Dry-Break Coupling for Process Instrument Replacement Under Pressure
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Solution Overview
Problem
Current process measuring assemblies, such as diaphragm seal and isolation ring assemblies, face inefficiencies in replacing and installing measurement instruments under pressure without fluid loss or air inclusion, leading to potential accuracy errors and seal damage.
Innovation Solution
The implementation of dry-break couplings that allow for the removal and replacement of measurement instruments while the process is under pressure, with the new instrument pre-filled and pre-charged to the same pressure level as the previous one, minimizing fluid loss and ensuring accurate pressure measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If measurement instruments are replaced while the process operates under pressure using conventional methods, then the process can continue without shutdown, but fluid loss and air inclusion occur leading to accuracy errors and seal damage
Solution Approach 1:
A coupling device acts as an intermediary between the process line and the measurement instrument. The coupling includes a process connection that remains sealed to the pressurized line and an instrument connection that can be detached. This intermediary mechanism allows the instrument to be replaced without directly breaking the seal with the pressurized process line, thereby preventing fluid loss and air inclusion while enabling continuous operation.
Solution Approach 2:
The system is segmented into three distinct parts: the process line, the coupling device, and the measurement instrument. The coupling device itself is segmented into a process connection portion and an instrument connection portion. This segmentation allows the instrument portion to be independently replaced while the process connection remains sealed, resolving the contradiction between continuous operation and measurement accuracy.
2Ease of repair
If measurement instruments are removed from the measuring assembly under pressure, then instrument replacement is enabled, but substantial loss of fill or sensing fluid/media occurs
Solution Approach 1:
The coupling device serves as an intermediary that isolates the sensing fluid within the process line from the instrument being replaced. The process connection of the coupling remains sealed to the pressurized line containing the sensing fluid, while the instrument connection allows the instrument to be detached. This prevents sensing fluid loss during instrument replacement while maintaining ease of repair.
3Productivity
If measurement instruments are replaced without pre-filling and pre-charging, then replacement speed increases, but accuracy errors occur due to pressure differences
Solution Approach 1:
The replacement instrument is pre-filled with the appropriate sensing fluid and pre-charged to the process pressure before being connected to the coupling device. This preliminary action ensures that when the instrument is quickly connected, there are no pressure differences that would cause fluid loss, air inclusion, or measurement inaccuracies. The pre-charging step is performed offline, so it does not slow down the actual replacement operation.
4Device complexity
If conventional instrument replacement methods are used, then simple equipment is required, but seal damage and air inclusion occur
Solution Approach 1:
The coupling device acts as a protective intermediary that prevents direct exposure of the process line seal to the instrument removal/attachment process. The process connection remains permanently sealed to the line, while the instrument connection handles the mechanical stresses of instrument replacement. This intermediary mechanism protects the seal from damage and prevents air inclusion without requiring complex additional equipment.
Data Source
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AI summary
The present disclosure provides improved process measurement assemblies and methods for replacing/installing devices/instruments (e.g., gauges, digital gauges, transducers, switches, etc.) associated with process measurement assemblies. More particularly, the present disclosure provides improved process measurement assemblies (e.g., diaphragm seal assemblies or isolation ring assemblies) having couplings (e.g., dry-break couplings) that allow a user to replace and/or install process measurement instruments/devices to and/or from the process measurement assemblies, and related methods of use. In general, the present disclosure provides for improved systems/methods for installing or replacing a process measurement instrument to and/or from process measurement assemblies (e.g., diaphragm seal assemblies or isolation ring assemblies). In exemplary embodiments, the present disclosure provides for a system/method for installing/replacing a process measurement instrument wherein the process operating under pressure is a flow stream process, the flow stream process having a solids content.