U.S. patent application number 14/253572 was filed with the patent office on 2014-10-16 for method and apparatus for deactivating a hydraulic device that is leaking hydraulic oil.
This patent application is currently assigned to GULFSTREAM SERVICES, INC.. The applicant listed for this patent is GULFSTREAM SERVICES, INC.. Invention is credited to Joey NAQUIN.
Application Number | 20140305508 14/253572 |
Document ID | / |
Family ID | 51685943 |
Filed Date | 2014-10-16 |
United States Patent
Application |
20140305508 |
Kind Code |
A1 |
NAQUIN; Joey |
October 16, 2014 |
METHOD AND APPARATUS FOR DEACTIVATING A HYDRAULIC DEVICE THAT IS
LEAKING HYDRAULIC OIL
Abstract
A method of deactivating an underwater hydraulic device provides
a hydraulic device that is capable of being operated under water,
the device having a hydraulic cylinder with a pushrod and a piston.
The device is lowered below a water surface with a hose reel that
is located at the water surface area such as on a marine vessel.
The hose reel includes first and second hydraulic hoses that
connect to the cylinder on opposing sides of the piston. Fluid flow
in the first and second hydraulic hoses is continuously monitored.
The ratio of the volume of fluid flowing into the cylinder from one
side of the piston to the volume of fluid flowing into the cylinder
from the other side of the piston is continuously calculated with a
computer or controller. The hydraulic device is deactivated if the
ratio varies from a preset value. One embodiment includes a
plurality of flow meters for measuring fluid flow to and from one
or more hydraulically powered apparatuses. In one embodiment
outputs of the flow meters are analyzed to determine if the
hydraulic system has a leak, and if a leak is detected, a warning
is issued and/or one or more of the connected hydraulically powered
apparatuses are shut down, and/or the hydraulic power supply is
shut down. In one embodiment, the flow lines are jointed flow lines
comprised of hose joints connected end to end. Some or all of the
hoses have check valves. In one embodiment, the check valves stop
flow in either direction if the flow pressure drops below a
selected pressure.
Inventors: |
NAQUIN; Joey; (Houma,
LA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GULFSTREAM SERVICES, INC. |
Houma |
LA |
US |
|
|
Assignee: |
GULFSTREAM SERVICES, INC.
Houma
LA
|
Family ID: |
51685943 |
Appl. No.: |
14/253572 |
Filed: |
April 15, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61812618 |
Apr 16, 2013 |
|
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|
Current U.S.
Class: |
137/12 ;
137/455 |
Current CPC
Class: |
F04B 49/02 20130101;
Y10T 137/0379 20150401; F04B 47/02 20130101; F04B 49/10 20130101;
Y10T 137/7722 20150401 |
Class at
Publication: |
137/12 ;
137/455 |
International
Class: |
F04B 49/10 20060101
F04B049/10 |
Claims
1. A method of deactivating an underwater hydraulic device,
comprising the steps of: a) providing a hydraulic device that is
capable of being operated under water, the device having a
hydraulic cylinder with a pushrod and a piston; b) lowering the
device below a water surface with a hose reel that is located at
the water surface area; c) wherein the hose reel of step "b"
includes first and second hydraulic hoses that connect to the
cylinder on opposing sides of the piston; d) intermittently
monitoring fluid flow in the first and second hydraulic hoses; e)
calculating the ratio of the volume of fluid flowing into the
cylinder from one side of the piston to the volume of fluid flowing
into the cylinder from the other side of the piston; f)
deactivating the hydraulic device if the ratio varies from a preset
ratio or preset value; and g) wherein the hoses are a plurality of
joints, wherein a plurality of said joints house a check valve.
2. The method of claim 1 wherein the device is a hydraulic
shear.
3. The method of claim 1 wherein the flow is measured with first
and second flow meters in step "d", one flow meter monitoring fluid
flow in the first hydraulic hose, the other flow meter monitoring
flow in the second hydraulic hose.
4. The method of claim 1 wherein the hydraulic device receives
hydraulic fluid under pressure from a prime mover and hydraulic
pump assembly and in step "f", the prime mover and pump assembly is
deactivated.
5. The method of claim 4 wherein the prime mover is
deactivated.
6. The method of claim 5 wherein the prime mover includes an engine
and in step "f" the engine is shut off.
7. The method of claim 3 wherein a controller continuously monitors
flow in the flow meters and continuously calculates the ratio of
step "e".
8. The method of claim 7 further comprising providing a selector
switch having multiple selectable switch positions and wherein the
ratio of step "e" can be varied by selecting a different position
of the selector switch.
9. The method of claim 8 wherein the computer uses a different
ratio depending upon which switch position is selected and the
dimensions of the cylinder and pushrod of the selected device.
10. The method of claim 1 wherein the volumes of step "e" are
automatically calculated after step "d".
11. A method of deactivating a hydraulic device, comprising the
steps of: a) providing a hydraulic device having a cylinder with a
pushrod and a piston, the device receiving flow from a jointed flow
line; b) wherein the flow line of step "a" includes first and
second hydraulic jointed hoses that connect to the cylinder on
opposing sides of the piston; c) intermittently monitoring fluid
flow in the first and second hydraulic hoses; d) continuously
comparing the volume of fluid that enters a pushrod retraction
chamber section of the cylinder with a pushrod extension section of
the cylinder; e) deactivating the hydraulic device if the ratio
varies from a preset value; and f) wherein the hoses are a
plurality of hose joints, wherein a plurality of said hose joints
are connected together end to end with connectors that each house a
check valve.
