Fluid seepage detection system and method thereof

Abstract

A system (100) for detecting fluid seepage to assist users in easily locating defective valves The system features a sealing flange assembly (200) with a groove (210) on the flange where the valve gasket is seated. The system comprising the sealing flange assembly with groove is strategically positioned within valve gasket to guide fluid seepage. A fluid collection plug (118) accumulates any leaked fluid resulting from gasket sealing issues. An optical liquid level sensor (112) installed in the fluid collection plug (118) detects the presence of fluid in real-time by monitoring changes in its infrared light path. Upon detection, the sensor generates alerts (308), which are transmitted to a control system for real-time data processing, The sensor's output is connected to a control system, enabling real-time monitoring and timely replacement of the defective valve (312).

Description

FLUID SEEPAGE DETECTION SYSTEM AND METHOD THEREOFFIELD OF THE INVENTION:

[0001] The present invention pertains to the field of engineering and chemical applications. More specifically, it addresses systems incorporating multiple fluid flow branches equipped with multiple valves, designed to detect and manage fluid seepage effectively. The present invention is particularly applicable in the field of chemical processing and water treatment including applications in transformers. Additionally, a method of operation for the system has been provided.BACKGROUND:

[0002] In fluid flow systems, particularly those with multiple branches and valves, ensuring leak-tightness between the valve sealing gasket and mating flange is critical. This challenge becomes more complex in industries like chemical processing and water treatment, where undetected fluid seepage can quickly escalate into costly leaks Additionally, the presence of multiple branches makes detecting the exact leak location cumbersome. Traditionally, maintenance teams must inspect each valve to identify the defective gasket, a labour-intensive and expensive process that affects overall system efficiency.

[0003] Existing leak detection technologies often require a substantial amount of fluid to accumulate before a detection occurs. Systems like float switches or level sensors rely on the fluid accumulating in a container, which typically needs several millilitres to activate the Level / Float Switch. Further, this leads to the additional requirement of bulky and expensive fluid collection chambers. However, early-stage fluid seepage detection remains a major gap, as many of these systems cannot detect small quantities such as few millilitres, as low as 10 millilitres of fluid, before they escalate into major leaks.

[0004] For example, Chinese Patent Application CN213958726, titled "Power Transformer with Oil Leakage Prevention Function," filed by Dingzhou Keda Electrical Equipment Co. Ltd., discloses a power transformer with an oil leakage prevention function. It features components such as a signal thermometer, high-voltage and low-voltage bushings, adesiccator, oil conservator, and a recovery circulation seat. This design prevents oil loss by recycling leaked oil, maintaining transformer efficiency.

[0005] Non-patent literature titled "Intelligent Gasket for Leakage Detection" by 2M Engineering discloses a smart gasket sensor system using intelligent photonics for remote leakage detection, condition monitoring, and predictive maintenance of gaskets, preventing spillage, pollution, and dangerous situations caused by pipeline leaks.

[0006] U.S. Patent 8349477B2, titled "Optical Leak Detection Sensor," filed by DEEYA ENERGY INC., PARAKULAM GOPALAKRISHNAN R, SAHL SAROJ KUMAR, and WINTER RICK, discloses a battery electrolyte leakage detection system using an optical light sensor, a light source, and a lens to capture refracted light. Based on the captured light frequency, the system determines if the electrolyte is free from foreign particles.

[0007] Although there are a few existing solutions, there is still a need to detect fluid seepage at an early stage before the seepage turns into a leak. The present invention, addresses this limitation by detecting fluid seepage as early as 10ml, far below the threshold of conventional systems. Unlike existing solutions, this system identifies seepage before it escalates, offering significant advantages in early maintenance, cost reduction and precise seepage detection The present invention uses transistor-based electronic switching for fluid detection, providing greater sensitivity and faster response times than traditional mechanical or float-based switches.OBJECTIVES OF THE INVENTION:

[0008] The primary objective of the present invention is to provide an automated system capable of detecting fluid seepage at an early stage, before it escalates into a leak. This early detection aims to improve the efficiency of maintenance processes by pinpointing defective valves quickly, reducing the need for costly and time-consuming inspections of all valves.

[0009] Another objective is to use transistor-based electronic switching method for fluid seepage detection, offering higher sensitivity and faster response times compared to conventional systems that rely on float switches or level sensors. This method enables the system to detect fluid seepage at much lower quantities, improving detection speed and efficiency.

