U.S. patent application number 15/816219 was filed with the patent office on 2018-03-22 for method and system for optimizing acetylene delivery.
The applicant listed for this patent is PRAXAIR TECHNOLOGY, INC.. Invention is credited to CARL J. CANTRELLE, WENDELL W. ISOM, RAZZACK SYED.
Application Number | 20180081377 15/816219 |
Document ID | / |
Family ID | 57758735 |
Filed Date | 2018-03-22 |
United States Patent
Application |
20180081377 |
Kind Code |
A1 |
ISOM; WENDELL W. ; et
al. |
March 22, 2018 |
METHOD AND SYSTEM FOR OPTIMIZING ACETYLENE DELIVERY
Abstract
This invention relates to a method and system for increasing the
utilization of the supply of acetylene from two acetylene sources.
The flow is provided at a substantially constant delivery pressure
to a point of use, such as a customer point of use. A portable
apparatus is configured to operably connect to each of the two
acetylene sources simultaneously and during operation automatically
provide flow from one of the acetylene sources through various
valving and piping assembled onto the portable apparatus followed
by supply to a customer point of use.
Inventors: |
ISOM; WENDELL W.; (GRAND
ISLAND, NY) ; CANTRELLE; CARL J.; (AMA, LA) ;
SYED; RAZZACK; (MISSISSAUGA, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PRAXAIR TECHNOLOGY, INC. |
DANBURY |
CT |
US |
|
|
Family ID: |
57758735 |
Appl. No.: |
15/816219 |
Filed: |
November 17, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14757396 |
Dec 23, 2015 |
9857804 |
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15816219 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G05D 16/00 20130101;
F17C 11/002 20130101 |
International
Class: |
G05D 16/00 20060101
G05D016/00; F17C 11/00 20060101 F17C011/00 |
Claims
1-7. (canceled)
8. A method for remotely monitoring an acetylene source which
attains a change in status to a remote unit, comprising: providing
a controller configured to monitor process variable information of
a first acetylene source and a second acetylene source, said
process variable information selected from the group consisting of
valve positon status, initial source pressure, source pressure,
flow rate, manifold pressure, pipeline pressure at the point of
use, and temperature; said controller detecting when the first
acetylene source has undergone the change in status between a
minimum pressure state, a permanent or temporary depleted state and
an online state; and transmitting in response to said change in the
status an alert notification to a remote unit over a cellular
network or cyber secure internet link.
9. The method of claim 8, further comprising: determining said
first acetylene source to have attained a change in the status to
the permanently depleted state, said permanently depleted state
defined as the first acetylene source having a measured pressure
that is reduced to a final pressure; transmitting in response to
said permanently depleted state the alert notification
corresponding to said permanently depleted state to a remote unit
over a cellular network or cyber secure internet link; replacing
the first acetylene source with a second acetylene source;
activating said second acetylene source; and supplying acetylene
from said second acetylene source to a portable apparatus that is
operably connected with said first acetylene source and said second
acetylene source.
10. The method of claim 9, further comprising transmitting a second
alert notification corresponding to said second acetylene source in
an online status.
11. The method of claim 8, further comprising: determining the
pressure in the first acetylene source to decrease by no more than
about 80% of an initial source pressure of the first acetylene
source so as to attain a temporary deplete state; designating the
first acetylene source to a standby mode; transmitting in response
to said standby mode the alert notification corresponding to said
standby mode to a remote unit over a cellular network or cyber
secure internet link; and switching from the first acetylene source
to the second acetylene source to resume the supply of
acetylene.
12. The method of claim 11, further comprising: monitoring the
source pressure of the first acetylene source during the standby
mode; switching the supply of acetylene from the second acetylene
source to the first acetylene source when the pressure in the first
trailer has increased to at least a set point pressure that greater
than a delivery pressure; and resuming the supply of acetylene from
the first acetylene source; updating the alert notification to
correspond to the first acetylene source having an online status
and the secondary acetylene source having an offline status; and
transmitting said updated alerted notification to the remote
unit.
13. The method of claim 8, wherein said remote unit is selected
from the group consisting of a cell phone, pager or computer.
14. The method of claim 11, wherein the first acetylene source
remains in standby mode for 1-75 hours.
15. A process for optimizing acetylene supply to a point of use,
comprising the steps of: directing a flow of acetylene from a first
acetylene source at a predetermined delivery pressure, said first
acetylene source characterized by a first initial source pressure;
switching to the second acetylene source when a pressure of the
first acetylene source has decreased by no greater than 80% of the
first initial source pressure; directing flow from the second
acetylene source; designating the first acetylene source in standby
mode and allowing the pressure of the first acetylene source to
increase to greater than 20% of the first initial source pressure;
and diverting supply of acetylene to the first acetylene source
when the pressure of the first acetylene source increases to
greater than 20% of the first initial source pressure.
