Portable Pressure Testing Module for Pipeline Field Sites
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Solution Overview
Problem
Existing methods for pressure testing of pressurized fluid-containing vessels in field conditions are prone to operator errors due to manual operations and lack of integration among individual components, which can compromise test results and safety.
Innovation Solution
A portable pressure testing system with a housing containing a supply port, conduit, valve, pressure sensor, flow meter, and processor that automates the pressure operation, records data, and outputs a report, enabling remote operation and reducing operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operations are used for pressure testing, then operators can directly control the testing process, but operator errors increase and test reliability decreases
Solution Approach 1:
The system enables self-service operation where the automated control unit independently manages the pressure testing process based on pre-programmed protocols. The control unit automatically operates valves, monitors sensors, and records data without requiring continuous manual intervention, thereby eliminating operator errors while maintaining full control over the testing procedure.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated electronic control system. The automated control unit uses electronic signals to operate pneumatic or electric valves, replace manual gauge readings with electronic pressure and temperature sensors, and substitute manual data recording with automated digital data acquisition and processing systems.
2Reliability
If individual components are used for pressure testing, then device complexity is reduced, but component integration and communication fail
Solution Approach 1:
The patent merges multiple independent testing components into a single integrated automated pressure testing system. The control unit consolidates valve control, sensor data acquisition, data processing, and result generation into one unified system. This integration ensures reliable communication between components through standardized interfaces and protocols, eliminating the communication failures that occur with separate independent components.
Solution Approach 2:
The automated control unit serves multiple functions within a single device: it controls valve operations, monitors pressure and temperature sensors, processes test data, generates reports, and manages the overall testing sequence. This multi-functionality reduces the need for multiple separate components while maintaining reliable integrated operation through a universal control platform.
3Object-affected harmful factors
If operators are required onsite for manual operations, then direct control is possible, but safety hazards increase due to operator exposure
Solution Approach 1:
The system performs pressure testing operations autonomously without requiring operators to be physically present onsite during the testing process. The automated control unit independently executes test sequences, monitors system parameters, and manages safety protocols, thereby eliminating operator exposure to potential hazards while maintaining full operational control through remote or automated management.
4Productivity
If manual data compilation is performed, then flexibility in handling test results is maintained, but time consumption and error potential increase
Solution Approach 1:
The patent replaces manual data compilation and analysis with automated electronic data processing. Sensors continuously acquire test data during the pressure testing process, and the automated control unit immediately processes this data according to pre-programmed algorithms. Results are automatically generated and reported, eliminating the time-consuming manual data transcription, calculation, and analysis processes while reducing errors associated with manual operations.
Data Source
AI summary
A system and method enable pressure testing a specimen with a portable module for deployment to a field site of the specimen, such as a pipeline. The module includes a processor capable of controlling various devices, such as valves and pumps, and recording sensed data from multiple sources, such as pressure/temperature/flow sensors, cameras and weather feed. The processor may receive input operation specifications for execution to perform the testing with limited human interaction through pressurization, hold and depressurization phases of the testing. The module includes safety features that may avoid over pressurization, require operator identifiers or initiate interlock protocols upon the processor detecting an anomaly. The processor then outputs notifications and reports of desired parameters from the test.