Inline Cycle Fuse for Pressure Vessel Fatigue Warning
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Solution Overview
Problem
Pressure vessels have limited lifetimes due to cyclic and static fatigue, and existing methods for predicting failure are uncertain and lack understanding of the interaction between these fatigue types, especially in applications with inconsistent pressure ranges and cycles.
Innovation Solution
A system with a fuse-like apparatus is introduced, where a conduit with a predetermined weakness fails at a calibrated point to indicate impending pressure vessel failure, using sensors and a controller to detect changes in physical properties within a containment cavity, allowing for preemptive removal from service.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mathematical projections and cycle counting are used to evaluate fatigue life, then an estimate of remaining vessel life can be obtained, but uncertainties inherent in calculation and estimation make the prediction unreliable
Solution Approach 1:
The fuse is pre-calibrated to fail at a predetermined number of cycles or pressure threshold before the pressure vessel reaches its failure point. This preliminary action creates a known reference point that eliminates uncertainty in predicting vessel fatigue life, as the fuse failure directly indicates when the vessel should be removed from service.
Solution Approach 2:
The fuse acts as an intermediary component between the pressure vessel and the operator. It translates complex fatigue cycle calculations into a simple, observable failure event (fuse rupture), eliminating the need for operators to interpret uncertain mathematical projections and cycle counts.
2Productivity
If the pressure vessel is operated beyond estimated fatigue life, then productivity is improved, but the risk of catastrophic failure increases
Solution Approach 1:
The fuse is pre-set to fail at a safe threshold before catastrophic vessel failure occurs. This allows the vessel to be operated for maximum productive time while ensuring that the fuse will provide early warning, enabling planned maintenance before dangerous conditions develop.
Solution Approach 2:
The fuse is designed as a sacrificial, disposable component that fails in place of the expensive pressure vessel. By using a low-cost fuse that can be replaced, the system enables continuous productivity while protecting against catastrophic vessel failure, as the fuse absorbs the fatigue damage instead of the vessel.
3Reliability
If a supplemental pressure vessel is used as a failure indicator, then the primary vessel can be protected from catastrophic failure, but the system complexity increases
Solution Approach 1:
The failure indicator function is extracted from the primary pressure vessel and implemented as a separate fuse component in the fluid line. This simplifies the overall system compared to using a supplemental vessel, as the fuse is a much simpler device that requires no additional pressure containment or complex integration with the primary vessel systems.
Solution Approach 2:
Instead of using a full supplemental pressure vessel to indicate failure, the invention uses a simplified fuse that copies only the essential function of indicating fatigue failure. The fuse replicates the failure indication capability without the complexity of a complete pressure vessel system, providing the same safety function with minimal complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system effectively predicts pressure vessel failure by calibrating the conduit to fail before the vessel does, triggering alarms and safely venting fluid, thereby preventing catastrophic failures and allowing for timely removal from service.
Implementation Method 1
the conduit wall fails at the weakness to permit the fluid to flow from the interior of the pipe into the cavity of the containment structure
Implementation Method 2
the conduit wall that is exposed to pressure cycling of the pressure vessel
Data Source
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AI summary
A system (10) and method of predicting impending failure of a pressure vessel (12) include a pressure vessel (12), a fluid source (16), a line (14) coupled to the pressure vessel (12) and to the fluid source (16), an apparatus (18), a sensor (24) and a controller (26). The apparatus (18) includes a conduit (36) and a containment structure (40). The containment structure (40) includes a cavity (38) separated from an interior of the conduit (36) by a portion of a conduit wall (44) of the conduit (36). The sensor (24) is configured to determine a value of a physical property in the cavity (38). The controller (26) is in signal communication with the sensor (24) and configured to detect a change in the value. The method includes determining a first value of a physical property in the cavity (38), experiencing a failure of the conduit wall (44), determining a second value of the physical property in the cavity (38), and detecting a difference between the first and second values.