16. The process of claim 15, further comprising: eliminating,
minimizing or reducing the amount of solvent that is removed from
the acetylene that is withdrawn from either the first acetylene
source or the second acetylene source.
17-25. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a divisional application of pending U.S.
patent application Ser. No. 14/757,396 filed Dec. 23, 2015, and
entitled METHOD AND SYSTEM FOR OPTIMIZING ACETYLENE DELIVERY.
FIELD OF THE INVENTION
[0002] This invention relates to a unique method and system for
delivery of acetylene from any multiple trailer combination, or
primary trailer-reserve bank configuration, to a point of use at a
constant delivery pressure without significant interruption in
supply.
BACKGROUND OF THE INVENTION
[0003] There are many operations that utilize large amounts of
acetylene, making the use of a single cylinder at a time
impractical. In these instances, as an alternative, several
cylinders can be interconnected and used in combination with a
manifold to provide a constant source of acetylene to an operation.
A conventional arrangement involves cylinders that are delivered to
the worksite or customer point of use where they are interconnected
together with a manifold. Equipment may be utilized to regulate the
delivery of acetylene to a point of use. However, such a manifold
of cylinders contains numerous drawbacks. For example, the supply
of acetylene can be interrupted due to delays in switching from an
empty acetylene source to a fresh acetylene source. Additionally,
there is generally a lack of proper monitoring means for ensuring
when the acetylene supply system has deviated from preset
operational limits. Still further, the cylinders generally have to
be transported to a refilling station when the delivery pressure
drops below a predetermined set point.
[0004] More recently, in an attempt to more effectively supply
larger amounts of acetylene in comparison to cylinders which are
interconnected by a manifold, multiple cylinders have been arranged
on a trailer and then used at a site while remaining on the
trailer. Such an approach eliminates the unloading and reloading of
the cylinders at the point of use, thereby making it easier to
replace empty cylinders with filled cylinders. However, such
acetylene trailer arrangements still suffer numerous drawbacks,
including interruptions in supply of acetylene to the point of use
as a result of delays occurring during switchover from an empty
trailer to a new trailer. Additionally, conventional acetylene
trailer systems continue to lack proper monitoring means for
ensuring when the acetylene supply system has deviated from preset
operational limits.
[0005] Interrupted supply of acetylene typically leads to
significant downtime, production costs and unacceptable reduction
in throughput. In view of such drawbacks, there is a need for
improved acetylene supply systems.
SUMMARY OF THE INVENTION
[0006] This invention in one aspect relates to a portable
skid-mounted apparatus that includes valving, conduit, pressure
regulators, transmitters, status indicators and other equipment
specifically tailored for safe and controlled acetylene flow at
controlled delivery pressures not exceeding a predetermined level.
The apparatus is compact and modular in design so that it can be
readily transported to a customer site where it can then be
installed to the customer acetylene sources. When one of the
acetylene sources is detected to reach a minimum pressure state, a
controller that is assembled onto the skid-mounted apparatus is
configured to automatically switch to the other acetylene source to
resume flow. The acetylene source is allowed to increase in
temperature until the partial pressure of acetylene increases to a
level that is sufficient to resume flow therefrom at the required
delivery pressure. Flow resumes from the original acetylene source
until the pressure in the source is reduced to a final value at
which point the source is removed from operation. Remote alert
notifications are provided to indicate a change in status of the
acetylene sources. In this manner, increased utilization is
provided form the acetylene sources and supply to a customer is
substantially uninterrupted. method for preparing a pressure vessel
for receiving high purity acetylene at elevated pressure, said
method comprising:
[0007] In one aspect, a system for maximizing utilization of supply
of acetylene at a substantially constant delivery pressure to a
point of use, comprising: a first acetylene source and a second
acetylene source; the first acetylene source characterized by an
initial source pressure comprising a first set of cylinders
manifolded together to provide the supply of acetylene at the
substantially constant delivery pressure; the second acetylene
source comprising a second set of cylinders manifolded together to
provide the supply of acetylene at the substantially constant
pressure; each of the first set and the second set of cylinders
comprising a porous filler with solvent selected from the group
consisting of dimethylformaldehyde (DMF), acetone and
N-methylpyrrolidone (NMP) into which pressurized acetylene is
absorbed; the first acetylene source and the second acetylene
source operably connected to a portable apparatus, said portable
apparatus, comprising: a discharge manifold in fluid communication
to the first acetylene source and the second acetylene source; and
a controller to maximize the supply of acetylene from the first
acetylene source, the controller having as an input, the delivery
pressure of the acetylene, and the controller configured to switch
supply to the second acetylene source when the controller
determines the initial source pressure from the first acetylene
source decreases by no more than 80% of the initial source
pressure, and further wherein the controller is configured to
divert from the second acetylene source back to the first acetylene
source to resume supply of acetylene from the first acetylene
source when determining the pressure of the first acetylene source
is greater than the delivery pressure.
