Compressed Gas Leak Detection via Flow Variance Analysis
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Solution Overview
Problem
Accurately detecting leaks in compressed gas systems is challenging due to the lack of visible indicators and the potential for small leaks to go unnoticed, leading to energy loss over time, with current methods requiring expensive manual ultrasonic inspections.
Innovation Solution
A monitoring system utilizing a wireless sensor network that measures gas flow through a series of sensors, processing data to identify leaks by averaging minimum gas flow measurements over time windows and validating results through variance analysis, allowing for the detection and localization of leaks within a compressed gas system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual ultrasonic inspections are used to detect leaks, then detection accuracy is improved, but cost increases
Solution Approach 1:
The system enables automated leak detection using existing flow sensors and processors that continuously monitor gas flow without requiring manual inspection. The leak detection processor automatically analyzes flow data, identifies leak patterns, and generates reports, making the system self-monitoring and eliminating the need for expensive manual ultrasonic inspections.
Solution Approach 2:
The patent replaces manual ultrasonic inspection methods with an automated electronic system that uses flow sensor data and computational analysis. The system substitutes human-operated mechanical ultrasonic detectors with electronic sensors and software-based leak detection algorithms that continuously process flow measurements to identify leaks.
2Loss of energy
If existing flow sensors are utilized for leak detection, then cost is reduced, but detection capability is improved
Solution Approach 1:
The system makes existing flow sensors serve dual purposes: their original function for monitoring gas flow and an additional function for leak detection. By repurposing the flow sensors and their data processing capabilities, the system eliminates the need for separate dedicated leak detection sensors, reducing costs while maintaining detection effectiveness.
Solution Approach 2:
The leak detection processor acts as an intermediary that transforms regular flow measurement data into leak detection information. It processes the flow data from existing sensors, applies leak detection algorithms, and generates leak alerts, thereby enabling leak detection capability through data processing rather than through dedicated detection hardware.
3Measurement precision
If continuous monitoring is implemented, then leak detection accuracy is improved, but system complexity increases
Solution Approach 1:
The system combines leak detection functionality with the existing flow monitoring infrastructure. The leak detection processor is integrated with the same sensors and communication networks used for flow monitoring, merging multiple functions into a unified system that reduces overall complexity despite providing continuous monitoring capabilities.
Solution Approach 2:
The system performs preliminary processing of flow data to identify leak conditions before they become significant problems. By continuously analyzing flow patterns and comparing them against established leak signatures, the system proactively detects leaks early, improving detection accuracy without requiring complex real-time intervention systems.
Data Source
AI summary
A monitoring system for a facility can automatically determine the presence of leaks in a compressed gas system at the facility. The monitoring system can use information from sensors in the compressed gas system to determine if there is a constant flow of gas in the system that can be indicative of a leak in the system. The monitoring system can process flow measurements from the sensors to determine minimum gas flow amounts for a series of time windows. The minimum gas flow amounts are then averaged to generate an average minimum gas flow amount. If the average minimum gas flow amount is greater than an average threshold, a variance of the minimum gas flow amounts can be determined. If the determined variance is less than a variance threshold, the average minimum gas flow amount is determined to correspond to a leak in the compressed gas system.