Intelligent pipe

Abstract

The present invention relates to an intelligent pipe (2) coated with a multilayer sheath (72) containing an elastic insulating layer (40) and conductive (3) and grounding (5) or (2) layers. In the event of a leak, the failure of the layer (40) results in electrical contact between layers (3) and (5) or (2), producing a detection signal associated with a unique identifier (ID), obtained by a resistor or a microcontroller (38). Alternatively, the sheath (72) may include frangible tracks (52) arranged helically or in a wraparound configuration, which, when broken, identify the leak, as well as pressure sensors (71) and sealing at the ends (77).

Description

[0001] "SMART PIPING"

[0002] Field of Invention

[0003]

[0001] The present invention also aims to provide improvements, based on the devices described in processes BR 10202024018408-4, BR 102024018978-7 and BR 102024024460-5, which monitor the integrity of pipelines and identify any leaks, regardless of the type of liquid or gas, in a pipeline. When the pipeline is punctured (51), and the mats installed over the pipeline, the detection is made, an alert is generated, and it is identified which part of the pipeline was punctured.

[0004]

[0002] The present invention also aims to provide improved means, in which an isolated conductive series coil is superimposed on the layer in order to also allow leak detection by the rupture of the coil when there is a leak, as well as innovative forms of construction of the blanket that surrounds the piping and other innovative forms of leak detection, thus enabling construction, installation and detection.

[0005] State of the art

[0006]

[0003] In processes BR 10202024018408-4, BR 102024018978-7 and BR 102024024460-5, provisions are made for leak detection depending on the type of liquid or gas, where detection requires a wide range of sensor mat models and sensing methods, and an intricate circuit complexity that implies higher costs and construction difficulties.

[0007]

[0004] Furthermore, in the aforementioned processes, leak detection is performed by layer-to-ground contact, by direct contact, by capacitance, and does not foresee the possibility of detection through a serial link opening, which in this case may only be by opening the link or may maintain all previous detections. The advantage of this combination of contact detection and rupture detection is that it allows for a plurality of functionalities, such as the effectiveness of trepanning detection, which is much greater with the contact of the layers and the ground, allowing the detection of minimal perforations in the outer layer without false positives. Detection through rupture is much more effective in detecting any fluid, air, and gases, but false positives can occur due to poor contact, for example.

[0008]

[0005] There is also a need to improve the construction of the serpentine-based detection device, leading to the need to develop innovative industrial forms of blanket construction, facilitating its construction as well as developing new forms of detection.

[0009] Fundamentals of the Invention

[0010]

[0006] The present invention relates to devices and methods for detecting leaks and perforations in metallic or non-metallic pipes and tanks intended for the transport of liquids, gases, air or other substances. The objective is to overcome deficiencies in known solutions, ensuring greater safety, redundancy, ease of installation and cost reduction.

[0011]

[0007] In this sense, the already known functionalities of detecting external perforations (by drill, hole saw, cutting disc, fire) and the ability to detect a multiplicity of fluids transported through the pipelines are maintained.

[0012]

[0008] The invention contemplates various constructive modalities that can be used individually or in combination, namely: multilayer elastic blanket; blanket with stretched elastic layer; blanket or tape with conductive coil applied over the piping; industrializable tape integrating coils, power and communication tracks; and blanket or tube with pressure sensor. In addition, different detection circuits are contemplated, which can be resistive, with single resistors, or digital, with microcontrollers, in topologies such as daisy chain.

[0013]

[0009] In this way, the invention is applicable not only in industrial pipelines, but also on flat surfaces, such as dams and tanks, offering constructive flexibility and multiple detection modes that reduce environmental, economic and safety risks.

[0014] Brief Description of the Drawings

[0015]

[0010] FIG. 1 - Piping covered by layers of the blanket.

[0016]

[0011] FIG. 2 - Complete arrangement of the layers on the pipe.

[0017]

[0012] FIG. 3 - Leakage situation forcing contact between layers.

[0018]

[0013] FIG. 4 - Simple circuit with identifier resistors.

[0019]

[0014] FIG. 5 - Circuit powered by MOSFETs, alarm state maintained.