[0010] Another objective of the invention is the system’s integration with control or annunciation systems, which is designed to optimize operational efficiency by providing realtime alerts. This enables operators to promptly address defective valves, ensuring smoother and uninterrupted fluid flow while minimizing downtime in critical processes.

[0011] Other objects and advantages of the present invention will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the invention.SUMMARY:

[0012] To achieve the aforementioned objectives, the present invention provides an automated system for detecting fluid seepage in valve systems, particularly in multi-branch configurations such as in chemical processing and water treatment plants as well as in transformers. The system integrates optical liquid level sensors and a specialized flange comprising a groove design, allowing fluid that drips through a defective valve to collect in a designated hole where an optical fluid level sensor is installed horizontally. This early detection of fluid seepage minimizes the need for full system inspections.

[0013] According to the present invention, the system comprises a groove strategically positioned on the valve flange, located after the inner diameter of the valve gasket. This groove directs any fluid seepage into a hole, where it is detected by an optical liquid level sensor. The sensor uses infrared light to identify fluid presence, with output connected to an annunciation or control system to provide real-time alerts to operators. This ensures efficient maintenance by enabling prompt identification and rectification of defective valves or installation.

[0014] Thus, the present invention offers an efficient solution to fluid seepage detection, capable of detecting even the smallest seepage at an early stage, unlike traditional methods that require larger quantities for detection. The system significantly reduces maintenance costs, enhances operational efficiency, and prevents minor seepage issues from escalating into major leaks, offering both time and resource savings. A method of operation of the above-said system has been provided hereunder.

[0015] The arrangement of the present invention has other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following brief description, which together serve to explain certain principles of the present invention.BRIEF DESCRIPTION OF THE DRAWINGS:

[0016] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of assisting in the explanation of the invention, there are shown in the drawings, embodiments that are presently preferred and considered illustrative. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown therein the drawings:

[0017] FIG. 1 shows the schematic representation of an automatic fluid seepage detection system according to an embodiment of the present invention utilized in a fluid flow system with multiple branches.

[0018] FIG. 2 shows the exploded / detailed view of a valve arrangement configured according to an embodiment of the present invention.

[0019] FIG. 3 shows a flow diagram depicting the working principle of the automatic fluid seepage detection system according to an embodiment of the present invention.REFERENCE NUMERALS:100 - automatic fluid seepage detection system102- inlet104- outlet108 - valve110- optical level sensor fixing arrangement112 -optical liquid level sensor116- bi-directional flow118 - fluid collection plug200 - sealing flange210 - groove300 - flow diagram of working principle of the automatic fluid seepage detection system 302 - 312 - process steps of the automatic fluid seepage detection systemDETAILED DESCRIPTION OF THE INVENTION:

[0020] The present invention will now be described more fully hereinafter. For the purposes of the following detailed description, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. Thus, before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified systems or embodiments that may, of course, vary. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and in no way limits the scope and meaning of the invention or of any exemplified term. Likewise, the invention is not limited to various embodiments given in this specification.

[0021] As used herein, the singular forms "a," "an," and "the" include plural reference unless the context clearly dictates otherwise. The term "and / or" means one or all of the listed elements or a combination of any two or more of the listed elements.

[0022] The terms “preferred” and “preferably” refer to embodiments of the invention that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention.

[0023] When the term “about” is used in describing a value or an endpoint of a range, the disclosure should be understood to include both the specific value and endpoint referred to.

[0024] As used herein the terms “comprises”, “comprising”, “includes”, “including”, “containing”, “characterized by”, “having” or any other variation thereof, are intended to cover a non-exclusive inclusion

[0025] The present invention provides an automated system for detecting fluid seepage such as oil in valve systems, especially for applications with multi-branch configurations, such as chemical processing and water treatment plants. This system is crucial for ensuring leak-tightness of valve sealing gaskets, as fluid seepage at any valve location could lead to significant system inefficiencies if not detected early. Traditional methods of leak detection, which require inspecting all valves, are time-consuming, costly, and often result in prolonged downtime, affecting the overall process. This invention addresses these issues by providing a targeted, cost-effective solution for detecting fluid seepage at an early stage.

[0026] Fig.l illustrates a schematic representation of a fluid flow system (100) with multiple branches, designed for efficient control and monitoring of fluid (such as oil) flow. It incorporates mechanisms to detect and manage seepage effectively. The attached figure is a schematic representation of a fluid flow system with multiple branches. It includes components designed for controlling and monitoring the flow of fluids (such as oil) through the system while providing mechanisms to detect and manage leakage effectively.

