Detecting a fluid leak from a pump

Abstract

A leak detector assembly for an air-operated diaphragm pump system. The system includes an air-operated diaphragm pump, a normally closed control valve positioned between an air source and the pump, and the leak detector assembly. The leak detector assembly is coupled to the exhaust of the pump. The leak detector assembly controls air flow through the pump responsive to detecting a leak in the pump. The leak detector assembly includes a float valve and a spring-loaded spool. The float valve moves responsive to a change in a fluid level in the leak detector assembly. The spring-loaded spool is coupled to the float valve. The spring-loaded spool, in a single motion, shuts the normally closed control valve and closes an exhaust from the leak detector assembly responsive to the change in the fluid level of the leak detector assembly equal to or above a threshold level.

Description

[0001] Atorney Docket No.: 45770-0183WO1

[0002] DETECTING A FLUID LEAK FROM A PUMP CROSS-REFERENCE TO RELATED APPLICATION This application claims priority to U.S. Utility Application No. 19 / 064,328, filed on February 26, 2025, which claims the benefit under 35 U.S.C. § 119(e) of U.S. Patent Application No. 63 / 759,814, entitled "‘Detecting A Fluid Leak From A Pump." filed February 18, 2025, which is incorporated herein by reference in its entirety'.

[0003] TECHNICAL FIELD

[0004] The present document relates to pumps, and more particularly detecting fluid leaks from an air operated pump.

[0005] BACKGROUND

[0006] Pumps are used in a multitude of industries to move fluids from one location to another. Some pumps are air-operated diaphragm pumps, which move the fluids by flowing air to a diaphragm to move the diaphragm within the pump. When the diaphragm moves, it creates pressure on the fluid, moving the fluid through the air-operated diaphragm pump. Sometimes, a portion of the air-operated diaphragm pump, such as the diaphragm, can fail, allowing the fluid to enter the air operating the pump and even being exhausted to the surrounding environment.

[0007] SUMMARY

[0008] Some embodiments of the air-operated pump and related assemblies can include one or more of the features and functions related to air-operated diaphragm pumps. Some embodiments can include features and functions to detect a leak in the air-operated diaphragm pump.

[0009] In an example aspect, an air-operated pump system includes an air-operated diaphragm pump, a normally closed pneumatic control valve, and a leak detector assembly. The normally closed pneumatic control valve is positioned between an air source and the air-operated diaphragm pump. The leak detector assembly is coupled to an exhaust of the air-operated diaphragm pump. The leak detector assembly controls air flow through the air-operated diaphragm pump responsive to detecting a leak in the air-operated diaphragm pump. The leak detector assembly includes a float valve and a spring-loaded spool. The float valve moves responsive to a change in a fluid level in theAttorney Docket No.: 45770-0183WO1

[0010] leak detector assembly. The spring-loaded spool is coupled to the float valve. The spring-loaded spool, in a single motion, shuts the normally closed pneumatic control valve and closes an exhaust of the leak detector assembly responsive to the change in the fluid level of the leak detector assembly equal to or above a threshold level.

[0011] In an example aspect combinable with any other example aspect, the spring-loaded spool moves between an open position allowing a flow of the exhaust through the leak detector assembly to a closed position preventing the flow of the exhaust through the leak detector assembly.

[0012] In an example aspect combinable with any other example aspect, moving the spring-loaded spool to the closed position prevents a flow of air out of the leak detector assembly, thereby isolating a downstream end of the air-operated diaphragm pump.

[0013] In an example aspect combinable with any other example aspect, the float valve is movable between a first position engaged to the spring-loaded spool and a second position disengaged from the spring-loaded spool. When in the float valve is in the second position disengaged from the spring-loaded spool, the spring-loaded spool is free to move.

[0014] In an example aspect combinable with any other example aspect, the float valve includes a float, a shaft, and a catch cylinder. The shaft has a first end and a second end. The first end is coupled to the float. The catch cylinder is coupled to the second end. The catch cylinder has a relieved portion. The catch cylinder can rotate about a longitudinal axis of the catch cylinder. In an example aspect combinable with any other example aspect, the spring-loaded spool includes a shaft and a relieved portion on the shaft. The spring-loaded spool selectively engages the relieved portion of the catch cylinder responsive to the float valve moving between the first position and the second position.

[0015] In an example aspect combinable with any other example aspect, the spring-loaded spool has a spring disposed around the shaft. The spring biases the shaft to the closed position responsive to the float valve moving to the second position. The spring is held in a compressed condition when the float valve is in the first position and the catch cylinder is engaged to the relieved portion of the shaft.

[0016] In an example aspect combinable with any other example aspect, the spring-loaded spool includes a knob coupled to a first end of the shaft of the spring-loaded spool. The first end of the shaft extends outside a body defining an interior void of theAtorney Docket No.: 45770-0183WO1

[0017] leak detector assembly. When the spring-loaded spool is in the second position and a user pulls on the knob, the spring-loaded spool moves from the second position to the first position, and responsive to the spring-loaded spool moving from the second position to the first position, the float valve moves from the second position to the first position and the catch cylinder reengages with the shaft.

[0018] In an example aspect combinable with any other example aspect, the spring-loaded spool includes a plunger coupled to a second end of the shaft. The second end of the shaft is opposite the first end. The plunger seals against an exhaust port of the leak detector assembly.

[0019] In an example aspect combinable with any other example aspect, the leak detector assembly includes a filter positioned a body of the leak detector assembly. The body defines an interior void. The filter removes a contaminant from the exhaust of the air-operated diaphragm pump.

[0020] In an example aspect combinable with any other example aspect, the leak detector assembly includes a partitioned structure positioned to receive the exhaust from the air-operated diaphragm pump. The partitioned structure provides a tortuous flow path to the exhaust.

[0021] In an example aspect combinable with any other example aspect, the partitioned structure includes a cupped base, an upper section, and multiple voids. The upper section has a vertical wall extending from a middle portion of the cupped base. The vertical wall extends from an edge of the cupped base across a portion of a first length of the cupped base. The vertical wall is positioned to receive the exhaust from the air-operated diaphragm pump from an inlet of the leak detector assembly on a first side of the vertical wall. The voids extend through the cupped base. The voids are positioned proximal a second side of the vertical wall. The second side of the vertical wall opposite the first side of the vertical wall.

[0022] In an example aspect combinable with any other example aspect, the normally closed pneumatic control valve is fluidly coupled to the air-operated diaphragm pump at an inlet of the air-operated diaphragm pump. The leak detector assembly controls a position of the normally closed pneumatic control valve responsive to detecting the leak in the air-operated diaphragm pump.

[0023] In an example aspect combinable with any other example aspect, the spring-loaded spool, in the single motion, shuts the normally closed pneumatic control valveAtorney Docket No.: 45770-0183WO1

[0024] responsive to the change in the fluid level of the leak detector assembly equal to or above the threshold level, thereby isolating an upstream end of the air-operated diaphragm pump.

[0025] In an example aspect combinable with any other example aspect, a supply of air is directed to both the air-operated diaphragm pump and the leak detector assembly. The supply of air flows through the leak detector assembly to control a position of an isolation valve at an inlet to the air-operated diaphragm pump and the leak detector assembly controls an air flow through the exhaust of the air-operated diaphragm pump.

[0026] In an example aspect combinable with any other example aspect, when the spring-loaded spool is in the open position, a supply of air is free to flow i) through the normally closed pneumatic control valve to the air-operated diaphragm pump to the leak detector assembly, past the spring-loaded spool in the leak detector assembly, and out the exhaust of the leak detector assembly, and ii) from upstream of the normally closed pneumatic control valve to the leak detector assembly, past the spring-loaded spool, and out the leak detector assembly to the normally closed pneumatic control valve, maintaining the normally closed pneumatic control valve in an open position. When the spring-loaded spool is in the closed position, the spring-loaded spool i) prevents the supply of air from passing through the leak detector assembly and out the exhaust of the leak detector assembly, thereby isolating a downstream end of the air-operated diaphragm pump, and ii) prevents the supply of air from upstream of the normally closed pneumatic control valve through the leak detector assembly, thereby allowing the normally closed pneumatic control valve to move from an open position to a closed position, thereby isolating an upstream end of the air-operated diaphragm pump.

[0027] In an example aspect combinable with any other example aspect, when the spring-loaded spool is in the open position, a supply of air is free to flow from the air source to the leak detector assembly, past the spring-loaded spool, and out the leak detector assembly to an upstream end of the air-operated diaphragm pump. When the spring-loaded spool is in the closed position, the spring-loaded spool prevents the supply of air from passing through the leak detector assembly, thereby isolating an upstream end of the air-operated diaphragm pump.

[0028] In an example aspect combinable with any other example aspect, the leak detector assembly includes a user alert flow port, and the spring-loaded spool controls aAtorney Docket No.: 45770-0183WO1

[0029] supply to air through the user alert flow port to a user alert device when the spring-loaded spool is in the closed position.

[0030] In another example aspect, a leak detector assembly detects a leak in an air-operated diaphragm pump. The leak detector assembly includes a housing and a spring-loaded spool. The housing can couple to an air exhaust of the air-operated diaphragm pump. The housing defines an air exhaust flow path from the air exhaust of the air-operated diaphragm pump to the atmosphere. The spring-loaded spool is positioned in the air exhaust flow path. The spring-loaded spool is operable, in a single motion responsive to a change in a fluid level of the leak detector assembly equal to or above a threshold level, to move between an open position allowing air to flow along the air exhaust flow path and a closed position i) preventing air to flow along the air exhaust flow path, thereby isolating a downstream end of the air-operated diaphragm pump and ii) directing air to shut an isolation valve upstream of the air-operated diaphragm pump, thereby isolating an upstream end of the air-operated diaphragm pump.

[0031] In an example aspect combinable with any other example aspect, the leak detector assembly includes a float valve positioned in the air exhaust flow path upstream from the spring-loaded spool. The float valve is movable responsive to the change in the fluid level in the leak detector assembly. The float valve is movable between a first position engaged to the spring-loaded spool and a second position disengaged from the spring-loaded spool. When in the float valve is in the second position disengaged from the spring-loaded spool, the spring-loaded spool is free to move from the open position to the closed position.

[0032] In another example aspect, a method includes detecting a leak in an exhaust of an air-operated diaphragm pump. The method includes responsive to detecting the leak, in a single motion of a spring-loaded spool, isolating the air-operated diaphragm pump both upstream and downstream of the air-operated diaphragm pump.