12. The method of claim 11 wherein the flow is measured with first
and second flow meters in step "c", one flow meter monitoring fluid
flow in the first hydraulic hose, the other flow meter monitoring
flow in the second hydraulic hose.
13. The method of claim 11 wherein the hydraulic device receives
hydraulic fluid under pressure from a prime mover and hydraulic
pump assembly and in step "e", the prime mover and pump assembly is
deactivated.
14. The method of claim 13 wherein the prime mover is an engine and
in step "e" the engine is shut off.
15. The method of claim 12 wherein a controller continuously
monitors flow in the flow meters and continuously calculates the
ratio of step "d".
16. The method of claim 11 further comprising providing a selector
switch having multiple selectable switch positions and wherein the
ratio of step "e" can be varied by selecting a different position
of the selector switch.
17. A hydraulic leak detection apparatus, comprising: a) a
hydraulic device that is operated with a prime mover, pump, and
hydraulic cylinder having a cylinder, a pushrod, and a piston; b)
the cylinder having a first chamber that is receptive of hydraulic
fluid when extending the pushrod and a second chamber that is
receptive of hydraulic fluid when retracting the pushrod; c) a
first hydraulic flow line that supplies hydraulic fluid to the
first chamber; d) a second hydraulic flow line that supplies
hydraulic fluid to the second chamber; e) at least one of said flow
lines being comprised of separate lengths of hose connected end to
end; f) a computer that continuously monitors the ratio of the
volume of fluid entering the first chamber to the volume of fluid
entering the second chamber; g) the computer operatively connected
to the prime mover so that the computer can deactivate the prime
mover when the ratio varies from a preset acceptable value of said
ratio; and h) at least one of the hydraulic flow lines being
comprised of a plurality of hose joints that are joined together
with connectors that each contain a check valve.
18. The apparatus of claim 17 wherein the hydraulic device is a
power tong.
19. The apparatus of claim 17 wherein each of said first and second
flow lines has a flow meter interfaced with said computer so that
the flow meters continuously transmit flow data to the
computer.
20. The apparatus of claim 17 further comprising a selector switch
that enables the computer to compare the said ratio with a selected
one of a plurality of ratios, each ratio of the plurality of ratios
corresponding to different hydraulic cylinder configurations.
21. The apparatus of claim 17 further comprising a selector switch
that enables the computer to compare the said ratio with a selected
one of a plurality of ratios, each ratio of the plurality of ratios
corresponding to different hydraulic cylinder dimensions.
22. The apparatus of claim 17 wherein the computer is programmable
to designate any ratio as the acceptable value.
23. The method of claim 17 wherein the acceptable value is a
range.
24. The apparatus of claim 22 wherein the acceptable value is a
range.
25. The apparatus of claim 17 further comprising a hose reel that
enables the device to be lowered to a sea bed area.
26. The apparatus of claim 25 wherein multiple hydraulic flow lines
are part of the hose reel.
27. The apparatus of claim 25 wherein each of said first and second
hydraulic hoses has a flow meter interfaced with a computer or
controller so that the flow meters continuously transmit flow data
to the computer.
28. The apparatus of claim 27 wherein each flow meter is in a said
hydraulic hose in between the hose reel and the device.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority of U.S. Provisional Patent Application Ser. No.
61/812,618, filed 16 Apr. 2013, which is hereby incorporated herein
by reference, is hereby claimed.
[0002] Incorporated herein by reference are U.S. patent application
Ser. No. 13/741,074, filed 14 Jan. 2013, International Patent
Application No. PCT/US2013/021457, filed 14 Jan. 2013, U.S.
Provisional Patent Application Ser. No. 61/586,530, filed 13 Jan.
2012, and U.S. Provisional Patent Application Ser. No. 61/727,324,
filed 16 Nov. 2012.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not applicable
REFERENCE TO A "MICROFICHE APPENDIX"
[0004] Not applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to devices for controlling a
flow line that has ruptured or that is leaking. More particularly,
the present invention relates to a method and apparatus for
deactivating a hydraulic system that uses jointed flow lines
equipped with a specially configured check valve in each joint of
the jointed flow line.
[0007] 2. General Background of the Invention
[0008] In the offshore oil and gas industry, there are certain
hydraulic devices that are needed in order to complete jobs in an
underwater environment. A hydraulic shear is employed to conduct
salvage operations. Such a hydraulic shear is lowered to a seabed
area, for example several hundred feet (meters) deep. In this
offshore environment, leakage of hydraulic oil has a profoundly
disastrous effect on the environment.
[0009] Therefore, there exists a need for a simple and
straightforward yet workable solution to the problem of leakage of
hydraulic fluid from devices that are used in a marine
environment.
[0010] It is not only important that a leak of hydraulic fluid be
detected. It is further important that the hydraulic device be
immediately disabled so that leakage is limited to a very minimal
quantity.
[0011] Patents have issued that relate generally to the detection
of leakage. One example is the Brandt patent (U.S. Pat. No.
5,748,077). The Brandt patent (U.S. Pat. No. 5,748,077) shuts down
the hydraulic system if the leak is detected and notifies
individuals in the area that a leak has occurred. The leak
detection system has sensors for measuring hydraulic system
parameters and a computer for detecting abnormalities in the system
based on values returned by the sensors. Sensors used include an
rpm pickup, a pressure transducer, a flow meter and a hydraulic
fluid level and temperature switch. Outputs of the sensors are
analyzed by the computer to determine if the hydraulic system has a
leak. If a leak is detected, the computer sends response signals to
a device for engaging or disengaging the prime mover from the
hydraulic pump and to another device for actuating a valve to stop
hydraulic fluid flow from the reservoir. The computer may also send
indicator signals to a display console for activating a warning
light, a buzzer or a display.