[0020]

[0015] FIG. 6 - Circuit with microcontroller, low power consumption, digital transmission.

[0021]

[0016] FIG. 7 - Daisy chain communication between blankets.

[0017] FIG. 8 - Redundant data transmission in both directions.

[0022]

[0018] FIG. 9 - Multiple conductive layers in the sensor layer, precise localization.

[0023]

[0019] FIG. 10 - Stretched elastic layer, rupture under pressure.

[0024]

[0020] FIG. 11 - Non-metallic pipes, metallic layer or grounded conductive paint.

[0025]

[0021] FIG. 12 - Coiled or longitudinal serpentine, rupture under tension.

[0026]

[0022] FIG. 13 - Contact between layers and ground or rupture of the coil.

[0027]

[0023] FIG. 14 - Tape with single serpentine track and power supply.

[0028]

[0024] FIG. 15 - Tape with two redundant coils.

[0029]

[0025] FIG. 16 - Serpentine blanket applied to piping or flat surface.

[0030]

[0026] FIG. 17 - Tape with integrated coil and side adhesive.

[0031]

[0027] FIG. 18 - Helically wound tape with multiple tracks.

[0032]

[0028] FIG. 19 - Ribbon with two coils in a chain loop.

[0033]

[0029] FIG. 20 - Tape with two coils connected to ground.

[0034]

[0030] FIG. 21 - Serpentine blanket placed over the pipe or flat surface.

[0035]

[0031] FIG. 22 - Blanket with pressure sensor.

[0036]

[0032] FIG. 23 - Blanket connected to power and communication.

[0037]

[0033] FIG. 24 - Pressure sensor with film and contacts.

[0034] FIG. 25 - Pressure sensor combined with external puncture detection.

[0038]

[0035] FIG. 26 - Resistive circuit with identifier resistor.

[0039]

[0036] FIG. 27 - Digital circuit with microcontroller.

[0040]

[0037] FIG. 28 - Piping with external piping and pressure sensors.

[0041] Detailed Description of the Invention

[0042]

[0038] The invention presents different constructive embodiments for detecting leaks and perforations. A first embodiment consists of a multilayer blanket (figures 1, 2 and 3), composed of an elastic layer (40) which can be made of PU, latex, nitrile, natural or synthetic rubber, resistant and at the same time flexible, capable of deforming when a leak occurs. Associated with it may be a conductive layer (5), connected to ground, an insulating layer (4) formed by foam, perforated material or open cell, and a metallic or conductive sensor layer (3). When the leak pressurizes the layer (40), it displaces the layer (5), compressing the insulation (4) until it breaks and allows contact with the layer (3), characterizing the occurrence of a leak.

[0043]

[0039] Alternatively, the elastic layer (40) can be stretched over the entire pipe (2), fixed at its ends. In this case, the leak pressurizes the layer (40) beyond the supported limit, causing it to rupture. Upon rupture, the layer (40) eliminates the insulation and allows the sensor layer (3) to come into contact with the ground of the metallic pipe or, in the case of non-metallic pipe, with an added conductive layer (5), which can be a screen, metallic sheath or conductive paint.

[0040] Figure 4 shows a simple form of event detection circuit, where the resistance (11) of a single value for each blanket and this resistance (11) connected to the layer (3) if there is contact with (5) or ground, will place an impedance of the resistance value between (10) and ground which, when read at the beginning and / or end of the pipe (2) of all the blankets, can determine where the leak is.In other words, each resistor is an identifier (ID) of the blanket which, when read by an ohmmeter or other equipment capable of reading impedance, can monitor (10) and ground, and report the problem and the value read, thus determining its location. Each installed blanket must have its geolocation identified with the resistor value (11). A very high value resistor can always be present between (10) and ground, at the end of all piping between (10) and ground, to identify if all blankets are connected to each other. This circuit does not require any power supply and is the least expensive circuit.

[0044]

[0041] Figure 5 shows a modified FIG 4 circuit, this is a circuit powered between (10) and ground, with the following advantage: in the event of a simple touch, i.e., a momentary contact of layer (5) and (3), the single-value resistor (11) is always present between (10) and ground, through the action of the MOSFET (33) which detected the touch to ground of layer (5), and when conducting, the ground is always present through the MOSFET (34). This is also useful in the case of momentary contact, for example, when leaking, there is a total rupture of the blanket, but at the moment of the total rupture, there is a momentary contact.