[0008] In a second aspect, a method for remotely monitoring an
acetylene source which attains a change in status to a remote unit,
comprising: providing a controller configured to monitor process
variable information of a first acetylene source and a second
acetylene source, said process variable information selected from
the group consisting of valve positon status, initial source
pressure, source pressure, flow rate, manifold pressure, pipeline
pressure at the point of use, and temperature; said controller
detecting when the first acetylene source has undergone the change
in status between a minimum pressure state, a permanent or
temporary depleted state and an online state; and transmitting in
response to said change in the status an alert notification to a
remote unit over a cellular network or cyber secure internet
link.
[0009] In a third aspect, a process for optimizing acetylene supply
to a point of use, comprising the steps of: directing a flow of
acetylene from a first acetylene source at a predetermined delivery
pressure, said first acetylene source characterized by a first
initial source pressure; switching to the second acetylene source
when a pressure of the first acetylene source has decreased by no
greater than 80% of the first initial source pressure; directing
flow from the second acetylene source; designating the first
acetylene source in standby mode and allowing the pressure of the
first acetylene source to increase to greater than 20% of the first
initial source pressure; and diverting supply of acetylene to the
first acetylene source when the pressure of the first acetylene
source increases to greater than 20% of the first initial source
pressure.
[0010] In a fourth aspect, a portable on-site apparatus configured
for automatically controlling supply of acetylene from multiple
acetylene trailers, said portable-onsite apparatus comprising: a
discharge manifold, said manifold adapted to interconnect to at
least a first acetylene source and a second acetylene source to
allow the supply of acetylene at a substantially constant delivery
pressure to a point of use from either the first acetylene source
or the second acetylene source; a controller to maximize the supply
of the acetylene from the first acetylene source, the controller
having as an input, the delivery pressure of the acetylene, and the
controller configured to switch supply from the first acetylene
source to the second acetylene source when the controller
determines a pressure of the first acetylene source decreases by no
greater than 80% of an initial source pressure of the first
acetylene source, and further wherein the controller is configured
to divert from the second acetylene source to the first acetylene
source to resume supply of acetylene from the first acetylene
source when determining the pressure of the first acetylene source
is sufficient to supply the acetylene at the substantially constant
delivery pressure; a modular platform characterized by a footprint
having an area of no more than about 50 ft2, said modular platform
configured to receive said controller and said discharge
manifold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a process schematic that employs a skid-mounted
apparatus for optimizing the supply of acetylene from two trailers
at substantially constant delivery pressure to a customer point of
use in accordance with the principles of the present invention;
[0012] FIG. 2 shows a top-down view of the skid mounted apparatus
of FIG. 1;
[0013] FIG. 3 illustrates the skid-mounted apparatus of FIG. 1 in
perspective view showing the various components responsible for
automatically controlling supply of acetylene from multiple
acetylene sources, including trailers and reserve banks;
[0014] FIG. 4 illustrates a process schematic that incorporates the
skid-mounted apparatus of FIG. 1 for an alternative switchover
methodology between an acetylene trailer and a reserve bank of
acetylene at substantially constant delivery pressure to a customer
point of use in accordance with the principles of the present
invention; and
[0015] FIG. 5 shows a remote monitoring and alert notification
system for the acetylene delivery process of FIG. 1 or FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
[0016] As will be described, the present invention offers a
transportable skid-mounted apparatus 50 that is designed to offer
substantially uninterrupted acetylene supply to a point of use 40
while increasing acetylene utilization from the sources. The
process 1 that incorporates the transportable skid-mounted
apparatus 50 is flexible and eliminates the need to assemble
acetylene supply systems at a point of use. Additionally, the
process 1 optimizes the use of large amounts of compressed
acetylene sources at the point of use 40.
[0017] In one aspect, and as will now be described with reference
to FIG. 1, the present invention relates to a method and system for
maximizing utilization of the supply of acetylene at a
substantially constant delivery pressure to a customer point of use
40 from an acetylene source that includes a first trailer 10 and a
second trailer 20. Other types of acetylene sources are
contemplated by the present invention, including, by way of
example, a reserve acetylene bank 401 that is configured to remain
stationary at the customer site, as will be described in accordance
with the embodiment of FIG. 4.