[0033] In another example aspect, an air-operated pump system includes an air-operated diaphragm pump and a leak detector assembly. The air-operated diaphragm pump has a process fluid pathway and a motive fluid pathway. The process fluid pathway extends between a process fluid inlet and a process fluid outlet. The motive fluid pathway is separate from the process fluid pathway. The motive fluid pathway extends between a motive fluid inlet and a motive fluid outlet. The leak detector assembly is fluidly coupled to the motive fluid inlet and the motive fluid outlet. The leak detector assemblyAttorney Docket No.: 45770-0183WO1

[0034] controls motive fluid flow to and from the motive fluid inlet and the motive fluid outlet, respectively, responsive to detecting a leak from the process fluid pathway to the motive fluid pathway. The leak detector assembly includes a float valve and a spring-loaded spool. The float valve is movable responsive to a change in a fluid level in the leak detector assembly. The spring-loaded spool is coupled to the float valve. The spring-loaded spool, in a single motion, responsive to the change in the fluid level of the leak detector assembly equal to or above a threshold level, isolates the motive fluid flow through the leak detector assembly to the motive fluid inlet of the air-operated diaphragm pump and isolate the motive fluid flow from the motive fluid outlet of the air-operated diaphragm pump.

[0035] The devices, systems, and techniques described herein may provide one or more of the following advantages. These systems and methods can reduce time to detect a leak. For example, separating and collecting the leaked process fluid with the leak detector assembly sooner relative to conventional methods.

[0036] These systems and methods can reduce a quantity of process fluid loss to the environment. For example, the leak detector can isolate the air-operated diaphragm pump upstream and downstream, reducing the quantity of process fluid leaked to the environment and preventing further leakage through a rupture diaphragm.

[0037] These systems and methods can improve personnel and environmental safety. For example, the leak detector can isolate the air-operated diaphragm pump upstream and downstream, reducing the quantity' of process fluid leaked to the environment and preventing further leakage through a rupture diaphragm of hazardous process fluid to the surrounding environment, improving personnel and environmental safety.

[0038] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

[0039] BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1A is a schematic view of an air-operated diaphragm pump system with a leak detector assembly where the leak detector assembly controls the position of an isolation valve at the inlet to an air-operated diaphragm pump.

[0040] FIG. IB is a fluid circuit view- of the air-operated diaphragm pump system of FIG. 13 A with the spring-loaded spool in the set position.Atorney Docket No.: 45770-0183WO1

[0041] FIG. 1C is a fluid circuit view of the air-operated diaphragm pump system of FIG. 3 A with the spring-loaded spool in the tripped position.

[0042] FIG. 2 is a side view of the leak detector assembly of FIG. 1A.

[0043] FIG. 3 is a perspective view of the internal portions of the leak detector assembly of FIG. 1 with the top cover removed.

[0044] FIG. 4 is a perspective view of the internal portions of the leak detector assembly of FIG. 1 with the top cover and a partitioned structure removed.

[0045] FIG. 5 is a cross-section view of the leak detector assembly of FIG. 1A w ith a spring-loaded spool of the leak detector assembly in a set condition.

[0046] FIG. 6 is another cross-section view of the leak detector assembly of FIG. 1A with the spring-loaded spool in a tripped condition.

[0047] FIG. 7A is a side view7of the spring-loaded spool of FIGS 5-6.

[0048] FIG. 7B is an exploded perspective view7of the spring-loaded spool of FIGS 5-6. FIG. 7C is a perspective view of the spring-loaded spool in the set position.

[0049] FIG. 7D is a perspective view of the spring-loaded spool in the tripped position. FIG. 7E is another perspective view7of the spring-loaded spool in the set position. FIG. 7F is another perspective view of the spring-loaded spool in the tripped position.

[0050] FIG. 8 is a side view of a catch cylinder of a float valve.

[0051] FIG. 9 is a cross-section view of the leak detector assembly of FIG. 1A show ing a partial cross-section of the body where the spring-loaded spool actuates to control air flow.

[0052] FIG. 10 is a perspective view of the partitioned structure of the leak detector assembly of FIG. 1A.

[0053] FIG. 11 is a perspective view of the internal portions of the leak detector assembly of FIG. 1A with the top cover, the partitioned structure, a filter, and portions of the spring-loaded spool removed.

[0054] FIG. 12 is a perspective view of the partitioned structure of the leak detector assembly of FIG. 1A.

[0055] FIG. 13A is a schematic view7of another air-operated diaphragm pump system with a leak detector assembly where the air supply of the air-operating diaphragm pump system is supplied to the leak detector assembly and the leak detector assembly controls the air supply to the air operated diaphragm pump.Atorney Docket No.: 45770-0183WO1

[0056] FIG. 13B is a fluid circuit view of the air-operated diaphragm pump system of FIG. 13A with the spring-loaded spool in the set position.

[0057] FIG. 13C is a fluid circuit view of the air-operated diaphragm pump system of FIG. 3A with the spring-loaded spool in the tripped position.

[0058] FIG. 14 is a schematic view of another air-operated pump diaphragm system with a leak detector assembly where the air supply is directed to both the air-operated diaphragm pump and the leak detector assembly, where the air flows through the leak detector assembly from the air supply to control a position of an isolation valve at an inlet to the air-operated diaphragm pump and the leak detector assembly controls an air flow through an exhaust of the air-operated diaphragm pump.

[0059] FIG. 15 is a schematic view of another air-operated diaphragm pump system with a leak detector assembly where the air supply is directed i) through the isolation valve to the air-operated diaphragm pump to the leak detector assembly, ii) to the leak detector assembly pilot valve for controlling an exhaust of the air-operated pump, and iii) to the leak detector assembly for controlling a user alert.

[0060] FIG. 16 is a flow chart of an example method of detecting a leak in an air-operated pump according to the implementations of the present disclosure.

[0061] Like reference symbols in the various drawings indicate like elements.

[0062] DETAILED DESCRIPTION

[0063] Air-operated diaphragm pumps are used in many industrial applications to move fluids from one location to another. A motive fluid, such as compressed air causes the diaphragm in the pump to move, forcing a process fluid to move from one location to another location. The motive fluid and the process fluid are separated by the diaphragm and pump body. Sometimes a part of the air-operated diaphragm pump can fail. For example, the diaphragm can deteriorate causing a leak or rupture. When some of these failures occur, the process liquid can leak into the motive fluid. The leak in the air-operated diaphragm pump can be detected and isolated using a leak detector assembly.

[0064] The leak detector assembly is fluidly coupled to an air exhaust of the air-operated diaphragm pump. The leak detector assembly has a spring-loaded spool which, in a single motion, controls the air exhaust flow from the leak detector assembly and a position of an isolation valve positioned at an air inlet to the air-operated diaphragm pump. The motive fluid, in this case air, flows from the exhaust of the air-operatedAtorney Docket No.: 45770-0183WO1

[0065] diaphragm pump through the leak detector assembly to the atmosphere. When the leak in the air-operated diaphragm pump occurs, the process fluid flows into the air (the motive fluid) in the air-operated diaphragm pump to the leak detector assembly. The leak detector assembly senses the motive fluid and, in a single motion, the spring-loaded spool shuts the air exhaust flow from the leak detector assembly by shutting a valve within the leak detector assembly and shuts the isolation valve positioned at the air inlet to the air-operated diaphragm pump, fluidly isolating the motive fluid system (i.e., the exhaust and air supply).

[0066] FIGS. 1A-1C shows an air-operated pump system 100 includes an air-operated diaphragm pump 102, a normally closed pneumatic control valve 104. and a leak detector assembly 106. The air-operated diaphragm pump 102 moves a process fluid from one location to another. The air-operated diaphragm pump 102 is operated by a supply of air. The supply of air passes into the air-operated diaphragm pump 102, through the air-operated diaphragm pump 102. and exits the air-operated diaphragm pump 102 into the leak detector assembly 106. The normally closed pneumatic control valve 104 is positioned in the supply of air to the air-operated diaphragm pump 102. The normally closed pneumatic control valve 104 is held open during operation by a supply of air from the leak detector assembly 106. The air flows through the leak detector assembly 106 and exits the leak detector assembly 106 to the surrounding atmosphere 108. When the leak detector assembly 106 detects process fluid in the air exhausted from the air-operated diaphragm pump 102, the leak detector assembly 106 closes in a single motion to stop the exhaust flow from the leak detector assembly 106 to the surrounding atmosphere 108 and to stop the supply of air to the normally closed pneumatic control valve 104 which causes the normally closed pneumatic control valve 104 to shut. This isolates the air-operated diaphragm pump 102 upstream and downstream, stopping the operation of the air-operated diaphragm pump 102 and sealing the process fluid leak within the air-operated diaphragm pump 102.

[0067] The leak detector assembly 106 operates in a single motion to seal the air portions of the air-operated diaphragm pump 102 to prevent the leaked process fluid from exiting the air-operated diaphragm pump 102 to the leak detector assembly 106. The leak detector assembly 106 is described in detail in reference to FIGS. 2-12.

[0068] The air-operated diaphragm pump 102 has a body 110. The body 110 defines an air pathway and a process liquid pathway. The air pathway and the process liquidAtorney Docket No.: 45770-0183WO1

[0069] pathway are separated from each other by the body 110 and the diaphragm. Moving air through the air pathway actuates the diaphragm, pumping the process liquid along a process liquid pathway through the body 110. The body 110 can be made of any suitable metal or metal alloy such as steel or aluminum, or a polymer. In some implementations the body 110 is a chemically resistant material.