[0012] The Cass patent (U.S. Pat. No. 4,471,797) provides a
hydraulic circuit breaker reset device. The system includes a pump,
reservoir and an actuator system. The hydraulic circuit breaker is
arranged to compare fluid flow to and from the actuator system and
to shut off this flow in the event the flow to the actuator system
is greater than the flow returning from the actuator system by more
than a predetermined differential, thereby indicating a leakage
condition. A hydraulic circuit breaker reset device is
hydraulically connected to the actuator system and to the circuit
breaker. When the circuit breaker is in a shut off condition, the
reset device continuously pressure tests the actuator system. If
the pressure in the actuator system increases to indicate the
absence of fluid leakage, the reset device responds to the pressure
increase in the actuator system to provide a reset signal to the
circuit breaker. After the circuit breaker is reset to its normal
operating position, a timing piston returns the reset device to its
normal operating condition.
BRIEF SUMMARY OF THE INVENTION
[0013] In one embodiment, the present invention can employ a
plurality of hose sections (e.g. 50 ft. (15.24 m) sections) with
less than 2.5 gallons (9.46 liters) of total contents within each
section. The primary design is to have a check type valve that
holds the contents of the hose when there is a breach within any
part of the hose, upon hydraulic power unit or "HPU" shutdown.
[0014] A specially configured connector joins each hose joint to
another hose joint with a threaded connection. The connector
contains a specially configured check valve arrangement. The
connector is preferably about equal in size to the current
connection not to cause any change in function externally due to
the fact it has to be spooled up on a hose reel.
[0015] The valve of the present invention employs springs that work
against each other on a shaft with a plunger or piston in the
middle. The springs can be calibrated to a selected pressure flow
value. When the flow pushes the plunger or piston in one direction,
a circular disk part of the plunger or piston moves to one side of
an annular sealing surface and compresses a first spring allowing
the flow to pass by the central disk.
[0016] When the flow changes direction, the plunger accommodates by
moving to the other side of the valve bode compressing the opposing
or second spring and allows flow in the other direction, when the
flow stops the valve centers due to the equal amount of spring
tension and shuts on a sealing area for the plunger.
[0017] There is a slight increase of system pressure when using
these specially configured check valves of the present invention.
For example, if a hydraulic system has two runs of 475 foot (145 m)
hose that are one inch (2.54 cm) diameter hose with nine joints of
hose, there would be an about 200 psi (1379 kPa) increase in
operating pressure.
[0018] This method can be used with or without a separate spill
mitigation system. The reaction time of a particular human operator
can directly affect the amount of hydraulic fluid that is spilled.
A computer controlled spill mitigation system can be more
consistent and reliable than a human operator.
[0019] The present invention includes a method of deactivating an
underwater hydraulic device. The method provides a hydraulic device
that is capable of being operated under water, the device can have
a hydraulic cylinder with a pushrod and a piston. The device can be
lowered below a water surface with a hose reel that is located at
the water surface area. The hose reel can include first and second
hydraulic hoses that connect to the cylinder on opposing sides of
the piston. The method includes intermittently monitoring fluid
flow in the first and second hydraulic hoses. The method further
includes calculating the ratio of the volume of fluid flowing into
the cylinder from one side of the piston to the volume of fluid
flowing into the cylinder from the other side of the piston. The
method of the present invention further includes deactivating the
hydraulic device if the ratio varies from a preset ratio or preset
value. The hoses can be a plurality of joints, wherein a plurality
of said joints house a check valve.
[0020] Preferably, the device can be a hydraulic shear.
[0021] Preferably, the flow can be measured with first and second
flow meters, one flow meter monitoring fluid flow in the first
hydraulic hose, the other flow meter monitoring flow in the second
hydraulic hose.
[0022] Preferably, the hydraulic device can receive hydraulic fluid
under pressure from a prime mover and hydraulic pump assembly and
the prime mover and pump assembly can be deactivated.
[0023] Preferably, the prime mover can be deactivated.
[0024] Preferably, the prime mover can include an engine and the
engine can be shut off.
[0025] Preferably, a controller can continuously monitor flow in
the flow meters and continuously calculates the ratio.
[0026] Preferably, the present invention further comprises
providing a selector switch having multiple selectable switch
positions and wherein the ratio can be varied by selecting a
different position of the selector switch.
[0027] Preferably, the computer can use a different ratio depending
upon which switch position is selected and the dimensions of the
cylinder and pushrod of the selected device.
[0028] Preferably, the volumes can be automatically calculated.
[0029] The present invention includes a method of deactivating a
hydraulic device. The method provides a hydraulic device having a
cylinder with a pushrod and a piston, the device receiving flow
from a jointed flow line. The flow line can include first and
second hydraulic jointed hoses that connect to the cylinder on
opposing sides of the piston. The method further includes
intermittently monitoring fluid flow in the first and second
hydraulic hoses. The method further includes continuously comparing
the volume of fluid that enters a pushrod retraction chamber
section of the cylinder with a pushrod extension section of the
cylinder. The method further includes deactivating the hydraulic
device if the ratio varies from a preset value. The hoses can be a
plurality of hose joints, wherein a plurality of said hose joints
are connected together end to end with connectors that each house a
check valve.
[0030] Preferably, the flow can be measured with first and second
flow meters, one flow meter monitoring fluid flow in the first
hydraulic hose, the other flow meter monitoring flow in the second
hydraulic hose.