[0018] Referring to FIG. 1, the first trailer 10 may be a primary
trailer that comprises a first set of cylinders 11 manifolded
together to supply acetylene. The term "primary" as used herein and
throughout refers to a primary or first acetylene source that is
utilized to supply acetylene until reduced to a predetermined
minimum pressure, at which point supply switches to a secondary
acetylene source until the pressure of acetylene in the first
acetylene source is detected to increase to a predetermined
pressure via ambient heat and/or other suitable heating means. When
the pressure in the primarily trailer has reached the predetermined
pressure, the process 1 is designed to resume supply from the
primary trailer until depleted to a final pressure. Upon reaching
the final pressure, the primary acetylene source is disengaged and
removed from the process 1, as will be described in greater detail.
The second trailer 20 comprises a second set of cylinders 21
manifolded together to provide a secondary source of acetylene. The
second trailer 20 may be a standby trailer that supplies acetylene
when the primary acetylene trailer has been depleted to a
particular pressure, as will be described in greater detail. The
term "secondary" as used herein and throughout refers to an
acetylene source that is utilized to provide back-up supply of
acetylene while the primary acetylene source (e.g., first trailer
10) is allowed to increase in pressure to a predetermined
level.
[0019] Because acetylene can decompose explosively into carbon and
hydrogen under conditions of high pressure and temperature, even in
the absence of air or oxygen, the acetylene cylinders as used
herein are specifically prepared to avoid decomposition of
acetylene. In particular, each of the first set and second set of
cylinders 11 and 21, respectively, are prepared to contain porous
filler with solvent distributed into the porous material. Solvent
such as acetone, dimethylformamide (DMF) or N-methylpyrrolidone
(NMP) can be employed. The porous filler is a porous mass generally
having a certain porosity, such as, by way of example, a porosity
of about 10-90% by volume; preferably about 30-90% by volume; and
more preferably about 50-90% by volume. The porous filler allows
the acetylene to be separated into small units in the pores that
help to inhibit the decomposition of acetylene when stored within
the first set and second set of cylinders 11 and 21, respectively.
The solvent absorbs a sufficient amount of acetylene to enable high
cylinder loading in the cylinders. DMF is preferably used as the
solvent. One method for possible cylinder preparation for charging
high purity acetylene is descried in U.S. Pat. No. 8,322,383, the
contents of which are hereby incorporated by reference in their
entirety. Other suitable methods for acetylene cylinder preparation
as known in the art may also be employed.
[0020] After preparation of the first set of cylinders 11 and the
second set of cylinders 21, acetylene may be charged therein.
Methods for filling the first set of acetylene trailers 10 and the
second set of acetylene cylinders 20 are described in U.S. Patent
Publication Application Nos. 20130213521 and 20140290791, the
contents of both which are hereby incorporated by reference in
their entirety. Other suitable methods may also be utilized. Having
filled the first set of cylinders 11 and the second set of
cylinders 21, they can be loaded onto their first trailer 10 and
second trailer 20, respectively, and thereafter transported to the
customer point of use 40. The point of use 40 can also be a
manufacturing process, a reservoir for storage, point of
consumption, a gas transport infrastructure, a pipeline or any
other location that requires compressed acetylene.
[0021] The first of set of cylinders 11 are loaded onto the first
trailer 10, and the second set of cylinders 21 are loaded onto the
second trailer 20. It should be understood that the loading of
cylinders 11 and 21 onto trailers 10 and 20, respectively, can
occur before or after acetylene charging into the first set of
cylinders 11 and the second set of cylinders 21. The first set of
cylinders 11 are preferably manifolded together in a parallel
arrangement so that each of the first set of cylinders 11 is
supplying acetylene during operation of the first trailer 10.
Similarly, the second set of cylinders 21 are preferably manifolded
together in a parallel arrangement so that each of the second set
of cylinders 21 is supplying acetylene during operation of the
second trailer 20. In a preferred embodiment, each of the first and
second trailers 10 and 20 can hold approximately 200 cylinders that
are manifolded together to give a total available volume of
approximately 75,000 cubic ft. It should be understood that the
first and second trailers 10 and 20 can be modified as known in the
art to hold a higher number or lower number of cylinders as needed
for a particular application.
[0022] In accordance with one aspect of the present invention, FIG.