[0070] The air-operated diaphragm pump 102 has a process liquid inlet 112, a process liquid outlet 114, a motive fluid inlet 116, and a motive fluid outlet 118. The process liquid inlet 112 is the suction of the air-operated diaphragm pump 102. The process liquid inlet 112 receives the process liquid from a first portion of a process liquid system. The process liquid outlet 114 is the discharge of the process fluid from the air-operated diaphragm pump 102 and is fluidly coupled to a second portion of the process liquid system. The process liquid inlet 112 and the process liquid outlet 114 are the beginning and the end of the process liquid pathway through the body 110 of the air-operated diaphragm pump 102. respectively. The motive fluid inlet 116 can be referred to as the air inlet 116 and the motive fluid outlet 118 can be referred to as the air outlet, the exhaust, or the pump exhaust. The motive fluid inlet 116 is coupled to an air supply system 120. The motive fluid inlet 116 receives a supply of air from the air supply system 120 to move the diaphragm, moving the process fluid along the process fluid pathway through the body 110 of the air-operated diaphragm pump 102. The motive fluid outlet 118 is the discharge of the air after actuating the diaphragm. The motive fluid outlet 118 is fluidly coupled to the leak detector assembly 106 and conducts the air from the air-operated diaphragm pump 102 to the leak detector assembly 106. The motive fluid inlet 116 and the motive fluid outlet 118 are the beginning and the end of the motive fluid pathway through the body 110 of the air-operated diaphragm pump 102, respectively. When there is a leak in the air-operated diaphragm pump 102, for example, in the diaphragm, some process liquid can enter the air and be exhausted to the leak detector assembly 106. The leak detector assembly 106 detects the presence of the leaked process fluid in the air received from the air-operated diaphragm pump 102.

[0071] Air-operated pumps move process liquids. The process liquid can be any suitable type of liquid, slurry7, gelatinous substance, or suspension. For example, the process liquid can be paints, stains, gasoline, strong acids, strong bases, or food pastes.

[0072] Air-operated diaphragm pumps 102 are driven by a motive fluid. For example, the motive fluid can be a gas such as compressed air. Motion of the motive air throughAtorney Docket No.: 45770-0183WO1

[0073] driving chambers of the air-operated diaphragm pump 102 causes the air-operated diaphragm pump 102 to then move a process liquid through the air-operated diaphragm pump 102. Air-operated diaphragm pumps 102 can be operated continuously for long periods of time, often for many millions of cycles, and can include numerous moving parts. Reliable and continuous transfer of the process liquid can be critical to the industrial or other processes in which the process liquids are used. A leak of air or process liquid between an air side of the air-operated diaphragm pump 102 and the process liquid side of the air-operated diaphragm pump 102, which are intended to remain separated during the use of the air-operated diaphragm pump 102, can cause significant contamination and / or spill issues. This unwanted occurrence can result in lost process liquid, extended downtimes for repair and cleanup, and expensive cleanup procedures.

[0074] The air-operated diaphragm pump 102 moves the process fluid when air pressure is applied inside the air-operated diaphragm pump 102 to the air-operated diaphragm pump 102 via the motive fluid flow path to a valve which alternates position, for example, moving up and down, causing air pressure to divert to an air side of the respective diaphragm chamber. Due to the movement of the valve, as air is diverted to one diaphragm chamber, air in the opposite chamber is exhausted out of the exhaust. This motive air process constantly alternates between diaphragm chambers (and specifically between the air sides of the chambers) to create a continuous cycle.

[0075] Movement of the diaphragms within the chambers causes pumping of the process liquid in a similar manner. One diaphragm creates suction into a process liquid side of a respective diaphragm chamber, drawing process liquid from the process liquid inlet 112. The other diaphragm expels process liquid from the opposite and respective diaphragm chamber to the process liquid outlet 114. This process cycles and continues concurrently with the movement of the motive fluid, thus pumping process liquid through the air-operated diaphragm pump 102.

[0076] The diaphragms also serve as barriers between the air side / air pathway and process liquid side / process liquid pathw ay of the air-operated diaphragm pump 102.

[0077] Sometimes, a leak may occur between the motive fluid flow7path and the process liquid flow7path. The leak may be caused by a worn or blown seal or diaphragm, or tension or stress in the body 110 of the air-operated diaphragm pump 102 related to installation, and / or improperly tightened fasteners coupling together portions of the bodyAtorney Docket No.: 45770-0183WO1

[0078] 22. Such failures or degradation can cause process liquid to begin to leak into the surrounding atmosphere 108. By coupling the leak detector assembly 106 to the motive fluid outlet 118 between the air-operated diaphragm pump 102 and the muffler 134, the leaked process fluid can be detected and the air-operated diaphragm pump 102 can be isolated in a single motion, reducing and / or preventing further leaking of process fluid to the surrounding atmosphere 108.

[0079] The air supply system 120 provides a pressurized fluid, for example, compressed air, as a motive fluid to the air-operated diaphragm pump 102. The air supply system 120 can include one or more of the following components. The air supply system 120 shown in FIG. 1A includes a motive fluid source. For example, the motive fluid source can be an air compressor, a compressed air tank, or compressed natural gas. The air supply system 120 includes a fdter / regulator 122, the normally closed pneumatic control valve 104, a pressure gauge 124, and a pressure release valve 126.

[0080] The filter / regulator 122 receives the supply of air from the motive fluid source. The filter / regulator 122 filters the air from the motive fluid source. The filter / regulator 122 can adjust the pressure of the air from the motive fluid source to a desired pressure for operating the air-operated diaphragm pump 102. The filter / regulator 122 supplies the filtered and adjusted air to the normally closed pneumatic control valve 104.

[0081] The normally closed pneumatic control valve 104 receives the supply of air from the filter / regulator 122. The normally closed pneumatic control valve 104 is upstream from the air-operated diaphragm pump 102. The normally closed pneumatic control valve 104 is operable between an open position and a closed position. When the normally closed pneumatic control valve 104 is in the open position, the supply of air is free to flow through the air supply system 120 to the air-operated diaphragm pump 102. When the normally closed pneumatic control valve 104 is in the closed position, the supply of air is interrupted and the air-operated diaphragm pump 102 is isolated from the motive fluid source upstream from the air-operated diaphragm pump 102.

[0082] The normally closed pneumatic control valve 104 is held in the open position by a supply of air from the leak detector assembly 106 through a control conduit 128. The control conduit 128 fluidly couples the leak detector assembly 106 to the normally closed pneumatic control valve 104 and conducts air from the leak detector assembly 106 to the normally closed pneumatic control valve 104, holding the normally closed pneumatic control valve 104 in the open position. When the leak detector assembly 106 operates inAtorney Docket No.: 45770-0183WO1

[0083] a single motion, as described in more detail in reference to FIGS. 2-12. the supply of air from the leak detector assembly 106 holding the normally closed pneumatic control valve 104 in the open position is stopped, and the normally closed pneumatic control valve 104 moves from the open position to the normally closed position, shutting the normally closed pneumatic control valve 104 and preventing air flow through the normally closed pneumatic control valve 104. Shutting the normally closed pneumatic control valve 104 isolates the air-operated diaphragm pump 102 upstream. In the same motion, as described in more detail in reference to FIGS. 2-12, the leak detector assembly 106 isolates the exhaust of the air-operated diaphragm pump 102.

[0084] The pressure gauge 124 senses and displays the pressure of the motive fluid at the inlet of the air-operated diaphragm pump 102. The pressure gauge 124 can transmit a signal representing the pressure of the motive fluid at the inlet of the air-operated diaphragm pump 102 to a controller.

[0085] The pressure release valve 126 can be manually or automatically operated to reduce the pressure of the motive fluid at the inlet of the air-operated diaphragm pump 102. For example, when the pressure of the motive fluid at the inlet of the air-operated diaphragm pump 102 exceeds a pre-determined threshold, the pressure release valve 126 can open, releasing the pressurized air into the surrounding atmosphere 108.

[0086] The leak detector assembly 106 has an inlet 130 and an outlet 132. The inlet 130 of the leak detector assembly 106 is coupled to the motive fluid outlet 118 of the air-operated diaphragm pump 102. The leak detector assembly 106 defines an exhaust flow path from the inlet 130 to the outlet 132. The leak detector assembly 106 is operable to open or close the exhaust flow path based on detecting the presence of the process fluid which has leaked into the motive fluid flow path and exhausted to the leak detector assembly 106, as described in more detail in reference to FIGS. 2-12. The inlet 130 can be referred to as an inlet port. The outlet 132 can be referred to as an exhaust port.

[0087] The air-operated pump system 100 includes a muffler 134. The muffler 134 reduces the sound level of the air exhausted from the air-operated pump system 100 to the surrounding atmosphere 108. The muffler 134 is coupled to an outlet 132. The muffler 134 receives the exhaust air from the leak detector assembly 106 after the exhaust air has passed through the leak detector assembly 106.

[0088] The air-operated pump system 100 includes a pressure regulator 136. The pressure regulator 136 is mounted to the leak detector assembly 106. The pressureAtorney Docket No.: 45770-0183WO1

[0089] regulator 136 supplies control air at a reduced pressure to the normally closed pneumatic control valve 104. In FIGS. 1A-1B, the motive fluid is supplied to the leak detector assembly 106 and goes first through the pressure regulator 136, then through the spring-loaded spool 210 when the spring-loaded spool 210 is in the open position 218, and then to the normally closed pneumatic control valve 104 to hold the normally closed pneumatic control valve 104 in the open position. The normally closed pneumatic control valve 104 can have a narrower operating pressure range than the air-operated diaphragm pump 102. In FIG. 1C, the closed position 604 the normally closed pneumatic control valve 104 is vented to the surrounding atmosphere 108 and therefore allowed to close, isolating the upstream portion of the air-operated diaphragm pump 102.

[0090] Referring to FIGS. 2-12, the leak detector assembly 106 is coupled to the air-operated diaphragm pump 102 downstream from the air-operated diaphragm pump 102. The leak detector assembly 106 receives the exhaust air from the air-operated diaphragm pump 102. The leak detector assembly 106 defines an exhaust flow path 302 (shown in FIGS. 3 and 5) between the air-operated diaphragm pump 102 and the muffler 134. The leak detector assembly 106 is coupled to the air-operated diaphragm pump 102 at the inlet 130 and the muffler 134 at the outlet 132. The exhaust air from the air-operated diaphragm pump 102 flows through the leak detector assembly 106 along the exhaust flow path 302. Sometimes, process liquid from the air-operated diaphragm pump 102 can leak past or through the diaphragm in the air-operated diaphragm pump 102 and enter the motive fluid How and enter the leak detector assembly 106 following the exhaust flow path 302 to the muffler 134 and enter the surrounding atmosphere 108. The leak detector assembly 106 can detect the process liquid in the exhaust flow path 302, and, in a single motion, isolate the air-operated diaphragm pump 102 upstream and dow nstream by removing the air supply to the normally closed pneumatic control valve 104 and shutting a valve (shown in FIGS. 3, 5-7, and 11) in the exhaust flow path 302 inside the leak detector assembly 106.