[0027] The system (100) consists of inlets (102) and outlets (104) positioned at the top and bottom, respectively. Fluid enters through the inlets (102), flows through the vertical branches, and exits via the outlets (104). Each branch is equipped with valve arrangements (106)comprising valves (108) (such as butterfly valves) to regulate the fluid flow. These valves are positioned at multiple points in the system to allow or stop the oil flow and are crucial for managing the flow within individual branches.

[0028] To address potential seepage issues, the system (100) features a seepage detection mechanism. This mechanism includes optical liquid level sensors (112), which are installed in the fluid collection plug (118) such as oils, at each branch. These sensors (112) detect oil / fluid seepage caused by gasket failure in the valves (108).

[0029] According to a preferred embodiment the system incorporates a grooved flange configuration, where the flange on which the butterfly valve gasket is seated contains a groove. This groove captures any seepage and directs it to the oil / fluid collecting plug (118), where the sensor (112) is installed to monitor the seepage. The fluid collection plug collects any fluid or oil that drips from the gasket sealing area and is positioned adjacent to the flange, where the seepage can be detected.

[0030] Another key feature is the control of the bidirectional flow (116) of the fluid, allowing the fluid to flow in either direction as per the requirements, which is indicated by the arrows in the Fig.l. The valve arrangement is strategically designed to regulate fluid flow and isolate sections for maintenance or operational adjustments as needed. This integrated fluid flow system (100) ensures efficient fluid control, timely detection of seepages, and ease of maintenance.

[0031] Referring back to Fig.l, the fluid or oil enters the system (100) through the inlets (102) at the top, flows through the branches, and exits via the outlets (104) at the bottom. The valves (108) on these branches manage the flow and ensure that only the required branches are operational at any given time. The flange, where the valve gasket is positioned, comprises a groove just after the gasket's sealing area. If the gasket fails and oil drips, the groove collects the seepage. The collected fluid from the flange groove is directed into a fluid / oil collection plug (118), which captures the dripped fluid. Installed in the fluid collection plug (118), theoptical liquid level sensors (112) use infrared light to detect the presence of oil. During normal operations without any leakage, the infrared light emitted by the sensor head remains undisturbed, and the sensor (112) outputs a signal indicating normal conditions (e.g., 24V output). When the dripped fluid reaches the sensor, the infrared light path gets disrupted, causing the sensor (112) to send a real-time alert which can be a visual or audible alarm or notification to a monitoring system. The alert pinpoints the exact branch with the leakage, allowing maintenance teams to focus on the defective valve.

[0032] The system (100) is designed to make detection of fluid seepage as well as maintenance efficient. The exact location of the faulty valve is identified, eliminating the need to inspect every valve in the system. Data from the sensors can be integrated into a cloud-based platform for centralized monitoring. This platform generates maintenance reports, helping to plan repairs and optimize system performance. By enabling proactive intervention, the control system helps to minimize operational disruptions and ensures the system's overall reliability and performance.

[0033] In Fig. 2, an exploded view of the valve arrangement. As an example, here a valve (108) with several key components and their configurations are depicted The sealing flange (200) consists of two connecting flanges, strategically positioned outside the valve’s gasket seal area. This ensures additional protection against leakage. The assembly includes primary components such as the inlet (102) and outlet (104) pipe sections for fluid flow, a centrally located valve (108) (in the form of a butterfly valve), and a groove (210) designed to capture any fluid seepage. Additionally, the fluid collecting plug (118) serves as a point where leaked fluid can accumulate, while an optical liquid level sensor (112) is integrated to monitor leakage in real time.

[0034] Figure 3 illustrates the process flow of the fluid seepage detection system (300), described step-by-step as follows: The process begins with designing a flange with a groove (302). This groove is positioned beyond the inner diameter of the valve gasket, ensuring that any fluid seepage caused by gasket leakage will first reach the groove. The groove serves as a channel to guide the seepage for further handling. Once the groove collects the seepage fluid,it is directed towards a fluid collection plug as in step (304). The plug enables controlled collection of the fluid, preparing it for detection.