1 illustrates a process 1 for acetylene delivery from a two trailer
system that includes a first trailer 10 and a second trailer 20
configured to supply acetylene to a customer point of use 40. The
trailers 10 and 20 are configured to supply acetylene to a customer
point of use 40 through skid-mounted apparatus 50.
[0023] FIG. 1 indicates by dotted line the skid-mounted apparatus
50. It should be understood that FIG. 1 is not drawn to scale, and
some features are intentionally omitted for purposes of clarity to
better illustrate the principles of the present invention. In this
regard, the skid-mounted apparatus 50 is intentionally shown to be
larger in overall size compared to other components, including the
first trailer 10 and the second trailer 20, for purposes of better
conveying the operation of the various aspects of the present
invention. The skid-mounted apparatus 50 is operably connected to
the first trailer 10 at location 81 by a suitable connection 102
(FIG. 2) and operably connected to the second trailer 20 at
location 82 by a suitable connection 103 (FIG. 2). Any suitable
connection 102 and 103 may be utilized, including for example, a
valve connection, such as a CPV union shutoff valve. Additionally,
the process 1 may employ any suitable conduit or flow leg. As used
herein and in the claims, the terms "conduit" and "flow leg" mean
flow paths within the process 1 for delivery of acetylene that are
formed by any conventional piping, hoses and the like.
[0024] The skid mounted apparatus 50 acts as a fluid conduit
between the trailers 10 and 20 and the customer point of use 40
that is able to activate flow from either the first trailer 10
(labelled Acetylene Trailer A in FIG. 1) or the second trailer 20
(labelled Acetylene Trailer B in FIG. 1) as will be described. The
skid-mounted apparatus 50 includes various components, including,
but not limited to, a programmable logic controller (PLC) 60;
pressure regulating devices 51 and 52; pressure transmitters 57 and
58; automatic control valves 53 and 54; a discharge manifold 70;
pressure flash arrestors 80; nitrogen cylinders 77 attached to the
platform 49 (FIG. 2); status indicators 93 and 94 for first and
second acetylene trailers 10 and 20 respectively; delivery valves
68 and 59; control valve 99; and suitable conduit connecting the
various components. The PLC 60 is preferably situated on the skid
mounted apparatus 50. The PLC 60 controls the supply of acetylene
from the first trailer 10 and the second trailer 20 in accordance
with the principles of the present invention. The PLC 60 also
controls the various valving, including automatic control valves 53
and 54 and pressure regulating devices 51 and 52. Dotted lines from
control valves 53 and 54 to PLC 60 designate communication
therebetween. Dotted lines from each of pressure transmitters 57,
58, 87 and 88 to PLC 60 also indicate communication therebetween.
The apparatus 50 comprises a modular platform 49 (best seen in
FIGS. 2 and 3) that preferably occupies a foot print of not more
than about 50 ft2 based on a design of approximately 5 feet wide by
10 feet long. In a preferred embodiment, the foot print is not more
than about 40 ft2, and more preferably about 30-35 ft2. The
compactness of the skid-mounted apparatus 50 allows it to be
transported to various customer points of use 40, where the
apparatus 50 can be readily coupled to acetylene sources such as
trailers 10 and 20. In this manner, the geometric design of the
skid-mounted apparatus 50 provides a modular "plug and operate"
capability for handling the delivery of acetylene from multiple
acetylene sources in an optimized manner.
[0025] Referring to FIG. 1, the skid mounted platform 50 contains
PLC 60 that initiates delivery of acetylene from the first trailer
10 by transmitting signals to one or more automatic control valves
to be set in an open position along the first flow leg 90. The
second trailer 20 is maintained off line in a standby mode. At
start-up, status indicator 93 for the first trailer 10 is "on line"
and the status indicator 94 for the second trailer 20 is indicated
as "off line" or "standby". With the first trailer 10 online, the
valves corresponding to the cylinders 11 are set to the open
positon to allow acetylene to be discharged from each of the first
set of cylinders 11 along the first flow leg 90. Preferably, for
ease of operation, the cylinders 11 remain configured in the open
position, even when off-line.
[0026] The PLC 60 preferably receives the delivery pressure as a
user input. The PLC 60 sends a signal to activate control valve 53
to an open position; sends another signal to activate control valve
99 to an open position to enable acetylene flow from the skid
mounted platform 50 to the customer point of use 40; and checks to
ensure that control valve 54 is set in the closed position so that
acetylene is not inadvertently flowing from the second set of
cylinders 21 loaded on the acetylene trailer 20 into the second
flow leg 91. If control valve 54 is in the open position, the PLC
60 sends a signal to activate control valve 54 into the closed
positon. Any suitable method can be employed by which the PLC
activates the various control valves 53, 54 and 99 into either the
open or closed position. One example is as follows. Nitrogen is
withdrawn from cylinders 77 and is directed to a pressure regulator
78 which regulates the pressure of the nitrogen to 90 psi.