[0091] The leak detector assembly 106 has a body 202 defining the exhaust flow path 302. The body 202 has a lower portion 204 and an upper portion 206. The upper portion 206 is mounted on top of and sealed to the lower portion 204 to define a sealed body 202 with the exhaust flow path 302 defined therethrough. The upper portion 206 is coupled to the lower portion 204 by a set of fasteners 208. In this implementation, the fastenersAttorney Docket No.: 45770-0183WO1

[0092] 208 are bolts with washers, however, in other implementations, any suitable fastener may be used to couple the upper portion 206 to the lower portion 204.

[0093] The inlet 130 to the leak detector assembly 106 is in the lower portion 204. The outlet 132 of the leak detector assembly 106 is in the upper portion 206.

[0094] The leak detector assembly 106 has a float valve 402 (shown in FIGS. 4-6 and 11) coupled to a spring-loaded spool 210 (shown in FIGS. 2-3, 5-7, 9, and 11) to detect and actuate to isolate the air-operated diaphragm pump 102 in the presence of leaked process fluid. The float valve 402 rests in a bowl 404 defined in the lower portion 204 of the leak detector assembly 106 (shown in FIGS. 4-6 and 11) to detect the presence of leaked process liquid. The bowl 404 defines a void 504 to receive the float valve 402. The float valve 402 and the bowl 404 are positioned to receive separated process fluid from the exhaust flow path 302 as show n by the separated process fluid flow path 304 in FIG. 5. The float valve 402 detects the process liquid in the leak detector assembly 106. The process liquid collects in the bowl 404 and the float valve 402 moves in an upward direction as the bowl 404 fills with the process liquid. Thus, the float valve 402 is movable responsive to a change in the fluid level in the bowl 404. When the level of collected process fluid in the bowl 404 reaches a pre-determined level, the float valve 402 trips, allowing the spring-loaded spool 210 to move. In a single motion, the spring-loaded spool 210 seals the air-operated diaphragm pump 102 upstream and downstream of the air-operated diaphragm pump 102 by stopping the supply of air to the normally closed pneumatic control valve 104 through the control conduit 128 and shutting the exhaust flow7path 302 through the leak detector assembly 106.

[0095] The spring-loaded spool 210 is coupled to the float valve 402 and rests inside the body 202 of the leak detector assembly 106. The spring-loaded spool 210 is movable between an open position 218, also referred to as a set position or a down position (shown in FIGS. 2 and 5), and the closed position 604, also referred to as a tripped position or an up position (shown in FIGS. 1C and 6). When the spring-loaded spool 210 is in the open position 218, the float valve 402 is engaged to the spring-loaded spool 210 and the float valve 402 holds the spring-loaded spool 210 in the open position 218, allowing exhaust air from the air-operated diaphragm pump 102 to flow through the leak detector assembly 106 to the muffler f34 and on to the surrounding atmosphere f08. When the float valve 402 moves in the upward direction as the bowl 404 fills with leaked process liquid, the float valve 402 reaches a height 602 above a bottom surface 502Attorney Docket No.: 45770-0183WO1

[0096] (shown in FIGS. 5-6) of the bowl 404 where the float valve 402 disengages from the spring-loaded spool 210 and the spring-loaded spool 210 moves in the upward direction 212 to the closed position 604 or tripped position. The height at which the float valve 402 disengages from the spring-loaded spool 210 is the threshold fluid level. The threshold fluid level can be selected by the user based on the type of process fluid and / or the quantity of process fluid leaked before a user desires to isolate the air-operated diaphragm pump 102.

[0097] The spring-loaded spool 210 has a knob 214. The knob 214 is knurled. The knob 214 allows the user to reset the spring-loaded spool 210 after the spring-loaded spool 210 has tripped. When the spring-loaded spool 210 is the closed position 604 or tripped position (i.e., fully in the upward direction 212), the user can pull the knob 214 in a downward direction 216, pulling the spring-loaded spool 210 from the tripped position 604 to the set position 218. Moving the spring-loaded spool 210 from the tripped position 604 to the set position 218 in the downward direction reengages the float valve 402 to the spring-loaded spool 210 and locks the spring-loaded spool 210 in the open / set position 218, allowing exhaust air to flow through the leak detector assembly 106 to the muffler 134 and also flow a supply of air through the control conduit 128 to the normally closed pneumatic control valve 104, moving the normally closed pneumatic control valve 104 from the closed position to the open position and allowing a supply of air to flow through the air supply system 120 to the air-operated diaphragm pump 102, reinitiating pumping of the process fluid through the air-operated diaphragm pump 102 in a single motion.

[0098] Referring to FIGS. 4-6 and 11, the float valve 402 detects the presence of the process liquid in the bowl. As the process liquid entrained or forced along the exhaust flow path 302 proceeds through the leak detector assembly 106, the process liquid falls from or is separated from the motive fluid (the air) and drains to the bowl 404, filling the bowl 404. The float valve 402 includes a float 406, a shaft 408, and a catch cylinder 410 (shown in detail and described in reference to FIGS. 4-6, 8, and 11). The shaft 408 extends between and is coupled to both the float 406 and the catch cylinder 410. The shaft 408 a first end 412 and a second end 414. The first end 412 of the shaft 408 is coupled to the float 406. The second end 414 of the shaft 408 is coupled to the catch cylinder 410. The catch cylinder 410 is optionally coupled to the spring-loaded spool 210. The catch cylinder 410 rotates in a void 416 in the lower portion 204 to engage andAttorney Docket No.: 45770-0183WO1

[0099] disengage from the spring-loaded spool 210. When the catch cylinder 410 is engaged to the spring-loaded spool 210, the catch cylinder 410 holds the spring-loaded spool 210 in the open position 218. When the catch cylinder 410 is disengaged from the spring-loaded spool 210, the spring-loaded spool 210 moves from the open position 218 to the closed position 604. The float 406 rests in the bowl 404. Based on the fluid level in the bowl 404 the height 602 of the float 406 changes within the bowl 404. As the height 602 of the float 406 changes, the first end 412 of the shaft 408 raises relative to the second end 414 of the shaft 408 and the catch cylinder 410 rotates, disengaging from the spring-loaded spool 210, allowing the spring-loaded spool 210 to move from the open position 218 to the closed position 604. The float 406 moves from a downward location 534, which is a first position as shown in FIG. 5, to an upward location 608 (shown in FIG. 6) at the height 602. The upward location 608 is a second position.

[0100] The threshold height 602 can be adjusted based on the different types of process liquids and the acceptable or desired amount of leaked process liquid. For example, a smaller diameter float 406 can be used, increasing the required travel of the float 406 to trip the catch cylinder 410 when a larger amount of process liquid or a longer time before tripping is acceptable. Sometimes, the user may want to decrease the time before a leak in the air-operated diaphragm pump 102 is isolated or decrease the amount of process liquid leaked into the motive fluid flow path. In such cases, a larger diameter float 406 may be used to decrease the required travel of the float 406.

[0101] Referring to FIGS. 1B-1C, 4-6, 8, and 11, the catch cylinder 410 is optionally coupled to the spring-loaded spool 210 to either hold the spring-loaded spool 210 in place in the open position 218 or release the spring-loaded spool 210 so the spring-loaded spool 210 moves to the closed position 604. The catch cylinder 410 is coupled to the second end second end 414 of the shaft 408. The catch cylinder 410 rotates in the void 416 about a longitudinal axis defined by the catch cylinder 410. The catch cylinder 410 rotates in the void 416 responsive to the change in height 602 of the float 406.

[0102] The catch cylinder 410 includes a relieved portion 506, shown in FIGS. 5-6 and 8. Based on the angle of rotation of the catch cylinder 410 about the longitudinal axis within the void 416, the catch cylinder 410 engages or disengages from the spring-loaded spool 210. Referring to FIG. 5, the float valve 402 is in the down position and an edge 508 of the relieved portion 506 of the catch cylinder 410 is engaged to the spring-loaded spool 210, holding the spring-loaded spool 210 in the open position 218. Referring toAtorney Docket No.: 45770-0183WO1

[0103] FIG. 6, process fluid has collected in the void 504 and the float 406 has risen to the height 602, causing the catch cylinder 410 to rotate in the counterclockwise direction 606. When the catch cylinder 410 rotates in the counterclockwise direction 606, the edge 508 of the relieved portion 506 disengages from the spring-loaded spool 210, and the spring-loaded spool 210 is free to move upward from the open position 218 to the closed position 604.

[0104] After the spring-loaded spool 210 has tripped, the operator may desire to reset the spring-loaded spool 210 to reinitiate leak detection operations. The bowl 404 is drained of the process fluid, so the float 406 is free to move in the downward direction 216 to the downward location 534. The operator pulls the knob 214 in the downward direction 216, and the catch cylinder 410 rotates in the clockwise direction so the edge 508 reengages with the spring-loaded spool 210.

[0105] Referring to FIGS. 5, 6, and 8, the second end 414 of the shaft 408 is threaded to engage a threaded void 802 (shown in FIG. 8) of the catch cylinder 410. The catch cylinder 410 includes grooves 804 on either side of the relieved portion 506. The grooves 804 are sized to receive o-rings 720 (shown in FIGS. 7C-7D). The o-rings 720 rest between the catch cylinder 410 and reduce or prevent motive fluids and process liquids from bypassing the catch cylinder 410 to exit the void 416 to the surrounding atmosphere 108. The catch cylinder 410 is held in the void 416 by a retaining ring 722 (shown in FIGS. 7C-7D) which snaps into a groove in the lower portion 204 of the body 202 accessed from outside the body 202 (i.e., the surrounding atmosphere 108).

[0106] Referring to FIGS. 1-3, 5-7, 9, and 11, the spring-loaded spool 210 is positioned within a ported void 510 (shown in FIGS. 5-7. 9, and 11) within the body 202. The spring-loaded spool 210 moves within the ported void 510 to control the flow of exhaust air along the exhaust flow path 302 through the body 202. The ported void 510 has multiple ports 902, 904, 906, and 908 (shown and described in more detail in reference to FIG. 5, 6. 9, and 13A-15) to which components of the air-operated pump system 100 can connect to, so air is supplied to, or prevented from, flowing to the various components of the air-operated pump system 100 depending on the position of the spring-loaded spool 210 and the desired (connected) component.

