angle.

4. The sensor of claim 2, wherein the oblique angle is between 30 degrees and 60 degrees.

5. The sensor of claim 1, wherein the main sensing element includes a sensing face and an inner face, and wherein a main slot extends continuously between a first end and a second end and through the main sensing element between the sensing face and the inner face.

6. The sensor of claim 5, wherein a portion of the filler is disposed within the main slot.

7. The sensor of claim 1, wherein the main sensing element and the referencesensing element are erosion sensor elements, and wherein the main sensing element is exposed to the flow of fluid and the reference sensing element is protected from the flow of fluid.

8. The sensor of claim 1, wherein the reference sensing element includes a reference slot that extend continuously between a first end and a second end and extends through a wall of the reference sensing element.

9. The sensor of claim 1, wherein the filler includes injection-molded PEEK material.

10. A sensor that measures erosion in a flow of fluid, the sensor comprising:a casing having a cylindrical wall that defines an open sensor end and an open signal end and a sensor axis extending therebetween, the sensor end arranged at an oblique angle with respect to the sensor axis;a main sensing element positioned in the sensor end and arranged at the oblique angle, the main sensing element having a sensing face that defines a normal direction, the main sensing element cooperating with the casing to define an inner space;a reference sensing element positioned fully within the inner space; anda filler formed within the inner space to completely fill the inner space, the main sensing element arranged within the flow of fluid such that the normal direction extends from the sensing face and away from the main sensing element in an upstream direction.

11. The sensor of claim 10, wherein the oblique angle is between 30 degrees and 60 degrees.

12. The sensor of claim 10, wherein the main sensing element includes an inner face offset and parallel to the sensing face, and wherein a main slot extends continuously between a first end and a second end and through the main sensing element between the sensing face and the inner face.

13. The sensor of claim 12, wherein a portion of the filler is disposed within the main slot.

14. The sensor of claim 10, wherein the main sensing element and the reference sensing element are erosion sensor elements, and wherein the main sensing element is exposed to the flow of fluid and the reference sensing element is protected from the flow of fluid.

15. The sensor of claim 10, wherein the reference sensing element includes a reference slot that extend continuously between a first end and a second end and extends through a wall of the reference sensing element.

16. The sensor of claim 10, wherein the filler includes injection-molded PEEK material.13

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