[0045]

[0042] Figure 6 shows another circuit, always powered (31) through a very low current consumption (uA) regulator circuit, which powers a microcontroller (38) that remains mostly in sleep mode where, on one of the I / O ports, when a ground fault is detected in the sensor layer (3) due to leakage (51), as described previously, it wakes up, and through a current loop (36), the microcontroller (38) pulses through (36) via a protocol, informing its unique ID for each blanket, which can, for example, be like a Morse code, to be sent between (10) and ground. The transmission speed is determined according to the total length of the pipe covered by the blankets and the distance to the blanket monitor. In this example, a digital code is sent to the Monitor, and there may also be a termination resistor at the end of the pipe (2) that allows knowing if the power supply circuit is present throughout the pipe (2).

[0046]

[0043] Figure 7 shows a circuit similar to that in FIG. 6, where communication occurs in Daisy Chain, i.e., each blanket communicates with the other adjacent blanket until it reaches the blanket monitor, through a unidirectional or bidirectional communication interface (48) (41) (42), which can be one-wire, RS485, Can, or other.

[0047]

[0044] Figure 8 shows the communication of the blankets (1) in daisy chain form, where it can be seen that when a leak event occurs, this information is sent to the blanket on the left and to the blanket on the right, and thus both the monitor present at the beginning and end of the pipes (2) can read and receive the unique identification of each blanket “ID”.

[0048]

[0045] Figure 9 shows a more complex form of implementation, where layer (3) is formed by several conductive layers and each conductive layer connected to a port of the microcontroller (38), thus allowing more precise identification of where the perforation or leak occurred. In this case, in addition to the blanket ID, the position or segment of the blanket that detected the leak would be transmitted.

[0049]

[0046] Figures 10 and 11 show another form of leak detection by means of, for example, a 2-layer sensor where an elastic insulating material (40) is placed over the grounded metal pipe (2), such as, but not limited to, latex, nitrile, rubber, which has elasticity and is stretched over the pipe (2), fixing it, for example, at the ends of the pipe, and breaks when stretched further or when a certain pressure exerted by the leak occurs. In the event of a leak through a hole or crack (51), there is layer (3), which can be a metal screen, without the presence of the insulator (40), which, when stretched, was broken by the pressure of the leak. This layer (3) is in contact with the grounded pipe, and since (3) is grounded by contact with the earth, the leak event is detected by the loss of insulation (40).

[0050]

[0047] Figures 12 and 13 show the same detection method, but for a non-metallic pipe, adding an additional layer, which can be covered with a grounded metallic layer (5) in this case perforated so that the liquid, gas or air can reach (40) or by a grounded conductive paint, which in the event of a crack or hole (51), the pressure of the liquid or gas, or air or any fluid transported by the pipe, can reach (40) which is an elastic insulator, and which is stretched over (5) and the pipe (2) and breaks when stretched further, and upon breaking puts the metallic and conductive sensor layer (3) in contact with the ground (5) by the loss of insulation, thus detecting the leak event.

[0048] Another detection method (figure 14) is obtained with the application of a layer of conductive coil (52) and over it there must be another insulating layer (4).The serpentine layer (52) can be installed longitudinally to the pipe (2) or preferably wrapped around the pipe (2). The layer (52) can be, for example, a thin aluminum, copper, or other electrically conductive material tape, a metallic wire, or a paint or conductive material over the insulation (40) that weakens and breaks when deformed or tensioned by the expansion of (40) due to a leak. The serpentine (52) acts like a fuse, but it does not break due to the passage of electric current, but rather due to mechanical tension offered by (40) which dilates or expands in the presence of a leak (51), the rupture being detected by the absence of electrical circulation after the rupture and / or if layers (3) and (5) are installed.