[0107] The upper portion 206 of the body 110 has a valve seat 512 (shown in FIGS. 5-6) which the spring-loaded spool 210 can out of contact with or move into contact with, alternately allowing or preventing flow through the leak detector assembly 106 along theAtorney Docket No.: 45770-0183WO1

[0108] exhaust flow path 302, as shown in FIGS. 5 and 6. respectively. Referring to FIG. 5, when the spring-loaded spool 210 is in the open position 218, the spring-loaded spool 210 is spaced apart from the valve seat 512, allowing the flow of exhaust air through the leak detector assembly 106. Referring to FIGS. 1C and 6, when the spring-loaded spool 210 is in the closed position 604, the spring-loaded spool 210 is in contact with and sealed against the valve seat 512, preventing exhaust air flow past the valve seat 512 to the outlet 132. This interrupts the exhaust flow path 302, isolating the exhaust air flow to the surrounding atmosphere 108. With the spring-loaded spool 210 in the closed position 604, the normally closed pneumatic control valve 104 is vented to the surrounding atmosphere 108, allowing the normally closed pneumatic control valve 104 to close and isolate the upstream side of the air-operated diaphragm pump 102. The discharge of the pump motive fluid to the surrounding atmosphere 108 is isolated within the leak detector assembly 106.

[0109] The spring-loaded spool 210 has a spring 514 positioned around a shaft 516, a plunger 518 coupled to a first end 520 of the shaft 516, and the knob 214 coupled to a second end 522 of the shaft 516. The first end 520 of the shaft 516 is within the leak detector assembly 106. The plunger 518 acts as a valve disc to selectively engage the valve seat 512. The second end 522 of the shaft 516 is outside the leak detector assembly 106, so the knob 214 is accessible to the operator. In FIG. 7A, the spring 514 has been removed for clarity. The first end 520 and the second end 522 of the shaft 516 are threaded.

[0110] The spring 514 is positioned contained within the upper void 542 in the lower portion 204 of the body 202. The spring 514 bias the shaft 516 to the closed position 218 responsive to the float valve 402 moving from the downward location 534 (the first position) to the upw ard location 608 (the second position).

[0111] When the spring-loaded spool 210 is in the open position 218, as shown in FIG.

[0112] 5, the spring 514 is compressed. The spring 514 is held in the compressed state when the spring-loaded spool 210 is in the open position 218 because the edge 508 of the catch cylinder 410 is engaged to the shaft 516. When the catch cylinder 410 rotates and the edge 508 of the catch cylinder 410 disengages from the shaft 516, the spring 514 expands to a relaxed state, as shown in FIG. 6, causing the plunger 518 to contact the valve seat 512, closing the outlet 132 of the leak detector assembly 106.Atorney Docket No.: 45770-0183WO1

[0113] The spring-loaded spool 210 includes a sleeve 524. The sleeve 524 is coupled to the first end 520 of the shaft 516 and extends in the dow nw ard direction 216 away from the plunger 518. In this embodiment, the plunger 518 has an outer diameter larger than the outer diameter of the sleeve 524 and an inner diameter of the outlet 132. In this implementation, this can help to ensure a positive seal of the plunger 518 to the valve seat 512, allowing the plunger 518 to partially deform past the valve seat 512 and into the outlet 132, as shown in FIG. 6.

[0114] The sleeve 524 extends from the plunger 518 into an upper void 542. The upper void 542 extends from the top surface of the lower portion 204 of the body 202 to receive the around the spring 514, the sleeve 524, and part of the shaft 516. The sleeve 524 allows the spring-loaded spool 210 to slide relative to the lower portion 204 within the void 542.

[0115] Referring to FIGS. 5-7E, the shaft 516 has a first relieved portion 526 and a second relieved portion 528. The first relieved portion 526 is spaced apart from the second relieved portion 528. The first relieved portion 526 is sized to allow the edge 508 of the catch cylinder 410 to extend past the outer diameter of the shaft 516 in an inward direction toward the centerline of the shaft 516. The first relieved portion 526 has a straight shelf 530 extending orthogonally from an outer diameter of the shaft 516 to partially define the first relieved portion 526. The edge 508 of the catch cylinder 410 contacts the straight shelf 530 of the first relieved portion 526, holding the shaft 516 in the open position 218. When the float 406 moves from the downward location 534 to the upward location 608, the catch cylinder 410 rotates in the counterclockwise direction 606 and the edge 508 of the catch cylinder 410 slides off the straight shelf 530. and then the spring-loaded spool 210 moves in the upward direction 212.

[0116] The second relieved portion 528 has a set of angled shelves 532 extending at an angle other than orthogonal from the outer diameter of the shaft 516 to at least partially define the second relieved portion 528. When the spring-loaded spool 210 is in the closed position 604 and the float 406 is in the upward location 608 with the void 504 full of process fluid, the bowl 404 can be drained. As the process fluid is removed from the bowl 404, the float 406 moves from the upw ard location 608 to the downward location 534. The catch cylinder 410 rotates in the clockwise direction and the edge 508 enters the second relieved portion 528.Atorney Docket No.: 45770-0183WO1

[0117] When the operator desires to reset the leak detector assembly 106. the operator pulls the knob 214 in the downward direction 216. Because the uppermost angled shelf 532 is angled, the uppermost angled shelf 532 engages the edge 508 of the catch cylinder 410 while the shaft 516 is moving in the downward direction 216 and forces the edge 508 to rotate in the counterclockwise direction 606, slightly lifting the float 406. The edge 508 travels the length of the uppermost angled shelf 532 to reach the outer diameter of the shaft 516. As the operator continues to pull the knob 214 in the downward direction 216, the edge 508 slides along the outer diameter of the shaft 516 until the edge reaches the straight shelf 530, at which point the catch cylinder 410 rotates in the clockwise direction and the edge passes from the outer diameter of the shaft 516 into the first relieved portion 526, resetting the spring-loaded spool 210. The float 406 has moved in the downward direction 216 back down to the downward location 534. The plunger open position 218 is spaced apart from the valve seat 512 and the exhaust flow path 302 through the leak detector assembly 106 is reopened.

[0118] The plunger 518 is coupled to the shaft 516 and the sleeve 524 by a fastener 536. In this implementation, the fastener 536 is a lock nut and an external tooth washer. However, in other implementations, any suitable fastener may be used.

[0119] FIG. 7C shows the spring-loaded spool 210 in the set position 218 . FIG. 7D shows the spring-loaded spool 210 in the tripped position 604. In FIGS. 7C-7D, the body 202, the spring 514, and other various components are not shown for clarity.

[0120] Referring to FIGS. 7A-7D and 9, the spring-loaded spool 210 includes an arrangement of o-rings 702, ported cylinders 704, 706, and 708, and a spacer 710 to control the flow of air through the ported void 510 to one or more of the ports 904. 906, and 908. The arrangement of o-rings 702, ported cylinders 704, 706, and 708, and spacer 710 surround the shaft 516 and are coupled to shaft 516. The arrangement of o-rings 702, ported cylinders 704, 706, and 708, and the spacer 710 are positioned within the ported void 510. The shaft 516 slides within the o-rings 702, ported cylinders 704, 706, and 708, and the spacer 710 as the spring-loaded spool 210 moves betw een the open position 218 and the closed position 604. The arrangement of o-rings 702, ported cylinders 704, 706, and 708, and the spacer 710 are held in place and coupled to the shaft 516 within the ported void 510 by a snap ring 714. The arrangement of o-rings 702, ported cylinders 704, 706, and 708, and the spacer 710 are stationary within the portedAtorney Docket No.: 45770-0183WO1

[0121] void 510 as the shaft 516 moves. The uppermost o-ring 702 prevents air from within the ported void 510 escaping along the shaft 516 into the upper void 542.

[0122] The shaft 516 has channels 712, shown in FIGS. 7B-7D. The channels 712 fluidly couple the ports 718 of the ported cylinders 704, 706, 708, based on the position of shaft 516 relative to the ported cylinders 704, 706. and 708 to one or more of the ports 904, 906, and 908. The channels 712 extend from an outer surface of the shaft 516 into the shaft 516. In this implementation, the channels 712 are generally linear and parallel to the longitudinal axis of the shaft 516. There are four channels 712 arranged symmetrically about the shaft 516. However, in other implementations, any suitable arrangement and size of channels 712 may be used to conduct exhaust air to one or more of the ports 904, 906, and 908.

[0123] In FIGS. 7C-7D, the ported cylinders 704, 706, and 708 are shown as transparent to illustrate the fluidic connection between the ported cylinders 704, 706, and 708 and the channels 712. In FIGS. 7E-7F, the ported cylinders 704. 706, and 708 are not shown to illustrate the fluidic connection between the ported cylinders 704, 706, and 708 and the channels 712 and the first relieved portion 526. The ported cylinders 704, 706, and 708 have ports 718 extending generally perpendicular through the ported cylinders 704, 706, and 708. The ports 718 can pass exhaust air. When the ports 718 are aligned to the channels 712, the exhaust air can pass to or from the ported void 510 based on the pressure differential between portions of the air-operated pump system 100.

[0124] Referring to FIGS 5, 7A-7C, and 9, when the spring-loaded spool 210 is in the open position 218, the shaft 516 is in the downward most position. The shaft 516 moves up and down between the closed position (tripped) 604 and the open position 218 (set). The channels 712 are machined grooves that span between the o-rings 720 to control air flow7between the ports 222, 224, and 226 based on the position of the shaft 516. In the open / set position 218, as show n in FIGS. 7C and 7E, air flow7is allowed coming into the leak detector assembly 106 at port 224 to exit at port 226. When the spring-loaded spool 210 is tripped in the closed position 604, as shown in FIGS. 7D and 7F, the channels 712 span the middle port 224 and the upper port 226, allowing air to go to the whistle 1404 instead, and the smaller diameter of the spring-loaded spool 210 at the first relieved portion 526 allows the air in from the normally closed pneumatic control valve 104 in the control conduit 128 to flow from the normally closed pneumatic control valve 104 into the ports 226 and to vent to the surrounding atmosphere 108.Atorney Docket No.: 45770-0183WO1

[0125] Referring to FIGS. 1C, 6. 7D, 7F, and 9. when the spring-loaded spool 210 is in the closed position 604, the shaft 516 is in the upward most position. Regulated air from the pressure regulator 136 enters into the leak detector assembly 106 at port 224 into the third port 906 and is routed to the fourth port 908 and on to the pressure regulator 136 during normal operation when the spring-loaded spool 210 is in the open position 218, or to port 904 to first threaded push-to-connect tube fitting 222 and on to the whistle 1404 when the spring-loaded spool 210 is tripped in the closed position 604.