Thereafter, the nitrogen is directed to one of the solenoid valves
61, 62 or 63 which are in parallel arrangement with one another.
The exact solenoid valve 61, 62 or 63 to which nitrogen is directed
depends on which control valve 53, 54 or 99 is to be activated.
Solenoid valve 61 is in communication with control valve 53;
solenoid valve 62 is in communication with control valve 54; and
solenoid valve 63 is in communication with control valve 99. Each
of the solenoid valves 61, 62 and 63 is controlled by the PLC 60;
and each of the solenoid valves 61, 62 and 63 is energized, as
nitrogen is supplied to a pneumatic positioner (not shown)
corresponding to the control valve 53, 44 and 99. For example, when
solenoid valve 61 is energized by a 4-20 mA signal, nitrogen from
the cylinders 77 is directed to the pneumatic positioner of the
control valve 53, thereby causing the control valve 53 to open and
close. Control valves 54 and 99 in FIG. 1 are activated in a
similar manner. This activation is merely one example that is
intended to illustrate a representative method for activation of
the control valves 53, 54 and 99 herein. It should be understood
other suitable means for activating control valves 53, 54 and 99
may be utilized as known in the art.
[0027] Valves 68 and 59 are shown in FIG. 1 as manual valves that
are turned to the open position by an operator or end-user. It
should be understood that valve 68 and/or 59 and other manual
valves in the process 1 may alternatively be configured as
automatic control valves that are activated by the PLC 60 as
described hereinbefore.
[0028] At least control valve 54 is set in the closed position
along the second flow leg 91 to prevent flow from the second set of
cylinders 21 of the second trailer 20 when the primary acetylene
trailer 10 is on-line.
[0029] Having configured the valving of the first flow leg 90 to
the open position and the appropriate valving of second flow leg 91
to the closed position so as to prevent flow from the secondary
acetylene trailer 20, acetylene can be supplied from the first set
of cylinders 11 of the primary trailer 10. As acetylene flows from
each of the first set of cylinders 11 contained in the primary
trailer 10 into the inlet 81 of skid mounted apparatus 50, pressure
regulating device 51 regulates the pressure of acetylene from the
initial source pressure in the manifolded first set of cylinders 11
(e.g., about 250 psig at start-up) to a predefined delivery
pressure. In a preferred embodiment, the predefined delivery
pressure is set to about, 10-40 psig, preferably 10-25 psig and
more preferably about 15 psig. It should be understood that the
present invention can also supply acetylene at other delivery
pressures. The exact delivery pressure may be dependent upon
several factors, including the pressure required by the customer at
the customer point of use 40 for the specific application for which
the acetylene is utilized (e.g., welding gas, heat treating gas or
carburization gas applications).
[0030] Acetylene continues to flow through a hose 71 connected to
the pressure regulating device 51 and thereafter through check
valve 74, and control valve 53 along the first flow leg 90.
Acetylene from the first set of cylinders 11 enters one side of a
discharge manifold 70, which is a conduit that unites the first
flow leg 90 with the second flow leg 91. A pressure
transducer/transmitter 87 measures the pressure of acetylene
flowing into the discharge manifold 70; and then relays the signal
as an input to the PLC 60. The PLC 60 may adjust the pressure if
necessary by, for example, adjusting the pressure regulating device
51 to ensure the pressure of acetylene along the first flow leg 90
is within acceptable tolerance limits of the delivery pressure
required at the customer point of use 40 (e.g., a delivery pressure
of 15 psig, plus or minus 1 psig). Thereafter, the acetylene flows
along a third flow leg 84 extending into the flash arrestors 80.
The flash arrestors 80 are a safety device designed to stop an
acetylene flash. The flash arrestors 80 as shown in FIG. 1 are
arranged in parallel and located between the first flow leg 90 and
the outlet flow leg 100. The stream of acetylene flowing along
third flow leg 84 is distributed into each flash arrestor 80.
Pressure transducers (not shown) are situated on either side of the
flash arrestors 80, and measure a differential pressure across the
flash arrestors 80 that will shut down the process 1 if the
differential pressure across the flash arrestors 80 reaches an
established set point.