[0031] Preferably, the hydraulic device receives hydraulic fluid
under pressure from a prime mover and hydraulic pump assembly and
the prime mover and pump assembly is deactivated.
[0032] Preferably, the prime mover can be an engine and the engine
can be shut off.
[0033] Preferably, a controller can continuously monitor flow in
the flow meters and continuously calculates the ratio.
[0034] Preferably, the present invention further comprises
providing a selector switch having multiple selectable switch
positions and wherein the ratio can be varied by selecting a
different position of the selector switch.
[0035] The present invention includes a hydraulic leak detection
apparatus. The apparatus of the present invention can include a
hydraulic device that can be operated with a prime mover, pump, and
hydraulic cylinder having a cylinder, a pushrod, and a piston. The
cylinder can have a first chamber that is receptive of hydraulic
fluid when extending the pushrod and a second chamber that is
receptive of hydraulic fluid when retracting the pushrod. A first
hydraulic flow line can supply hydraulic fluid to the first
chamber. A second hydraulic flow line can supply hydraulic fluid to
the second chamber. At least one of said flow lines can be
comprised of separate lengths of hose connected end to end. A
computer can continuously monitor the ratio of the volume of fluid
entering the first chamber to the volume of fluid entering the
second chamber. The computer can operatively connect to the prime
mover so that the computer can deactivate the prime mover when the
ratio varies from a preset acceptable value of said ratio. At least
one of the hydraulic flow lines can be comprised of a plurality of
hose joints that are joined together with connectors that each
contain a check valve.
[0036] Preferably, the hydraulic device can be a power tong.
[0037] Preferably, each of said first and second flow lines can
have a flow meter interfaced with said computer so that the flow
meters continuously transmit flow data to the computer.
[0038] Preferably, the present invention further comprises a
selector switch that enables the computer to compare the said ratio
with a selected one of a plurality of ratios, each ratio of the
plurality of ratios corresponding to different hydraulic cylinder
configurations.
[0039] Preferably, the present invention further comprises a
selector switch that enables the computer to compare the said ratio
with a selected one of a plurality of ratios, each ratio of the
plurality of ratios corresponding to different hydraulic cylinder
dimensions.
[0040] Preferably, the computer can be programmable to designate
any ratio as the acceptable value.
[0041] Preferably, the acceptable value can be a range.
[0042] Preferably, further comprises a hose reel that enables the
device to be lowered to a sea bed area.
[0043] Preferably, multiple hydraulic flow lines can be part of the
hose reel.
[0044] Preferably, each of said first and second hydraulic hoses
can have a flow meter interfaced with a computer or controller so
that the flow meters continuously transmit flow data to the
computer.
[0045] Preferably, each flow meter can be in a said hydraulic hose
in between the hose reel and the device.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0046] For a further understanding of the nature, objects, and
advantages of the present invention, reference should be had to the
following detailed description, read in conjunction with the
following drawings, wherein like reference numerals denote like
elements and wherein:
[0047] FIG. 1 is a partial elevation view of a preferred embodiment
of the momentum controller;
[0048] FIG. 2 is a sectional view taken along lines 2-2 of FIG.
1;
[0049] FIG. 3 is a partial sectional view of a preferred embodiment
of the apparatus of the present invention;
[0050] FIG. 4 is a partial sectional view of a preferred embodiment
of the apparatus of the present invention;
[0051] FIG. 5 is a sectional view taken along lines 5-5 of FIG.
2;
[0052] FIGS. 5A and 5B are fragmentary views of a preferred
embodiment of the apparatus of the present invention;
[0053] FIG. 6 is a sectional view taken along lines 6-6 of FIG.
2;
[0054] FIG. 7 is a side, partially cut away view of a preferred
embodiment of the apparatus of the present invention;
[0055] FIG. 8 is a side, partially cut away view of a preferred
embodiment of the apparatus of the present invention;
[0056] FIGS. 9A and 9B provide a schematic diagram of a preferred
embodiment of the apparatus of the present invention wherein lines
A-A of FIGS. 9A and 9B are match lines; and
[0057] FIG. 10 is a schematic diagram of an alternate embodiment of
the present invention, wherein lines A-A of FIGS. 10 and 9B are
match lines.
DETAILED DESCRIPTION OF THE INVENTION
[0058] FIGS. 9A and 9B show a preferred embodiment of the apparatus
of the present invention, designated generally by the numeral 10.
In FIG. 9A, hydraulic power is provided with a hydraulic power unit
or HPU which is designated generally by the numeral 17. Hydraulic
power unit 17 includes a prime mover 20 which can be for example a
diesel engine (20) or electric motor 44 (as seen in FIG. 10). The
prime mover 20 powers a pump 21 which can be a compensating pump.
Such compensating pumps are commercially available (e.g. from Linde
Hydraulics (www.lindeamerica.com)). The pump 21 receives hydraulic
fluid from reservoir 22 and flow line 27. A case drain line or
recycle line 24 is provided for bypassing the hose reel 40 which is
a condition that can occur with such a compensating pump 21 in some
situations. Fuel is provided for the hydraulic power unit 17, for
example tank 23 which can be a diesel fuel tank for supplying
diesel fuel via flow line 65 with valve 64 to prime mover/diesel
engine 20. Pump 21 has a discharge flow line 25 which is a pressure
line that communicates with hydraulic control valve 54. Hydraulic
control valve 54 has a lever or operator handle 69 that is used to
operate an implement 11 (e.g., cutter 11) such as to either open or
close the jaw 30 of implement or shear 11. In FIG. 9B, the lever or
handle 69 is in a position that transmits fluid to lines 31, 32 so
that jaw 30 is opened. The lever or handle 69 can be moved to a
position (see dotted lines in FIG. 9B) that transmits fluid to
lines 31, 32 so that jaw 30 is closed. Valve 54 is commercially
available such as from Hawe North America, Inc. of Charlotte,
N.C.