[0126] In this implementation, as explained in more detail in reference to FIGS. 1-2, 6, 7D, 7F, and 9, the second port 904 is fluidly coupled to an audible alarm such as a whistle to alert the operator of the leak and the isolation of the air-operated diaphragm pump 102. Alternatively or in additionally, the second port 904 can be fluidly coupled to an air controlled switch that would indicate a fault to a user device such as a computer or control system via a local or wireless network and stopping air flow to the air-operated diaphragm pump 102.

[0127] Referring to FIGS. 3-6 and 9-11, the leak detector assembly 106 includes a filter 306. The filter 306 is positioned within the body 202 of the leak detector assembly 106 in the exhaust flow' path 302. The filter 306 can remove contaminant from the exhaust of the air-operated diaphragm pump 102 as the exhaust air moves through the filter 306 to the outlet 132.

[0128] The filter 306 rests on an upper surface 308 of the lower portion 204. The filter 306 surrounds an upper portion 544 partially defining the void 542. The upper portion 544 extends from the top surface of the lower portion 204 to guide the sleeve 524. The filter 306 is coupled to and sandwiched between the lower portion 204 and the upper portion 206.

[0129] In this implementation, the filter 306 is a hollow' cylinder. However, in other implementations, the filter 306 may be any suitable size or shape.

[0130] The filter 306 is a porous body that can remove particulates from the exhaust air flow 302 to reduce the quantity or prevent particulates from entering the surrounding atmosphere 108. The filter 306 can be sintered polyethylene, sintered polypropylene, paper fiber, wound polymer, or any other suitable material.

[0131] Referring to FIGS. 3-6 and 10-11, the leak detector assembly 106 includes a partitioned structure 310 positioned within the body 202 of the leak detector assembly 106 to provide a tortuous flow' path to the exhaust air received from the air-operatedAtorney Docket No.: 45770-0183WO1

[0132] diaphragm pump 102. The tortuous flow path can remove a portion of the process liquid entrained in the exhaust air flow path 302 from the exhaust air. The removed process liquid can fall to the top surface 312 of the partitioned structure 310 and drain through the partitioned structure 310 to the bowl 404, as shown by the separated process fluid flow path 304. where the process liquid collects. When enough process liquid collects in the bowl 404, the float 406 rises, actuating the spring-loaded spool 210.

[0133] The partitioned structure 310 can both remove a portion of the process fluid from the exhaust air flow and reduce the velocity of the exhaust air flowing through the leak detector assembly 106. When the velocity of the exhaust air is too high, the exhaust air flow can entrain or pick up some process fluid within the leak detector assembly 106 and blow out the entrained process fluid into the filter 306. The filter 306 can become soaked with the process fluid. As a result, sometimes the filter 306 can freeze up and become caked with ice. In some cases, the ice can continue to build up and fill the leak detector assembly 106, or even continue to build and freeze other upstream components, affecting air-operated diaphragm pump 102 performance or even freezing up the air-operated diaphragm pump 102. In some cases, the entrained process fluid can exit the leak detector assembly 106 and cause icing of the muffler 134. The partitioned structure 310 can reduce the level of process fluid in the exhaust air which enters the filter 306 or exits the leak detector assembly 106.

[0134] The partitioned structure 310 is positioned at the inlet 130 of the leak detector assembly 106 between the inlet 130 and the filter 306. The partitioned structure 310 receives the exhaust air from the inlet 130.

[0135] The partitioned structure 310 includes a cupped base 314, an upper section 316 extending from the cupped base 314, and an array of voids 318 extending through the cupped base 314. The upper section 316 receives the exhaust air from the inlet 130. As the exhaust air flows around the upper section 316, the upper section 316 provides a tortuous flow path to the exhaust air, reducing the velocity of the exhaust air and / or removing a portion of the process fluid entrained in the exhaust air. The removed process fluid falls to an upper surface 320 of the cupped base 314 as shown by the separated process fluid flow path 304. As shown in FIG. 4, the removed process fluid falls through the voids 318 along the separated process fluid flow path 304 below the cupped base 314 to collect in the bowl 404. The cupped base 314 upper section 316 also directs the exhaust flow- path 302 in the upward direction 212 toward the filter 306 andAtorney Docket No.: 45770-0183WO1

[0136] away from the separated process fluid which has collected in the bowl 404. separating the exhaust flow path 302 from the bowl 404 so the collected process fluid does not become re-entrained in the exhaust flow path 302.

[0137] The upper section 316 has an inlet 322 fluidly coupled to the inlet 130. The inlet 322 passes the exhaust air from the inlet 130 into the partitioned structure 310. The inlet 322 is generally concentric with the inlet 130 of the leak detector assembly 106.

[0138] The upper section 316 has a vertical wall 324 positioned opposite the inlet 322 to receive and redirect the exhaust air from the inlet 322 through the partitioned structure 310. The vertical wall 324 extends from a middle portion 326 of the cupped base 314. The vertical wall 324 extends from an edge 328 of the cupped base 314 across a portion of a first length 330 of the cupped base 314.

[0139] The vertical wall 324 has a first side 332 and a second side 334 opposite the first side 332. The exhaust flow path 302 flows along the inlet 322 to a distal edge 336 of the vertical wall 324, where the exhaust flow path 302 changes direction to flow back along the inlet 322. This reduces the velocity of the exhaust air. As a result, a portion of the entrained process fluid can fall out to the cupped base 314.

[0140] The array of voids 318 extends through the cupped base 314. The array of voids 318 are positioned next to (proximal) the second side 334 of the vertical wall 324 past the distal edge 336 of the vertical wall 324 to collect the separated process liquid from the exhaust flow path 302. In this implementation, there are twelve voids 318. However, in other implementations, any suitable number or size of voids 318 may be used.

[0141] The cupped base 314 has a domed section 338 extending in the upward direction 212 in a concave arrangement. The domed section 338 is sized to receive a portion of the float 406 as the float valve 402 moves from the downward location 534 to the upward location 608.

[0142] The partitioned structure 310 is coupled to the lower portion 204 of the body 202 by a vertical support structure 340 which engages tabs 342 extending from the lower portion 204 of the body 202. The partitioned structure 310 is coupled to and sandwiched between the lower portion 204 and the upper portion 206 of the body 202.

[0143] The leak detector assembly 106 can include a pressure gauge to sense an internal pressure of the leak detector assembly 106. In some cases, the pressure gauge can transmit a signal indicating the internal pressure of the leak detector assembly 106 to aAttorney Docket No.: 45770-0183WO1

[0144] system controller. The leak detector assembly 106 can include a pressure release valve to decrease the internal pressure of the leak detector assembly 106 when the internal threshold is equal to or greater than an internal pressure threshold. The leak detector assembly 106 can include a fluid level detector to sense a fluid level in the bowl 404. In some cases, the fluid level detector can transmit a signal indicating the fluid level in the bowl 404 to the system controller. In other implementations, the leak detector assembly 106 can include a process liquid level sensor, a float valve position sensor, a temperature sensor, or an ice presence sensor.

[0145] Referring to FIGS. 2, 7C-7D, and 9, the leak detector assembly 106 includes a proximity sensor 220. The proximity sensor 220 is threadedly engaged to the first port 902. The proximity sensor 220 can detect the position of the spring-loaded spool 210 and transmit a signal representing the position of the spring-loaded spool 210 to a controller. In this implementation, the proximity sensor 220 is a magnetic proximity switch. However, in other implementations, any suitable type of sensor may be used to detect the position of the spring-loaded spool 210.

[0146] The leak detector assembly 106 includes multiple threaded push-to-connect tube fittings 222, 224, and 226. Tubes can be connected to the threaded push-to-connect tube fittings 222, 224, and 226 to supply air to or receive air from other components of the air-operated pump system 100.

[0147] The first threaded push-to-connect tube fitting 222 is threadedly engaged to the second port 904. The audible user alert, i.e., the whistle, can be connected to the first threaded push-to-connect tube fitting 222 to receive a flow of control air when the spring-loaded spool 210 is in the closed position 604 as described in reference to FIGS. !C and 7D and 7F.

[0148] The second threaded push-to-connect tube fitting 224 is threadedly engaged to the third port 906. The third port 906 can be fluidly coupled to other components of the air-operated pump system 100. For example, the third port 906 can receive air from the air source, the pressure regulator 122, or the other pressure regulator 136 mounted to the leak detector assembly 106.

[0149] The third threaded push-to-connect tube fitting 226 is threadedly engaged to the fourth port 908. The fourth port 908 can be fluidly coupled to other components of the air-operated pump system 100. For example, in this implementation, the fourth port 908 supplies air to the normally closed pneumatic control valve 104, holding the normallyAtorney Docket No.: 45770-0183WO1

[0150] closed pneumatic control valve 104 in the open position allowing motive air to flow into the air-operated diaphragm pump 102 or stopping air flow as described in reference to FIGS. 6, 7C, and 7E based on the position of the spring-loaded spool 210.

[0151] Referring to FIGS. 2 and 3, the leak detector assembly 106 can include a drain plug 228. The drain plug 228 seals a drain port 230 in the lower portion 204 at the bottom of the bowl 404. The drain plug 228 can be removed by the operator to drain process liquid from the bowl 404 or perform other maintenance or inspections through the drain plug 228. In other implementations, the drain plug 228 can replaced with a drain tube and control valve to automate draining operations.

[0152] Referring to FIG. 1A, the leak detector assembly 106 can include a mounting bracket 138. The mounting bracket 138 can couple the leak detector assembly 106 to a frame 140 mounted on the ground 142 or some other structure. In other implementations, the mounting bracket 138 can mount the leak detector assembly 106 directly to the air-operated diaphragm pump 102. The mounting bracket 138 aligns the inlet 130 of the leak detector assembly 106 horizontally and vertically relative to the motive fluid outlet 118 of the air-operated diaphragm pump 102. The mounting bracket 138 spaces the inlet 130 of the leak detector assembly 106 relative to the motive fluid outlet 118 of the air-operated diaphragm pump 102. Although the leak detector assembly 106 is shown as mounted directly to the air-operated diaphragm pump 102, the leak detector assembly 106 may be any suitable distance from the air-operated diaphragm pump 102.