[0051]

[0049] Figure 15 shows a simple event detection circuit, where the resistor (11), with a unique value for each blanket, is connected between 10 and ground. If there is contact between (3) and (5) or ground, and / or through a break in the coil (52), which, when read at the beginning and / or end of the piping (2) of all blankets, the leak can be determined. That is, each resistor is an identifier (ID) of the blanket that, when read by an ohmmeter or other equipment capable of reading impedance, can monitor (10) and ground, and report the problem and the value read, thus determining its location. Each installed blanket must have its geolocation identified with the value of resistor (11). A very high value resistor can always be present between (10) and ground, at the end of all piping between (10) and ground, to identify if all blankets are connected to each other. This circuit requires power and is low cost.

[0052]

[0050] Figure 16 shows a modified circuit from Figure 15, this being a circuit powered between (10) and ground, with the following advantage: in the event of a simple touch, i.e., a momentary contact of layer (5) and (3), the single-value resistor (11) is always present between (10) and ground, through the action of the MOSFET (33) which detected the touch to ground of layer (5), and when conducting, the ground is always present through the MOSFET (34). This is also useful in the case of momentary contact, for example, when leaking, when there is a total or partial rupture of the blanket, when there is momentary contact, and also when there is a rupture of the coil (52), the resistor (11) will be present. Note that in this case the value of the resistor (11) is unique for each blanket, which allows identifying which blanket was ruptured, i.e., an ID.

[0053]

[0051] To enable large-scale industrial production, the tape (70) shown in Figure 17 was developed. This tape (70) must be a rigid material to be placed over the pipe (2) so that it does not break the coil (52) during installation, but flexible in case of a leak, using, for example, latex, natural or synthetic rubber, PU or PVC with this characteristic. This tape must have at least one coil track (52) which must be of conductive material. Figure 17 also shows the pipe (2), which may or may not be metallic. Over the pipe (2) comes the layer (40), which may be very thin metallic, or rubber, heat shrink, latex, nitrile, i.e., any material that can expand or deform in the presence of a leak in the pipe (2) under pressure, and glued / fixed in such a way as to prevent leakage until it can expand due to the leak.

[0054] (51) coming from the pipe. The sensor (52) is a serial conductive sensor, or coil (52), which, when the layer (40) expands, tensions the coil.

[0055] (52), electrically isolated (4) from (5), also pushing the metallic and conductive layer (5) connected to ground, which in turn compresses the insulating layer (4), for example a material like foam, or another that when compressed allows contact of the layer connected to ground (5) to layer (3), generating the leak detection event, either by the rupture of the coil (52) or by the contact of layers (3) and (5).

[0056]

[0052] In certain cases, it is also possible to use only the coil (52) as a leak detector, and in this case it is easier to allow for trepanation (when thieves puncture the pipes to steal, for example, fuel).

[0057]

[0053] Figure 18 shows the pipe (2), the tensioning insulating layer (40), the serpentine layer (52) and over it another insulating layer (4). The serpentine layer (52) can be installed longitudinally to the pipe (2) or, preferably, wrapped around the pipe (2). The serpentine (52) can be, for example, a thin strip of aluminum, copper or other electrically conductive material; a metal wire (e.g. AWG 30); or a conductive paint / material over the insulation (40), which weakens and breaks when deformed or tensioned by expansion due to leakage.

[0058]

[0054] The serpentine (52) functions as if it were a fuse — but it does not break due to the passage of electric current, but rather due to mechanical tension offered by the leak in the pipe (2). When the electrical circulation ceases after the break, the leak is detected through the electronic circuit figure 27, present in each blanket. Each pipe can have a plurality of interconnected blankets, each with its own ID (digital, electronic or resistive).

[0059]

[0055] To facilitate interconnection between blankets, these may have several other tracks: more than one coil track (redundancy), power tracks (VCC), ground track (GND), analog or digital electronic circuit signal tracks (reporting detection status). These tracks must be more resistant, not breaking as easily as the coils (52).

[0060]

[0056] The tape (70), when wrapped around the pipe (2), must be applied by helical overlap. It must have an adhesive (64) on its side to prevent leakage and, on the other side, without adhesive or with very weak adhesive (65), so that it can easily allow expansion and thus break the coil (52) when there is leakage.

