Rotating Equipment Sensor Placement for Early Valve Temperature Detection
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Solution Overview
Problem
Equipment in chemical and petrochemical plants, such as compressors and turbines, face issues like surge, bearing and seal failures, and contamination, leading to efficiency decreases and potential damage, which existing technologies struggle to address effectively.
Innovation Solution
A system comprising sensors, a data collection platform, and a data analysis platform that monitors equipment performance, detects issues like temperature increases downstream of valves, and automatically adjusts valve operation to prevent damage and maintain efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional monitoring methods are used for compressor valves, then equipment reliability is maintained, but temperature increases downstream of valves are not detected in time leading to potential damage
Solution Approach 1:
The patent places temperature sensors downstream of compressor valves to detect temperature increases before they cause equipment damage. This preliminary detection allows the system to identify valve issues early and take corrective action before catastrophic failure occurs, resolving the contradiction between maintaining reliability and detecting temperature increases in time.
2Productivity
If manual monitoring and adjustment of valve operation is performed, then equipment complexity is reduced, but productivity and efficiency decrease due to delayed response to operational issues
Solution Approach 1:
The patent implements an automated monitoring system with temperature sensors that continuously monitor downstream temperatures and provide feedback to the control system. When abnormal temperature increases are detected, the system automatically adjusts valve operation or triggers alerts, enabling rapid response to operational issues and maintaining high productivity without requiring manual intervention.
Solution Approach 2:
The monitoring system is designed to automatically detect temperature anomalies and trigger corrective actions without requiring constant manual oversight. The system serves itself by autonomously identifying problems and initiating responses, which maintains equipment efficiency while reducing the need for complex manual monitoring procedures.
3Duration of action of stationary object
If no automated re-seating mechanism is implemented, then device complexity is minimized, but equipment lifespan decreases due to undetected valve issues leading to failure
Solution Approach 1:
The system performs preliminary detection of temperature increases that indicate valve seating issues. By detecting these problems early through downstream temperature monitoring, the system can trigger automated re-seating commands before the valve failure progresses to catastrophic breakdown, thereby extending equipment lifespan.
Solution Approach 2:
The automated re-seating mechanism uses temperature feedback from downstream sensors to determine when valve adjustment is needed. When abnormal temperature patterns are detected, the system automatically commands the valve to re-seat, creating a closed-loop control system that prevents failure and extends equipment life without requiring complex manual intervention protocols.
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 system effectively prevents equipment damage, maintains efficiency, and extends the lifespan of compressors and turbines by automatically addressing operational issues before they lead to failure.
Implementation Method 1
one or more temperature sensors downstream of the valves
Data Source
AI summary
A plant or refinery may include equipment such as condensers, regenerators, distillation columns, rotating equipment, compressors, pumps, turbines, or the like. Different operating methods may impact deterioration in equipment condition, thereby prolonging equipment life, extending production operating time, or providing other benefits. Mechanical or digital sensors may be used for monitoring equipment to determine whether problems are developing. For example, sensors may be used in conjunction with one or more system components to perform invariant mapping, monitor system operating characteristics, and/or predict pressure, volume, surges, reactor loop fouling, gas quality, or the like. An operating condition (e.g., of one or more pieces of equipment in the plant or refinery) may be adjusted to prolong equipment life or avoid equipment failure.