[0153] The air-operated pump system 100 includes an output conduit 144 extending between the motive fluid outlet 118 of the air-operated diaphragm pump 102 and the inlet 130 of the leak detector assembly 106. The output conduit 144 conducts the flow of the motive fluid from the air-operated diaphragm pump 102 to the leak detector assembly 106.

[0154] In this implementation, the leak detector assembly 106 is coupled to the motive fluid outlet 118 of a single air-operated diaphragm pump 102. However, in other implementations, the leak detector assembly 106 may be connected to the motive fluid outlets 118 of multiple air-operated diaphragm pumps 102. In such an implementation, the leak detector assembly 106 can be arranged to isolate one, more than one, or all of the connected air-operated diaphragm pumps 102.Attorney Docket No.: 45770-0183WO1

[0155] In this implementation, a single leak detector assembly 106 is used to detect and isolate leaks in the air-operated diaphragm pump 102. However, in other implementations, two or more leak detector assemblies 106 may be connected in series. This type of redundant arrangement can increase personnel and environmental safety.

[0156] FIGS. 13A-13C show an air-operated pump system 1300 including the air-operated diaphragm pump 102 and the leak detector assembly 106 previously described in reference to FIGS. 1-12, but with a different arrangement of components. In FIGS.

[0157] 13B and 13C, the leak detector assembly 106 and the spring-loaded spool 210 are shown as fluid circuit views to illustrate the change in position of the spring-loaded spool 210 relative to the body 202 of the leak detector assembly 106 and the associated change in fluid flow paths. In the air-operated pump system 1300, the leak detector assembly 106 is fluidly positioned between the air supply system 120 and the air-operated diaphragm pump 102. The supply of motive air flow s through the ported void 510 controlled by the position of the spring-loaded spool 210 and the leak detector assembly 106 supplies the motive fluid to the motive fluid inlet 116 of the air-operated diaphragm pump 102. The motive fluid outlet 118 of the air-operated diaphragm pump 102 is coupled to the inlet 130 of the leak detector assembly 106. Leak detection operations and downstream isolation of the air-operated diaphragm pump 102 are performed as described in reference to FIGS. 2-12.

[0158] The air supply system 120 of air-operated pump system 1300 includes the pressure regulator 122, the pressure release valve 126, and the pressure release valve 126. The air supply system 120 of air-operated pump system 1300 includes a first conduit 1302 and a second conduit 1304. The first conduit 1302 and the second conduit 1304 conduct air betw een components of the air-operated pump system 1300.

[0159] The first conduit 1302 is coupled between the pressure regulator 122 and the third port 906. The first conduit 1302 flows the motive air from the pressure regulator 122 to the third port 906 of the leak detector assembly 106.

[0160] The second conduit 1304 is coupled between the fourth port 908 of the leak detector assembly 106 and a location 1306 upstream from the air-operated diaphragm pump 102. and the third port 906. The second conduit 1304 flows the motive air from the fourth port 908 of the leak detector assembly 106 to the air-operated diaphragm pump 102.Atorney Docket No.: 45770-0183WO1

[0161] The spring-loaded spool 210 is disposed within the ported void 510 and controls the flow of motive air through the ported void 510 from the third port 906 to the fourth port 908. When the spring-loaded spool 210 is in the open position 218, as shown in FIGS. 13A-13B, the motive air is free to flow from the pressure regulator 122 through the first conduit 1302 to the third port 906, through the ports 718 of the ported cylinder 706, along the channels 712 extending between the ported cylinder 706 and the ported cylinder 708, out the port 718 of the ported cylinder 708 to the fourth port 908. The air then flows from the fourth port 908 through the second conduit 1304 to the location 1306, where it is supplied to the air-operated diaphragm pump 102. The air-operated diaphragm pump 102 operates to move the process fluid, and the leak detector assembly 106 is online receiving the motive air.

[0162] When a leak of the process fluid into the motive air is detected by the leak detector assembly 106, the spring-loaded spool 210 is tripped and moves to the closed position 604, as shown in FIG. 13C, and the ported cylinders 706, 708 are no longer fluidly coupled to the channels 712, so the supply of motive air to the air-operated diaphragm pump 102 is interrupted and the air-operated diaphragm pump 102 is isolated upstream, by the leak detector assembly 106. The plunger 518 isolates the exhaust air flow path 302 as previously described. The air-operated diaphragm pump 102 is isolated both upstream and downstream by the leak detector assembly 106. The air supply is connected to the whistle 1404. The

[0163] FIG. 14 shows an air-operated pump system 1400 including the air-operated diaphragm pump 102, the normally closed pneumatic control valve 104, the leak detector assembly 106 previously described in reference to FIGS. 1-12, but with a different arrangement of components. Within the leak detector assembly 106, the various flow paths are shown schematically for clarity.

[0164] In the air-operated pump system 1400, the air supply system 120 supplies motive air to both the normally closed pneumatic control valve 104 and the ported void 510. The normally closed pneumatic control valve 104 supplies motive air to the air-operated diaphragm pump 102. The air-operated diaphragm pump 102 exhausts to the leak detector assembly 106 as described in reference to FIGS. 2-12. The exhaust flow path 302 and a closed path 1402 are shown in the schematic diagram of the leak detector assembly 106. The closed path 1402 illustrates schematically the plunger 518 sealing the valve seat 512. The spring-loaded spool 210 changes positions between the openAttorney Docket No.: 45770-0183WO1

[0165] position 218 and the closed position 604 and shifts between the exhaust flow path 302 and the closed path 1402.

[0166] The air supplied to the ported void 510 can either control the supply of pilot air back to the normally closed pneumatic control valve 104 or to the whistle 1404. When the spring-loaded spool 210 is in the open position 218, the pilot air supply flow path 1406 through the spring-loaded spool 210 is open, allowing motive air to flow through the ported void 510 to hold the normally closed pneumatic control valve 104 in the open position allowing motive air to flow to the air-operated diaphragm pump 102. When the spring-loaded spool 210 is in the closed position 604, the motive air through the ported void 510 to the normally closed pneumatic control valve 104 is blocked, and the motive air pathway 1408 to the whistle 1404 is open, audibly alerting the user to the leak.

[0167] The air-operated pump system 1400 includes a main air supply conduit 1410, a first air supply conduit 1412 branching from the main air supply conduit 1410, a second air supply conduit 1414 branching from the main air supply conduit 1410. The air supply system 120 supplies motive air to the first air supply conduit 1412 and the second air supply conduit 1414. The first air supply conduit 1412 flows motive air from the main air supply conduit 1410 to the normally closed pneumatic control valve 104.

[0168] The second air supply conduit 1414 flows motive air to the ported void 510 of the leak detector assembly 106. When the spring-loaded spool 210 is in the open position 218, the motive air flows through the third port 906 to the fourth port 908. The motive air continues to flow from the fourth port 908 through a third air supply conduit 1416 providing pilot air to the normally closed pneumatic control valve 104, maintaining the normally closed pneumatic control valve 104 in the open position. When the spring-loaded spool 210 shifts to the closed position 604, flow through the ported void 510 from the third port 906 to the fourth port 908 is blocked, but motive air is supplied to the whistle 1404, audibly alerting the user to the presence of a leak.

[0169] FIG. 15 shows an air-operated pump system 1500 including the air-operated diaphragm pump 102, the normally closed pneumatic control valve 104, the leak detector assembly 106 previously described in reference to FIGS. 1-12, but with a different arrangement of components. Within the leak detector assembly 106, the various flow paths are shown schematically for clarity. In the air-operated pump system 1500, the air supply is directed i) through the normally closed pneumatic control valve 104 to the air-operated diaphragm pump 102 and on to the leak detector assembly 106, ii) to the spring-Atorney Docket No.: 45770-0183WO1

[0170] loaded spool 210 to force and hold the plunger 518 open, and iii) to the ported void 510 for changing the flow of motive air between holding the normally closed pneumatic control valve 104 in the open position or removing the motive air holding the normally closed pneumatic control valve 104 in the open position and flowing air to the whistle 1404.

[0171] The air supply system 120 for the air-operated pump system 1500 includes a main air supply conduit 1502, a first air supply conduit 1504 branching from the main air supply conduit 1502, a second air supply conduit 1506 branching from the main air supply conduit 1502, and a third air supply conduit 1508 branching from the main air supply conduit 1502.

[0172] The air supply system 120 supplies motive air to the main air supply conduit 1502. The main air supply conduit 1502 supplies motive air to the first air supply conduit 1504, the second air supply conduit 1506, and the third air supply conduit 1508. The first air supply conduit 1504 is coupled between the main air supply conduit 1502 and the normally closed pneumatic control valve 104. The first air supply conduit 1504 supplies motive air to the normally closed pneumatic control valve 104. The second air supply conduit 1506 is coupled between the main air supply conduit 1502 and the spring-loaded spool 210. The ported void 510 flows air to the spring-loaded spool 210 to force the spring-loaded spool 210 into the open position 218.

[0173] When the spring-loaded spool 210 shifts to the closed position 604, flow through the ported void 510 from the third port 906 to the fourth port 908 is blocked, but motive air is supplied to the whistle 1404, audibly alerting the user to the presence of a leak.

[0174] Each of the systems 100. 1300, 1400, and 1500 can include a controller communicatively coupled, and / or operatively coupled to the air-operated diaphragm pump 102, the normally closed pneumatic control valve 104, the leak detector assembly 106, or any of the other components of the various systems. The controller can receive inputs representing various states of the components and operate the various components. Communication between any components may be wireless or wired. For example, the communications can be conducted using signals that may be sent such as by way of LAN, WAN, Bluetooth®, Zigbee®, cellular, token ring, WiFi, or any other suitable communications mode or protocol.

[0175] The controller may include one or more processors, storage, or memory for controlling the system components. Accordingly, aspects described in the presentAtorney Docket No.: 45770-0183WO1

[0176] disclosure may be embodied in any one or more of a system including hardware and / or software, software apart from hardware, or a method.

[0177] Although air-operated diaphragm pump 102 is described as an air-operated diaphragm pump, in other implementations, the air-operated diaphragm pump 102 may be any suitable type of air assisted (pneumatic) pump having a failure mode where process liquid can exit the process liquid pathway and enter the exhaust air flow path 302.