[0059] From control station 29, the line 31 exits to supply
pressurized hydraulic fluid to hose reel 40. A first flow meter 45
is placed in flow line 31 or at the junction of flow lines 25, 31
as shown in FIGS. 9A-9B.
[0060] Line 32 also receives flow from control station 29 to
communicate with hose reel 40. The flow line 32 carries a second
flow meter 46. Return flow is able to travel from the hose reel 40
to the flow line 32 through the flow meter 46 and then to the
control station 29. From the control station 29, the flow in line
32 communicates with the return line 26 for returning fluid to
hydraulic tank or reservoir 22. Flow meters 45, 46 can be
commercially available CT Series flow meters from Webster
Instruments of Milwaukee, Wis.
[0061] The hose reel 40 provides flow lines 41, 42 which enable a
hydraulic cylinder on implement 11 to either open jaw 30 or close
jaw 30 by either extending a pushrod or retracting the pushrod.
This is accomplished by connecting one flow line 41 to hydraulic
cylinder on one side of a piston (that is on implement 11 and that
operates jaw 30) and by connecting the other flow line 42 to the
hydraulic cylinder on the other side of the piston.
[0062] The prime mover can be either an engine 20 or an electric
motor 44 (see FIG. 10). The engine 20 (e.g., diesel) is provided
with a battery 71 for starting the engine 20. The battery 71 also
provides positive and negative leads 72, 73 that communicate with
control station or controller 29 as shown in FIGS. 9A-9B. The
control station 29 can include a commercially available computer or
controller 33 such as a Model Plus 1 from Sauer Danfoss such as
Model No. MC024-010 or MC024-012.
[0063] The computer or controller 33 is part of the control station
29. The control station 29 can provide a key switch for enabling
the control station 29 to be activated or deactivated. A rotary cam
switch 74 can be provided to pre-program controller 33 for a number
of different configurations (e.g., dimensional changes) of
cylinder, pushrod and chamber sections of hydraulic cylinder of
implement 11. The cam switch 74 enables an operator to dial in or
select a particular hydraulic cylinder by selecting a
pre-programmed cam switch position. Such a rotary cam switch is
commercially available from Control Switches International,
Inc.
[0064] A start button 75 can be provided for enabling use of
control station 29. Lamps 76, 77 can be provided to indicate
whether or not the control station 29 has been activated or is
deactivated. For the diesel engine 20, a valve (e.g., solenoid
operated valve) 64 is provided in flow line 65 which supplies
diesel fuel from tank 23 to engine 20. This solenoid operated valve
64 is closed in a situation where a leak is detected (e.g., see
leakage/damage at 70 in FIG. 8). In alternate embodiment 10A seen
in FIG. 10, for an electric motor 44 (as prime mover), a solenoid
operated switch 78 is provided. The switch 78 deactivates the
electric motor 44 if a leak situation is detected. For each of the
diesel engine 20 (or electric motor 44), a cooler 67 can be
provided in the flow line 24 as shown.
[0065] In one embodiment, the method and apparatus can be provided
with a display which may include a leak detection visual and/or
audible alarm. A display console can be provided for controller 33
which can include a selector or cam switch 74, on-off button 75,
indicator lamps 76 and 77, along with default program button.
Controller 33 can be operatively connected to a computer (e.g., a
notebook computer) for programming operating values into controller
33 regarding its operations.
[0066] FIGS. 9A and 9B provide schematic block diagrams of leak
detection system 10 connected to two hydraulic systems--(a)
hydraulic shears 11 and (b) the reel drive motor 38 for hose reel
40. Leak detection system 10 can detect undesirable conditions in
one or both of these two connected hydraulic systems.
[0067] A plurality of flow meters 45 and 46 can be used to measure
flow to and from the monitored hydraulic systems (e.g., shears 11
and reel drive motor 38). The flow meter 45 sends a signal to
controller 33 which is proportional to the rate of fluid flow in
flow line 31. The flow meter 46 sends a signal to controller 33
which is proportional to the rate of fluid flow in flow line
32.
Pre-Leak Detection Testing
[0068] Leak detection 10 system can go through various pre-leak
detection monitoring checks which are designed to ensure that the
connected hydraulic systems (e.g., shears 11 and reel drive motor
38) are operating correctly. In one embodiment leak detection
system 10 will shut off hydraulic power to the hydraulic pump 21 if
one or more pre-monitoring exceptions are found.
[0069] Pre-monitoring exceptions can include, but are not limited
to: [0070] (a) powering hydraulic pump 21 not operating such as not
rotating between a predefined rotational range; [0071] (b) the
level of hydraulic fluid in reservoir tank 22 not being above a
predefined reservoir tank level; [0072] (c) the pressure in flow
line 31 not being above a predefined pressure for such flow line;
[0073] (d) the pressure in flow line 32 not being above a
predefined pressure for such flow line; [0074] (e) the pressure in
flow line 41 not being above a predefined pressure for such flow
line; and [0075] (f) the pressure in flow line 42 not being above a
predefined pressure for such flow line. If one or more of the above
pre-monitoring exceptions are found, leak detection system 10 can
turn off power to pump 21, and issue a warning signal indicating
the identification of a pre-monitoring exception. The pressure
exerted by the hydraulic fluid can be monitored by pressure
transducers in flow lines 31, 32, 41, and 42.