[0061]

[0057] Figure 19 shows a ribbon (70) with two coils (52). Instead of being grounded, they are connected to each other, closing the current loop.

[0062]

[0058] Figure 20 shows the tape (70) also with two coils (52), both connected to (GND), as if it were a redundancy, where, to detect that there was actually a leak, it would be necessary for both tracks (52) to be broken.

[0063]

[0059] Figure 21 shows a different type of serpentine blanket (52), which does not use tape (70), but rather a blanket that overlaps the pipe (2) or is fixed onto a flat surface (for example, a dam). In the case of pipe (2), it is glued (64) or welded one on top of the other. The construction material of the blanket may be similar to that of the tape (70), as well as the serpentine tracks (52), power supply (VCC), ground (GND) and signal tracks (73).

[0064]

[0060] Unlike the tape (70) in figure 17, this blanket is placed as if covering the pipe (2), transversely or circumferentially, and not rolled in a spiral. At the ends, it must be glued or fixed to prevent leakage, so that the blanket swells and breaks the coil (52).

[0065]

[0061] Like the tape (70), each blanket has an electronic circuit with ID (digital or analog electronic identification). All blankets can be interconnected along the pipeline.

[0066]

[0062] This type of blanket would also serve to detect problems in dams: instead of enclosing a pipe (2), it would be fixed next to the outer / inner wall of the dam, breaking the coil (52) when the dam gave way.

[0067]

[0063] Figure 22 shows a new type of pipe leak sensor mat (2), based on pressure detection. In this case, the pipe (2) is coated with a non-adhesive layer, and at the ends the mat must be glued or fixed to prevent leakage. The material (72) can be plastic, metal or others described in the tape (70), but more rigid and not easily deformed by leakage.

[0068]

[0064] Pressure sensors are placed on this blanket, either at central points or distributed throughout (figure 24). In the event of a leak, it seeks out the weakest point and ruptures the sensor, which then detects it.

[0069]

[0065] Each blanket has its own electronic circuit and the power supply (VCC, GND) and signal (73, 10) tracks are interconnected to the electronic circuit and between blankets, being placed longitudinally to the pipe (2).

[0066] Another industrial form would be for the pipe (2) to have a layer (72), as if it were another pipe superimposed with a gap between them, with pressure sensors (figure 24) present. The ends would be welded / closed to prevent leakage.

[0070]

[0067] Figure 23 shows the blanket (72) with pressure sensor (71) figure

[0071] 24, connected to the power supply (VCC, GND) and with communication traces (73).

[0072]

[0068] Figure 24 shows the pressure sensor (71), formed by a film (76) that easily breaks. When it breaks, it causes the small coil (52) (74) to break, opening the current loop and forming a NC (normally closed) sensor. Alternatively, when the film (76) breaks, it can allow contact between two metal blades (75) and (80), forming a NO (normally open) sensor.

[0073]

[0069] Figure 25 shows the same pressure sensor (76) figure 24, with two conductive layers (3) and (5) insulated (4), superimposed on the pressure detection blanket, with the aim of detecting external perforation through the rupture of the insulation (4).

[0074]

[0070] Figure 26 shows an example of an electronic circuit containing N-Mosfet (34). When the coil (52) breaks due to leakage, the N-Mosfet (34) conducts, or when layers (3) and (5) short-circuit, causing a resistor (11) with a unique value per blanket to be identified, allowing distinguishing which blanket detected the leakage or external perforation.

[0075]

[0071] Figure 27 shows the same circuit containing N-Mosfet (34), but instead of connecting a resistor (11), it activates a microcontroller (48) which, when activated, sends to the adjacent blankets (41, 42) the identification of the blanket that detected the leak or external perforation.

[0072] Figure 28 shows an example of a pipe (12) with another external pipe (72), sealed (77) only at the ends, allowing the leak from pipe (12) to circulate between the two. Pressure sensors (Figure 24) are installed on pipe (72). In the event of a leak, it circulates between the two pipes until it encounters the pressure sensor (76), which is more fragile than the walls of (72), breaking it and allowing identification.

[0076]

[0073] In accordance with the figures above, the “Multi-sensory piping with coil” can be constructed in various ways. The examples, figures and circuits presented are merely illustrative and not limiting.

