Pipe-Mounted Acoustic Sensing for Passing Valve Detection
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Solution Overview
Problem
Passing valves in oil and gas plants cause costly environmental hazards and business losses due to unintentional gas leaks, which are often a result of human error or valve degradation, and existing detection methods are inadequate.
Innovation Solution
A sensor device with a piezoelectric sensor and onboard computer system is attached to pipes to detect acoustic emissions from valves, using machine learning to identify passing valves and provide real-time alerts without relying on cloud or network transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If data is transmitted to cloud or network server for processing, then processing capability is improved, but data security deteriorates
Solution Approach 1:
The sensor device integrates both sensing capabilities and edge computing capabilities into a single unit. The onboard processor can independently analyze sensor data and generate alerts without requiring cloud connectivity, while still maintaining the option to transmit data when needed. This multi-functionality resolves the contradiction by providing both local processing (for security) and cloud connectivity (for enhanced processing capability when available).
Solution Approach 2:
The system architecture is segmented into edge computing components (onboard processor) and cloud computing components (remote server). The edge segment handles critical real-time processing locally to ensure data security and immediate response, while the cloud segment provides supplementary processing power for non-critical analysis and historical data storage. This segmentation allows the system to maintain data security while still leveraging cloud processing capabilities when appropriate.
2Measurement precision
If sensor device is placed inside pipe for direct detection, then detection accuracy is improved, but device complexity and installation difficulty worsen
Solution Approach 1:
The pipe wall serves as an intermediary medium that transmits acoustic emissions from the valve to the external sensor. Instead of placing the sensor inside the pipe, the system uses the pipe wall as a natural transmission path for acoustic waves. This approach maintains detection accuracy by capturing valve acoustic emissions through the pipe wall while avoiding the complexity of internal pipe sensor installation. The sensor is positioned externally against the pipe wall, eliminating the need for pipe disassembly or internal mounting structures.
3Power
If conventional wireless networks are used for data transmission, then communication capability is improved, but transmission range deteriorates
Solution Approach 1:
The communication system is designed to dynamically adapt between different transmission modes based on environmental conditions and distance requirements. The device can switch between conventional wireless networks for short-range high-bandwidth communication and long-range low-power transmission modes for extended distance communication. This dynamic capability allows the system to maintain effective communication across varying distances and network availability conditions, resolving the contradiction between communication capability and transmission range.
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
The sensor device effectively detects passing valves on the edge, enhancing data security and reducing environmental and financial losses by enabling early mitigation of leaks, with energy harvesting and adaptable design for various pipe sizes.
Implementation Method 1
A piezoelectric sensor can be positioned in the housing and configured to detect acoustic emissions from a valve in the pipe system
Implementation Method 2
A spring can be positioned around a portion of the sensor holder to bias the sensor holder away from the cover plate and toward the first side of the housing
Data Source
AI summary
Systems and methods include a sensor device for detecting passing valves. The sensor device includes a housing including a first side configured to contact a wall of a pipe in a pipe system. A cover plate is coupled to a second side of the housing opposite the first side. A piezoelectric sensor is disposed in the housing and configured to detect acoustic emissions from a valve in the pipe system. A sensor holder is disposed within the housing to maintain a position of the piezoelectric sensor. A spring is positioned around a portion of the sensor holder and configured to bias the sensor holder away from the cover plate and toward the first side of the housing. A computer system is mounted to the housing and configured to determine that a valve is a passing valve based on acoustic emissions detected by the piezoelectric sensor.