Tank Jacket Leak Testing During Production Operation
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Solution Overview
Problem
Current liquid tank jacket testing methods require tanks to be taken out of service for hours or days, are time-consuming, and pose risks of undetected cracks leading to contamination or loss of cooling water due to health and safety regulations.
Innovation Solution
A testing apparatus with a controller and supply system delivers liquid at pressure above atmospheric to the jacket, monitoring parameters like pressure and conductivity to detect leaks in the tank and jacket walls, allowing continuous testing without removing the tank from service.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hydraulic pressure testing is used to detect cracks in the jacket, then crack detection capability is improved, but the tank must be taken out of service for extended periods and the testing process becomes time-consuming
Solution Approach 1:
The patent replaces traditional mechanical hydraulic pressure testing with an automated electronic testing system that uses sensors, controllers, and digital processing to monitor pressure differentials and detect leaks, thereby reducing manual intervention and testing time while maintaining detection capability
Solution Approach 2:
The testing system is designed to automatically perform crack detection without requiring the tank to be taken out of service, using self-contained sensors and controllers that can operate while the tank remains in its normal environment, enabling continuous operation during testing
2Reliability
If the tank is taken out of service for annual crack testing, then crack detection is performed, but the tank becomes vulnerable to undetected cracks appearing between tests and requires extensive cleaning and disconnection procedures
Solution Approach 1:
The system performs crack detection as a preliminary routine operation that can be conducted frequently without taking the tank out of service, preventing the development of undetected cracks rather than relying on annual inspections
Solution Approach 2:
The testing apparatus is designed to be integrated with the existing tank system, using the same liquid medium and pressure mechanisms already present in the tank's operation, thereby eliminating the need for separate testing procedures and reducing complexity
3Reliability
If hydraulic pressure testing is performed to detect cracks, then leak detection capability is improved, but skilled personnel are required and health and safety regulations increase testing time
Solution Approach 1:
The patent replaces manual hydraulic pressure testing performed by skilled personnel with an automated electronic system that uses pressure sensors, flow meters, and digital controllers to automatically detect leaks, thereby simplifying operation while maintaining detection capability
Solution Approach 2:
The system incorporates continuous feedback through sensors that monitor pressure differentials and flow rates, with the controller automatically processing this data to detect leaks and alert operators, eliminating the need for skilled personnel interpretation and reducing operation 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
The apparatus quickly and automatically detects leaks in the tank jacket, reducing the risk of contamination and loss of cooling water by continuously monitoring tank integrity during operation, while requiring minimal human intervention.
Implementation Method 1
delivering liquid at pressure above atmospheric to the jacket
Implementation Method 2
monitoring a parameter of the jacket to detect if there is a leak from the tank into the jacket
Data Source
AI summary
A testing apparatus is for a tank with a jacket having an internal wall shared with the tank and an external wall. The testing apparatus has an automated controller to perform tests even during use of the tanks in a production environment. There is supply system for delivering liquid at pressure above atmospheric to the jacket. The controller detects when the tank is filled to a level above the tank jacket height to create a higher pressure in the tank than is in the jacket. The controller monitors a parameter of the jacket to detect if there is a leak from the tank into the jacket. The parameter may be jacket pressure, arising after sealing the jacket, of flow via a venting valve as detected by a flow meter. A second test can be carried out irrespective of the level in the tank, be pressurising the jacket and monitoring it for a drop in pressure.