[0178] FIG. 16 shows a flow chart of an example method of detecting a leak in an air-operated pump according to the implementations of the present disclosure. At 1602, a leak is detected in the exhaust of the air-operated diaphragm pump. For example, as described in reference to FIGS. 4-6, process liquid can collect in the bowl 404 of the leak detector assembly 106, causing the float 406 to rise from the downward location 534 to the upward location 608.

[0179] At 1604. responsive to detecting the leak, in a single motion of a spring-loaded spool, the air-operated diaphragm pump is isolating both upstream and downstream of the air-operated diaphragm pump. For example, as described in reference to FIGS. 1-12, the spring-loaded spool 210 moves from the open position 218 to the closed position 604 in a single motion, closing the plunger 518 on the valve seat 512, stopping flow along the exhaust flow path 302 to the surrounding atmosphere 108 (i.e., sealing downstream of the air-operated diaphragm pump 102) and removing pilot air holding the normally closed pneumatic control valve 104 in the open position, causing the normally closed pneumatic control valve 104 to move to the closed position (i.e., sealing upstream of the air-operated diaphragm pump 102.

Claims

Atorney Docket No.: 45770-0183WO1WHAT IS CLAIMED:

1. An air-operated pump system comprising:an air-operated diaphragm pump;a normally closed pneumatic control valve configured to be positioned between an air source and the air-operated diaphragm pump; anda leak detector assembly coupled to an exhaust of the air-operated diaphragm pump, the leak detector assembly configured to control air flow through the air-operated diaphragm pump responsive to detecting a leak in the air-operated diaphragm pump, the leak detector assembly comprising:a float valve movable responsive to a change in a fluid level in the leak detector assembly; anda spring-loaded spool coupled to the float valve, the spring-loaded spool configured to, in a single motion, shut the normally closed pneumatic control valve and close an exhaust of the leak detector assembly responsive to the change in the fluid level of the leak detector assembly equal to or above a threshold level.

2. The air-operated pump system of claim 1, wherein the spring-loaded spool is configured to move between an open position allowing a flow of the exhaust through the leak detector assembly to a closed position preventing the flow of the exhaust through the leak detector assembly.

3. The air-operated pump system of claim 2, wherein moving the spring-loaded spool to the closed position prevents a flow of air out of the leak detector assembly, thereby isolating a downstream end of the air-operated diaphragm pump.

4. The air-operated pump system of claim 2, wherein the float valve is movable between a first position engaged to the spring-loaded spool and a second position disengaged from the spring-loaded spool, wherein when the float valve is in the second position disengaged from the spring-loaded spool, the spring-loaded spool is free to move.

5. The air-operated pump system of claim 4, wherein:the float valve comprises:a float;Atorney Docket No.: 45770-0183WO1a shaft having a first end and a second end, the first end coupled to the float; anda catch cylinder coupled to the second end, the catch cylinder comprising a relieved portion, the catch cylinder configured to rotate about a longitudinal axis of the catch cylinder; andthe spring-loaded spool comprises:a shaft; andrelieved portion on the shaft, the relieved portion of the spring-loaded spool configured to selectively engage the relieved portion of the catch cylinder responsive to the float valve moving between the first position and the second position.

6. The air-operated pump system of claim 5, wherein the spring-loaded spool further comprises a spring disposed around the shaft, the spring configured to bias the shaft to the closed position responsive to the float valve moving to the second position, the spring held in a compressed condition when the float valve is in the first position and the catch cylinder is engaged to the relieved portion of the shaft.

7. The air-operated pump system of claim 5. wherein the spring-loaded spool further comprises:a knob coupled to a first end of the shaft of the spring-loaded spool, the first end of the shaft extending outside a body defining an interior void of the leak detector assembly, wherein when the spring-loaded spool is in the second position and a user pulls on the knob, the spring-loaded spool moves from the second position to the first position, and responsive to the spring-loaded spool moving from the second position to the first position, the float valve moves from the second position to the first position and the catch cylinder reengages with the shaft.

8. The air-operated pump system of claim 5, wherein the spring-loaded spool further comprises a plunger coupled to a second end of the shaft, the second end of the shaft opposite the first end, wherein the plunger is configured to seal against an exhaust port of the leak detector assembly.

9. The air-operated pump system of claim 1, wherein the leak detector assembly further comprises a filter positioned a body of the leak detector assembly, the bodyAtorney Docket No.: 45770-0183WO1defining an interior void, the filter configured to remove a contaminant from the exhaust of the air-operated diaphragm pump.

10. The air-operated pump system of claim 1, wherein the leak detector assembly further comprises a partitioned structure positioned to receive the exhaust from the air-operated diaphragm pump, the partitioned structure configured to provide a tortuous flow path to the exhaust.

11. The air-operated pump system of claim 10, wherein the partitioned structure comprises:a cupped base;an upper section comprising a vertical wall extending from a middle portion of the cupped base, the vertical wall extending from an edge of the cupped base across a portion of a first length of the cupped base, the vertical wall positioned to receive the exhaust from the air-operated diaphragm pump from an inlet of the leak detector assembly on a first side of the vertical wall; anda plurality of voids extending through the cupped base, the plurality of voids positioned proximal a second side of the vertical wall, the second side of the vertical wall opposite the first side of the vertical wall.

12. The air-operated pump system of claim 2, wherein the normally closed pneumatic control valve is fluidly coupled to the air-operated diaphragm pump at an inlet of the air-operated diaphragm pump, and the leak detector assembly is configured to control a position of the normally closed pneumatic control valve responsive to detecting the leak in the air-operated diaphragm pump.

13. The air-operated pump system of claim 12, wherein the spring-loaded spool is further configured to, in the single motion, shut the normally closed pneumatic control valve responsive to the change in the fluid level of the leak detector assembly equal to or above the threshold level, thereby isolating an upstream end of the air-operated diaphragm pump.

14. The air-operated pump system of claim 12, wherein a supply of air is directed to both the air-operated diaphragm pump and the leak detector assembly, where the supply of air flows through the leak detector assembly to control a position of an isolation valveAtorney Docket No.: 45770-0183WO1at an inlet to the air-operated diaphragm pump and the leak detector assembly controls an air flow through the exhaust of the air-operated diaphragm pump.

15. The air-operated pump system of claim 12, wherein:when the spring-loaded spool is in the open position, a supply of air is free to flow i) through the normally closed pneumatic control valve to the air-operated diaphragm pump to the leak detector assembly, past the spring-loaded spool in the leak detector assembly, and out the exhaust of the leak detector assembly, and ii) from upstream of the normally closed pneumatic control valve to the leak detector assembly, past the spnng-loaded spool, and out the leak detector assembly to the normally closed pneumatic control valve, maintaining the normally closed pneumatic control valve in an open position; andwhen the spring-loaded spool is in the closed position, the spring-loaded spool i) prevents the supply of air from passing through the leak detector assembly and out the exhaust of the leak detector assembly, thereby isolating a downstream end of the air-operated diaphragm pump, and ii) prevents the supply of air from upstream of the normally closed pneumatic control valve through the leak detector assembly, thereby allowing the normally closed pneumatic control valve to move from an open position to a closed position, thereby isolating an upstream end of the air-operated diaphragm pump.

16. The air-operated pump system of claim 2, wherein:when the spring-loaded spool is in the open position, a supply of air is free to flow from the air source to the leak detector assembly, past the spring-loaded spool, and out the leak detector assembly to an upstream end of the air-operated diaphragm pump; andwhen the spring-loaded spool is in the closed position, the spring-loaded spool prevents the supply of air from passing through the leak detector assembly, thereby isolating an upstream end of the air-operated diaphragm pump.

17. The air-operated pump system of claim 1, wherein the leak detector assembly comprises a user alert flow port, and the spring-loaded spool is further configured to control a supply to air through the user alert flow port to a user alert device when the spring-loaded spool is in the closed position.Atorney Docket No.: 45770-0183WO118. A leak detector assembly configured to detect a leak in an air-operated diaphragm pump, the leak detector assembly comprising:a housing configured to couple to an air exhaust of the air-operated diaphragm pump, the housing defining an air exhaust flow path from the air exhaust of the air-operated diaphragm pump to an atmosphere; anda spring-loaded spool positioned in the air exhaust flow path, the spring-loaded spool operable, in a single motion responsive to a change in a fluid level of the leak detector assembly equal to or above a threshold level, to move between an open position allowing air to flow along the air exhaust flow path and a closed position i) preventing air to flow along the air exhaust flow path, thereby isolating a downstream end of the air-operated diaphragm pump and ii) directing air to shut an isolation valve upstream of the air-operated diaphragm pump, thereby isolating an upstream end of the air-operated diaphragm pump.

19. The leak detector assembly of claim 18, further comprising a float valve positioned in the air exhaust How path upstream from the spring-loaded spool, the float valve movable responsive to the change in the fluid level in the leak detector assembly, the float valve movable between a first position engaged to the spring-loaded spool and a second position disengaged from the spring-loaded spool, wherein when in the float valve is in the second position disengaged from the spring-loaded spool, the spring-loaded spool is free to move from the open position to the closed position.

20. A method comprising:detecting a leak in an exhaust of an air-operated diaphragm pump; and responsive to detecting the leak, in a single motion of a spring-loaded spool, isolating the air-operated diaphragm pump both upstream and downstream of the air-operated diaphragm pump.

21. An air-operated pump system comprising:an air-operated diaphragm pump comprising:a process fluid pathway extending between a process fluid inlet and a process fluid outlet; andAtorney Docket No.: 45770-0183WO1a motive fluid pathway separate from the process fluid pathway, the motive fluid pathway extending between a motive fluid inlet and a motive fluid outlet; anda leak detector assembly fluidly coupled to the motive fluid inlet and the motive fluid outlet, the leak detector assembly configured to control motive fluid flow to and from the motive fluid inlet and the motive fluid outlet, respectively, responsive to detecting a leak from the process fluid pathway to the motive fluid pathway, the leak detector assembly comprising:a float valve movable responsive to a change in a fluid level in the leak detector assembly; anda spring-loaded spool coupled to the float valve, the spring-loaded spool configured to, in a single motion, responsive to the change in the fluid level of the leak detector assembly equal to or above a threshold level, isolate the motive fluid flow through the leak detector assembly to the motive fluid inlet of the air- operated diaphragm pump and isolate the motive fluid flow from the motive fluid outlet of the air-operated diaphragm pump.

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