[0076] If an exception condition is found, including satisfaction
of the time periods for existence of such exception, the leak
detection system 10 shuts down the identified leaking hydraulic
system (e.g., shears 11 and/or reel drive motor 38). Shutting down
a hydraulic system can include shutting off the flow of hydraulic
fluid from the reservoir tank 22 to pump 21 and shutting off power
to pump 21. The hydraulic fluid flow can be shut off at reservoir
tank 22 by turning a valve in line 27 to a closed position.
[0077] If a leaking exception condition satisfying leaking
parameters has been found, the leaking hydraulic system (e.g.,
shears 11 or reel drive motor 38) causing the leaking event to be
identified may be shut down and the indicator or display signals
are sent to console to warn that a leaking event has been
identified. Leak detected light 76 or 77 can be provided and turned
on and optionally an auditory alarm can also be issued.
Leak Detection Monitoring
[0078] In one embodiment, following the completion of the various
pre-leak detection monitoring checks, leak detection system 10 can
monitor one or both connected hydraulic systems (shears 11 and/or
reel drive motor 38) by monitoring flow though flow meters 45 and
46 and comparing such monitored flow to certain predefined flow
amounts for the particular hydraulic system being monitored.
[0079] In one embodiment leak detection system 10 provides a
predefined startup period of time from activation of a hydraulic
system to beginning of monitoring operations of flow meters 45 and
46. Such predefined start up period of time allows the monitored
hydraulic system time to stabilize before leak detection system 10
begins looking for leaking exceptions in monitoring conditions. In
one embodiment such predefined start up period of time can be at
least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25,
30, 35, 40, and/or 50 seconds. In various embodiments such
predefined period of time can be a range between any two of the
specified time periods.
[0080] Exceptions for leak detection can be identified by leak
detection system 10 where a measured parameter falls outside of the
predefined allowed ranged for such measured parameter.
Additionally, preferably leak detection system 10 requires that the
exception be present for a predetermined period of time before
considering that an identified leaking exception is considered a
leaking event and acting accordingly, such as by shutting down pump
21 and/or the hydraulic system (e.g., shears 11 or reel drive motor
38) causing the identified leaking exception to be present.
Frequency of Sampling Flow Meter Readings
[0081] In one embodiment leak detection system 10 can be user
programmed regarding the frequency of sampling of which the system
accepts signals from the plurality of flow meters 45 and 46.
Although "continuous" is used in this specification it is
anticipated that, in any given time period, only a finite number
sampling of measurements can be taken by leak detection system
10.
[0082] In various embodiments embodiment sampling rates can be at
least 1, 5, 10, 50, 100, 120, 150, 200, 300, 500, 1000, 2000, or
3000 Hertz. In various embodiments sampling rates can be a range
between any two of the specified sampling rates.
Time Period for Existence of Leaking Exception
[0083] In one embodiment leak detection system 10 responds or
reacts rapidly to an identified leaking event, such as by shutting
off power to pump 21 along with shutting off fluid flow from
reservoir 22 to pump 21. With the occurrence of such an event, leak
detection system 10 can also issue a warning signal such as be
lighting lamp 76 or lamp 77, along with possibly issuing a audible
warning signal such as a siren.
[0084] In one embodiment, after a leaking event is determined, leak
detection system 10 will shut down the flagged hydraulic system
(shears 11 or reel drive motor 38). This can occur after
determining a leaking exception exists for a predetermined time. In
one embodiment such predefined period of time that the leaking
exception must exist before a leaking event can be identified, can
be at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18,
20, 25, 30, 35, 40, 50, and/or 60 seconds. In various embodiments
such predefined period of time can be a range between any two of
the specified time periods. In various embodiments the user can
program this predefined period of time and/or range into leak
detection system 10.
Programming Based on Actual Operating Conditions of Hydraulic
Systems in a Non-Leaking Condition
[0085] In one embodiment benchmark conditions in known non-leaking
conditions to be expected when taking sampling measurements can be
automatically programmed into the method and apparatus. In one
embodiment predefined exception conditions can be programmed into
leak detection system 10 based on actual operating conditions of
the hydraulic system being monitored (e.g., shears 11 and/or reel
drive motor 38). In one embodiment, the default predefined button
can be provided in leak detection system 10, and a method of
programming predefined conditions for flow meters 45 and 46 can be
as follows:
[0086] (1) Shear System
[0087] With hydraulic shear system 11, hydraulic power can be
supplied by pump 21 though lines 31 and 32 which respectively flow
through lines 41 and 42. The ratio of flow measured by flow meter
45 to compared to flow meter 46 (or vice versa) can be calculated
by controller 33 and such ratio be set in the method and apparatus
as the ideal predefined ratio in a non-leaking condition.
[0088] For any particular movement of the piston inside of the
hydraulic cylinder of implement 11, the amount of hydraulic fluid
entering/leaving one chamber is less than the amount of hydraulic
fluid entering/leaving the other chamber. The difference is a
result of the pushrod taking up part of the volume of one chamber
section. Although not expected to be a 1:1 ratio, because the
pushrod has a substantially uniform cross sectional area the ratio
of the amount of fluid exchange between the two chamber sections is
expected to be constant regardless of the position of piston in the
cylinder. In a preferred embodiment the ratio can be 1:2.28 and
measured variations from this ratio can be used by leak detection
system 10 to identify leaking exceptions for shear 11 and, if such
identified leaking exception persists, a leaking event for shear
11.