[0031] The acetylene emerges from the outlet of each of the flash
arrestors 80, and then converges as a single stream that flows
along the outlet flow leg 100. A pressure gauge 86 along the outlet
flow leg 100 measures the pressure of the acetylene stream. FIG. 1
also shows a downstream pipeline pressure transmitter 88 which
measures the pressure and relays a signal input to the PLC 60 to
ensure the pressure of the acetylene stream is at the predetermined
delivery pressure prior to the acetylene stream exiting from the
outlet leg 100; exiting the skid 50 through the control valve 99
and a subsequent mass flow meter 98; and then supplied to the
customer point of use 40. Although flow is not controlled in the
embodiment of FIG. 1, the acetylene in accordance with one aspect
of the present invention can be supplied at a substantially
constant delivery pressure of 10-30 psig with a flow rate no
greater than approximately 3000 standard cubic feet per hour
(SCFH); preferably a substantially constant delivery pressure of
15-25 psig and a flow rate no greater than approximately 3000 SCFH;
and more preferably 15 psig at a flow greater no greater than
approximately 3000 SCFH.
[0032] Acetylene at substantially constant delivery pressure
continues to be supplied in this manner from the first set of
cylinders 11 of the primary trailer 10 until the source pressure of
acetylene from the first set of cylinders 11 in the primary trailer
10 has reduced to a predetermined minimum pressure. In particular,
this predetermined minimum pressure is defined as the source
pressure of acetylene decreasing by no more than about 70% of its
initial source pressure, preferably no more than about 75% of its
initial source pressure, and more preferably no more than about 80%
of its initial source pressure. It should be understood that the
source pressure may be measured with a pressure gauge (not shown)
or pressure transducer, either of which is preferably located
within the respective manifolded regions at which the first set 11
of cylinders are interconnected. Other suitable means for measuring
the pressure are also contemplated. The process 1 of FIG. 1 is
designed and operated such that supply of acetylene from the
first/primary trailer 10 does not occur below a source pressure
that has been reduced to this predetermined minimum pressure. In
particular, unlike conventional acetylene supply systems, the
present invention has discovered that solvent carry-over or
entrainment into the acetylene withdrawn from the first set of
cylinders 11 may occur when the source pressure of acetylene in the
cylinders 11 reduces below the predetermined minimum pressure,
thereby undesirably introducing solvent impurities (e.g.,
dimethylformaldehyde (DMF), acetone and N-methylpyrrolidone (NMP))
into the acetylene that is withdrawn from the first set of
cylinders 11. For example, when the source pressure of acetylene in
the first set of cylinders 11 has decreased by a predetermined
level of 80% or greater, it has been discovered by Applicants that
the carry-over of solvent into the withdrawn acetylene can increase
by approximately a factor of 10-50, which reduces the purity level
of acetylene that is supplied to the customer point of use 40. As
such, unlike conventional acetylene delivery sources, the present
invention is directed to not only maintaining a substantially
constant supply of acetylene with regards to delivery pressure, but
also maintaining the purity of the acetylene supply by preventing
the source pressure of the primary trailer 10 from dropping below a
predetermined minimum pressure no more than about 70% of its
initial source pressure, preferably no more than about 75% of its
initial source pressure, and more preferably no more than about 80%
of its initial source pressure. Accordingly, the process 1 has the
ability to control the amount of carry-over solvent to minimize,
reduce or eliminate the solvent contamination of the acetylene
withdrawn from the first set of cylinders 11. A suitable chemical
analyzer as known in the art may be incorporated into the process 1
to measure impurities of the acetylene along the first flow leg
90.
[0033] A switchover from the first trailer 10 to the second trailer
occurs 20 when the source pressure of the first trailer 10 has
reduced to this predetermined minimum pressure level. Specifically,
and in a preferred aspect of the present invention, the pressure
transmitter 57 along the first flow leg 90 measures the source
pressure of the acetylene from the first trailer 10 to decrease
from an initial source pressure of 250 psig to no more than about
50 psig, which represents a 80% decrease in pressure. In response
thereto, pressure transmitter 57 sends a signal to the PLC 60,
which then directs control valve 53 to be set in the closed
position along the first flow leg 90; and directs control valve 54
to be set in the open position along the second flow leg 91. The
PLC 60 may direct the other valves on the second flow leg 91 to be
set to the open position if previously in a closed position.
Alternatively, such other valves may remain open to minimize the
number of valves required to be opened and closed during switchover
of acetylene supply between the first trailer 10 to second trailer
20 and vice versa. Valves 59 and 88 are manually configured in the
open positon. Alternatively, the valves 59 and 88 may be configured
by signals relayed from the PLC 60 to the valves 59 and 88 if the
valves 59 and 88 are control valves.