[0077]

[0074] The invention can be used not only for refineries, water and sewage networks and dams, but also for commercial and industrial pipelines (2), fuel tanks, liquid and gas storage tanks, and can be installed in existing structures or in new constructions that incorporate these functionalities.

[0078]

[0075] Thus, the invention encompasses everything from simpler, low-cost arrangements to more complex and redundant arrangements, ensuring support for different operating conditions and expanding the field of application. The proposed solutions can be applied in refineries, water and sewage networks, fuel transport and storage, industrial tanks and dams, providing accurate detection, cost reduction and environmental benefits.

Claims

1. CLAIMS 1. Intelligent piping, characterized by comprising a flexible multi-layered blanket or medium installed around the piping (2), containing at least one elastic insulating layer (40) and at least two conductive and grounding layers (3, 5) or (3,2), arranged so that, in case of leakage or trepanation of the piping (2), the rupture of the insulating layer (40) causes an electrical contact between the conductive layer (3) and the grounding layer (5) or (2), generating a detection signal associated with a unique blanket identifier (ID), or through a unique resistor monitored by a blanket monitoring device.

2. Intelligent piping, according to claim 1, characterized in that when the piping (2) is metallic and grounded, and when it is not metallic it has a grounded and perforated metallic layer (5) to allow leakage to reach layer (40).

3. Intelligent piping, according to claim 1 or 2, characterized by identifying the grounded layer (3), allows the unique identification of each ID sheet by a resistor of unique value for each sheet, or by a microcontroller (38) capable of generating this ID through a current loop between (10) and ground, in a given communication protocol, which can be monitored by equipment present at the beginning of the piping (2).

4. Intelligent piping, according to any one of claims 1 to 3, characterized in that the communication protocol consists of sequential pulses equivalent to a predefined code and a speed dependent on the distance to be traveled.

5. Intelligent piping, according to claim 1, characterized by the monitor being configured to detect the presence of ID resistors present in the blankets, or to detect signals through the current loop and the termination resistor installed at the end of the piping (2), in order to verify the continuity of power supply and communication of all blankets.

6. Multi-sensory piping with a serpentine, characterized by comprising a blanket or tape (72) containing at least one fragile conductive track (52) helically arranged around the piping (2), so that a leak causes deformation or rupture of the conductive track (52), and when it breaks, it identifies the rupture by placing a single-value resistor (ID) between (10) and ground, or by having its ID transmitted by a current loop, generated by a microcontroller (38) to the blanket monitor.

7. Multi-sensory piping with a coil, according to claim 6, characterized in that the conductive track (52) is formed by metallic wire, conductive paint or equivalent material applied over the blanket (72), which breaks due to mechanical tension.

8. Multi-sensory piping with coil, according to claim 6 or 7, characterized in that the blanket comprises a rollable tape (70) containing fragile conductive tracks (52) and additional non-fragile power supply tracks (VCC, GND) and communication, allowing interconnection between multiple blankets (10).

9. Multi-sensory piping with a coil, according to any one of claims 6 to 8, characterized in that the blanket is applied in an enveloping and not helically shaped manner with overlapping flaps (64) over the pipe (2), so that the rupture of the conductive track (52) indicates the leak.

10. Multi-sensor piping with coil, according to any one of claims 6 to 9, characterized by including pressure sensors (71) distributed over the blanket (72), configured to detect the pressure increase caused by leakage and communicate the respective unique identifier (ID) to the monitor, 11. Multi-sensory piping with a coil, according to any one of claims 6 to 10, characterized in that the blanket (72) comprises plastic, metallic or hybrid material, flexible, rigid / flexible or configured as an external piping overlaying the piping (2).

12. Multi-sensor piping with coil, according to any one of claims 6 to 11, characterized in that the blanket (72) is sealed at its ends (77), allowing the leaked fluid to circulate between the blanket (72) and the piping (2) until it reaches the pressure sensors (71).

13. Multi-sensor piping with a coil, according to any one of claims 10 to 12, characterized in that the pressure sensors (71) are of the normally open (NO) or normally closed (NC) type.

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