[0089] (2) Driving Motor for Hose Reel
[0090] For reel drive motor 38 hydraulic power can be supplied by
pump 21 though lines 31 and 32 which power reel drive motor 38 to
outlay or take up lines 41 and 42. The ratio of flow measured by
flow meter 45 to 46 can be calculated by controller 33 and such
ratio be set as a predefined ratio in a non-leaking condition.
However, this ratio in a non-leaking situation is expected to be
1:1 and this step can be omitted for programming the leak detection
parameters for reel drive motor 38.
[0091] Unlike shears 11, reel drive motor 38 operably connected to
hose reel 40 (and rotating reel 40 to outlet and take up of flow
lines 41 and 42) will have input and output lines which, in a
non-leaking condition, are expected to have a 1:1 ratio of
hydraulic fluid entering and exiting driving motor 38.
Use of Physical Dimensional Parameters to Calculate Predefined
Ratios
[0092] For any particular movement of the piston inside of the
hydraulic cylinder, the amount of hydraulic fluid entering/leaving
one chamber section is less than the amount of hydraulic fluid
entering/leaving the chamber section. The difference is a result of
the pushrod taking up part of the volume of chamber section.
Although not expected to be a 1:1 ratio, because the pushrod has a
substantially uniform cross sectional area the ratio of the amount
of fluid exchange between the two chamber sections is expected to
be constant regardless of the position of the piston in the
cylinder. In a preferred embodiment the ratio can be 1:2.28 and
measured variations from this ratio can be used by leak detection
system 10 to identify leaking exceptions for shear 11 and, if such
identified leaking exception persists, a leaking event for shear
11.
[0093] In one embodiment, where the push rod has a diameter D.sub.r
and the piston has a diameter D.sub.P the ratio between the two
flow rates will be the same as the ratio of the cross sectional
areas on either side of the piston, and can be calculated by the
formula:
[ D p 2 - D r 2 ] D p 2 ##EQU00001##
In this embodiment a user can enter the diameter of the rod
"D.sub.r" and the diameter of the piston "D.sub.P" and the method
and apparatus can calculate the ideal predefined ratio in a
non-leaking condition from which allowable variations can be looked
for by the method and apparatus. Customizing Allowable Variations
from Predefined Non-Leaking Ratios
[0094] In various embodiments a user can custom program leak
detection system 10 to allow a variation of a selected amount from
the predefined ratio in a non-leaking condition for either the
hydraulic shear system 11 and/or reel drive motor 38. In various
embodiments such can be a symmetrical variation from the initial
predefined ratio and can be an allowable percentage variation from
the initial predefined ratio. In various embodiments this allowable
percentage can be at least about 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8,
9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, and/or 50 percent. In
various embodiments such exception variations can differ from
variations above compared to variations below the user selected
value in a non-leaking condition (e.g., the initial predefined
ratio).
[0095] In various embodiments the lower limit can be one of the
specified allowable variations, and the upper limit can be a
different one of the specified allowable variations.
[0096] In various embodiments such user selected predefined
parameters may be changed from time to time as the user
desires.
[0097] At different points in time the user can use the default
program button to calculate another predefined ratio for either
hydraulic system (shear 11 or drive motor 38) as either hydraulic
system's non-leaking characteristics may change over time. In one
embodiment such predefined variations can be numerically entered
into controller 33 by a computer.
[0098] As disclosed herein it is anticipated that leak detection
system 10 can have programmed multiple sets of ratios for flow in
flow meters 45 and 46 based on the different hydraulic systems
which flow meters 45 and 46 are measuring flow in relation to. For
example, when reel drive motor 38 is operating to lay out or take
up hoses 41 and 42 (respectively lowering or raising shears 11),
hydraulic shears 11 will not be operating. Accordingly, the values
programmed for reel drive motor 38 are used by leak detection
system 10.
Catastrophic Leak Detection Testing
[0099] During operations, leak detection system 10 system can go
through various checks for catastrophic leaking events which are
designed to ensure that the connected hydraulic systems (e.g.,
shears 11 and reel drive motor 38) do not suffer a catastrophic
leaking event. In one embodiment leak detection system 10 will shut
off hydraulic power to the hydraulic pump 21 and/or hydraulic
systems if one or more pre-monitoring exceptions are found.
[0100] Catastrophic monitoring exceptions can include, but are not
limited to: [0101] (a) no flow read by flow meter 45 while flow is
read by flow meter 46; [0102] (b) no flow read by flow meter 46
while flow is read by flow meter 45; [0103] (c) the pressure in
flow line 31 not being above a predefined pressure for such flow
line; [0104] (d) the pressure in flow line 32 not being above a
predefined pressure for such flow line; [0105] (e) the pressure in
flow line 41 not being above a predefined pressure for such flow
line; and [0106] (f) the pressure in flow line 42 not being above a
predefined pressure for such flow line.
[0107] If one or more of the above catastrophic leak detection
monitoring exceptions are found, leak detection system 10 can turn
off power to pump 21, shut down the hydraulic systems, and issue a
warning signal indicating the identification of a catastrophic leak
detection event. The pressure exerted by the hydraulic fluid can be
monitored by pressure transducers in flow lines 31, 32, 41, and
42.