[0035] The next step involves detecting fluid presence with an optical liquid level sensor as in step (306). This sensor, installed horizontally in the fluid collection plug, uses infrared rays to monitor fluid presence. When no fluid is present, the light path remains undisturbed; however, when fluid is present, the light path is disrupted, signalling the detection of fluid seepage. Following detection, the system progresses to generating real-time alerts and notifications (308). The optical liquid level sensor is connected to a monitoring system, which continuously tracks fluid presence. Upon detecting, the system generates alerts to notify operators, enabling the timely identification and replacement of defective valves.

[0036] Additionally, the system integrates seamlessly with a cloud-based platform (310), enabling operators to remotely monitor and control its functions for enhanced operational flexibility. Furthermore, the system includes report generation for maintenance optimization (312), providing insights into valve gasket performance and trends in seepage incidents. These reports assist in predictive maintenance and improve industrial planning.

[0037] The type of seepage fluid that may be detected depends on the application and the environment in which the sealing flange is used. The fluid may vary from water and wastewater, oil and lubricants, fuel and chemicals, etc. A key advantage of the system is its ability to detect fluid seepage at an early stage, even with as little as 10ml of fluid. Unlike traditional methods requiring larger fluid accumulation for detection, this system ensures timely identification of seepage, reducing maintenance costs and operational downtime. The real-time alerts generated by the monitoring system facilitate swift intervention, enhancing efficiency and minimizing risks of severe damage or costly repairs.

[0038] The system’s integrated design and automation promote effective early seepage detection, operational efficiency, and reduced maintenance expenses while supporting sustainability goals and mitigating environmental risks. Its scalability and adaptability make it suitable for various industries, including chemical processing, water treatment, and oil and gassectors. The incorporation of the groove and sensor within the valve assembly reduces the need for additional equipment, resulting in a compact and efficient design. Moreover, the system enables long-term monitoring and analysis of seepage trends, supporting predictive maintenance strategies and advancing operational planning.

[0039] While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above-described embodiment, method, and examples, but by all embodiments and methods within the scope of the invention as claimed.

Claims

WE CLAIM:

1. A fluid seepage detection system, comprising:a plurality of fluid flow branches, each branch comprising:an inlet (102) and outlet (104) for fluid flow;a valve (108) comprising a valve gasket positioned between the said inlet (102) and outlet (104);the valve gasket is seated on a sealing flange assembly (200), whereina groove (210) is configured to capture fluid seepage;a fluid collection plug (118) in fluid communication with said groove (210) is configured to collect the fluid seepage; andan optical liquid level sensor (112) installed within the said fluid collection plug (118) is configured to detect presence of fluid seepage in real time, upon which said optical liquid level sensor (112) is configured to generate alerts on detection of fluid seepage.

2. The system as claimed in claim 1 wherein said groove (210) is positioned on an inner diameter of the said valve gasket.

3. The system as claimed in claim 1, wherein the groove (210) is configured to channel seepage fluid from the said gasket towards the fluid collection plug (118) for precise collection and detection.

4. The system as claimed in claim 1, comprises a control system configured to:receive signals from said optical level sensor (112);generate real time-alerts based on detected fluid seepage; andtransmit said alerts to a monitoring system to identify a defective valve location to enable maintenance.

5. The system as claimed in claim 1, wherein the optical liquid level sensor (112) comprises an infrared light emitter and detector, said sensor configured to provide a 24V output when no fluid is detected and said sensor configured to detect fluid presence through disruption of an infrared light path.

6. The system as claimed in claim 1, wherein the monitoring system integrates with a control system to alert operators about seepage locations, reducing downtime and maintenance costs.

7. The system as claimed in claim 1, wherein the control system is further configured to display real-time data and alert patterns via a remote or cloud-based interface.

8. A method for detecting fluid seepage in a valve system, comprising the steps of:a) directing fluid through a plurality of fluid flow branches, each branch having an inlet (102) and an outlet (104);b) positioning a valve (108) with a valve gasket between the inlet (102) and the outlet (104) to regulate fluid flow;c) seating the valve gasket on a sealing flange assembly (200), the sealing flange includes a groove (210) beyond the inner diameter of the valve, the groove (210) configured to capture fluid seepage;d) collecting the captured seepage fluid in a fluid collection plug (118) in fluid communication with the groove (210);e) detecting presence of fluid seepage in real time utilizing an optical liquid level sensor (112) by monitoring infrared light path disturbances; andf) generating real-time alerts and notifications via a monitoring system upon detection of fluid seepage by the optical liquid level for timely identification and replacement of defective valves.

9. The method as claimed in claim 8, comprising the step of integrating the monitoring system with a cloud-based platform for remote monitoring and control.

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