[0108] FIGS. 1-8 show a specially configured valve to be employed
with a preferred embodiment of the apparatus of the present
invention. Leak detection system 10 employs a specially configured
valve assembly or valve 12 which also can function as a connector
to connect one joint of hose 13 to another joint of hose 14 as seen
in FIGS. 7 and 8. The valve 12 can have male connector ends 57, 58
that each connect to a female connector end on a joint of hose 13
or 14. Once so configured, the joints of hose 13, 14 can be
connected end to end to make up a long hose run of for example
300-500 feet (91-152 m) or more. Connector ends 57, 58 could be
both male as shown, both female, or one male and one female, for
example.
[0109] In FIGS. 1-8, valve 12 includes an annular or generally
cylindrically shaped or tubular valve body 16 having a central
longitudinal flow bore 56. Valve body 16 can be in three sections
59, 60, 61 (see FIGS. 1-4). The section 60 is central section. The
sections 59, 61 are end sections that connect to the central
section with a threaded connection. In FIGS. 2-4, section 59
connects to section 60 with threaded connection 62. In FIG. 2,
section 61 connects to section 60 with threaded connection 62.
[0110] Plunger or piston 63 is mounted within body 16, attached to
a pair of spaced apart flow through disks 19, 28 (see FIGS. 5A,
5B). Each disk 19, 28 has a central opening 79 and a plurality of
circumferentially extending arcuate openings 80, 81, 82 as seen in
FIGS. 5, 5A, 5B. Piston or plunger 63 has a rod or shaft 87 that
extends through the opening 79 of disks 19 and also through the
opening 79 of disk 28 as seen in FIGS. 2-4. Disk 66 is mounted on
rod 87. Springs 83, 84 normally center disk 66 upon annular or
cylindrically shaped sealing surface 49. Beveled annular surfaces
or inclined sections 47, 48 can be provided on opposing sides of
sealing surface 49 as seen in FIG. 2. Spring 83 is positioned in
between disk 66 of plunger/piston 63 and disk 19 which is anchored
to valve body 16 between sections 59 and 60 (see FIGS. 3-4). Spring
84 is positioned in between disk 66 of plunger/piston 63 and disk
28 which is anchored to valve body 16 between sections 60 and 61
(see FIGS. 3-4).
[0111] Disk 66 of piston/plunger 63 has an annular groove 68 fitted
with an o-ring 85. When o-ring 85 registers upon annular
surface/sealing surface 49, flow through valve body 16 bore 56 is
halted. Springs 83, 84 are calibrated so that if a selected flow
pressure value is overcome, the piston or plunger 63 moves toward a
disk 19 or 28 and the plunger/piston leaves sealing surface 49 to
open the flow. Thus, if a leak occurs in any length or joint of
hose (e.g., 13 or 14 or 41 or 42) the pressure will drop below the
preselected pressure value and wherein the springs 83, 84 center
disk 66 on sealing surface 49 to close flow and stop any further
leakage.
[0112] The hydraulic control system of the present invention
provides a valve arrangement that works in two directions. Flow
from either direction of hose joint 13 or 14 will open the valve
bore 56 as long as sufficient pressure is available to overcome
spring pressure. Conversely, in the event of leakage a pressure
drop below a preset minimum pressure value will enable springs 83,
84 to center disk 66 on sealing surface 49 to halt flow. FIG. 7
shows position of piston 63 if no damage has occurred. In FIG. 3,
arrows 55 show normal flow that overcomes and compresses spring 84.
In FIG. 4, arrows 86 show normal flow that overcomes spring 83.
FIG. 8 shows damage and leakage 70 in line 13. Pressure in hose
bore 15 drops as a result of the leak at 70. Springs 83, 84 center
piston 63 is seen in FIG. 8.
[0113] Incorporated herein by reference are U.S. patent application
Ser. No. 13/741,074, filed 14 Jan. 2013, and International Patent
Application No. PCT/US 13/21457, filed 14 Jan. 2013. The present
invention is preferably used with the inventions disclosed
therein.
[0114] The following is a list of parts and materials suitable for
use in the present invention:
TABLE-US-00001 PARTS LIST: PART NUMBER DESCRIPTION 10 hydraulic
spill control apparatus 10A hydraulic spill control apparatus 11
implement/shear 12 valve assembly/valve 13 hose joint with damage
and leakage 14 hose joint 15 hose bore 16 valve body 17 hydraulic
power unit 19 flow through disk 20 prime mover/engine 21 pump 22
reservoir/hydraulic fluid 23 fuel tank 24 flow line 25 flow line 26
flow line 27 flow line 28 flow through disk 29 control station 30
jaw 31 flow line 32 flow line 33 controller/computer 38 hose reel
motor 40 hose reel 41 flow line 42 flow line 43 flow line 44
electric motor 45 flow meter 46 flow meter 47 inclined section 48
inclined section 49 annular surface/sealing surface 54 control
valve 55 arrow 56 flow bore 57 connector end 58 connector end 59
section 60 section 61 section 62 threaded connection 63
plunger/piston 64 solenoid operated valve/valve 65 flow line 66
disk 67 cooler 68 annular groove 69 lever/handle 70 leaking/damaged
section 71 battery 72 positive lead 73 negative lead 74 rotary cam
switch 75 start button 76 lamp 77 lamp 78 switch 79 central opening
80 arcuate opening 81 arcuate opening 82 arcuate opening 83 spring
84 spring 85 O-ring 86 arrows 87 rod/shaft
[0115] All measurements disclosed herein are at standard
temperature and pressure, at sea level on Earth, unless indicated
otherwise. All materials used or intended to be used in a human
being are biocompatible, unless indicated otherwise.
[0116] The foregoing embodiments are presented by way of example
only; the scope of the present invention is to be limited only by
the following claims.
* * * * *