[0034] The PLC 60 transmits a signal to status indicator 93 that
changes the status indicator 93 for the first trailer 10 from
"online" to "offline"; and the PLC 60 sends another signal to
status indicator 94 that changes the status indicator 94 for the
second trailer 20 from "offline" to "online". Additionally, the PLC
60 detects when the first acetylene trailer 10 has undergone the
change in status between a minimum pressure state and an online
state; and subsequently transmits an alert notification to a main
central location and/or remote unit (e.g., cell phone, pager,
computer) over a cellular network or cyber secure interne link
indicating the first trailer 10 has changed status from an "online`
mode to an "offline" or "minimum pressure" mode, as will be
explained in greater detail with respect to the embodiment of FIG.
5. The remote alert notification may further indicate that the
first trailer 10 is not to be removed from the process 1, but
rather allowed a certain duration for the first set of cylinders 11
to absorb ambient heat and/or remain subject to suitable heating
means sufficient to re-vaporize residual acetylene absorbed within
the solvent, as will be described below.
[0035] Second trailer 20 is shown in FIGS. 1 and 2 to be operably
connected to the inlet 82 of skid-mounted apparatus 50 via
connection 103 (FIG. 2 and FIG. 3). The acetylene flows from each
of the second set of cylinders 21 loaded on the secondary trailer
20 and then into the inlet 82 of skid mounted apparatus 50.
Pressure regulating device 52 regulates the pressure of acetylene
from the source pressure in the manifolded cylinders 21 (e.g.,
about 250 psig at start-up) to the predetermined delivery pressure
(e.g., preferably about 10-20 psig). Acetylene continues to flow
through a hose 72 connected to the pressure regulating device 52
and thereafter the acetylene flows through check valve 73 and
control valve 54. Acetylene enters a second side of the discharge
manifold 70. The second side of the discharge manifold 70 is
preferably a different conduit from the first side of the discharge
manifold 70 into which acetylene from the first trailer 10 is
supplied, as shown in FIG. 1. A pressure transducer/transmitter 87
measures the pressure of acetylene flowing into the discharge
manifold 70; and then relays the signal as an input to the PLC 60.
The PLC 60 may adjust the pressure if necessary by, for example,
adjusting the pressure regulating device 52 to ensure the pressure
of acetylene is within acceptable tolerance limits of the delivery
pressure required at the customer point of use 40 (e.g., a delivery
pressure of 15 psig, plus or minus 1 psig). Thereafter, the
acetylene flows along a third flow leg 84 extending into the flash
arrestors 80. The acetylene along third flow leg 84 is distributed
into each flash arrestor 80. Pressure transducers (not shown) are
situated on either side of the flash arrestors 80, and measure a
differential pressure across the flash arrestors 80 that will shut
down the process 1 if the differential pressure across the flash
arrestors 80 reaches an established set point.
[0036] The acetylene emerges from the outlet of each of the flash
arrestors 80, and then converges as a single stream that flows
along the outlet flow leg 100. A pressure gauge 86 along the outlet
flow leg 100 measures the pressure of the acetylene stream. FIG. 1
also shows a downstream pipeline pressure transmitter 88 which
measures the pressure and relays a signal input to the PLC 60 to
ensure the pressure of the acetylene stream is at the predetermined
delivery pressure prior to the acetylene stream exiting the outlet
leg 100 and exiting the skid 50 through the control valve 99; a
subsequent mass flow meter 98; and then reaching the customer point
of use 40. As with acetylene supply from the first trailer 10,
although flow is not controlled, in accordance with an aspect of
the present invention, the acetylene can be supplied from the
second set of cylinders 20 at a substantially constant delivery
pressure of 10-30 psig with a flow rate no greater than
approximately 3000 standard cubic feet per hour (SCFH); preferably
a substantially constant delivery pressure of 15-25 psig and a flow
rate no greater than approximately 3000 SCFH; and more preferably
15 psig at a flow greater no greater than approximately 3000
SCFH.
[0037] As acetylene is supplied from the second set of cylinders 21
of the second trailer 20, the present invention maintains operable
connection of the first trailer 10 to the process 1. This is
contrary to conventional acetylene supply systems which disconnect
the primary acetylene source from operational use for re-filling.
Applicants have discovered that as acetylene is withdrawn from the
first set of cylinders 11, there is a cooling effect whereby the
temperature of the cylinders 11 is reduced. Without being bound by
any theory, the cooling effect may occur to a degree where a
portion of the acetylene liquefies. As a result of the
liquefaction, the cylinder 11 pressure is reduced as hereinbefore
described, and may be reduced further to a level that is below the
predetermined minimum pressure limit (e.g., no more than about 80%
decrease in initial source pressure of the first set of cylinders
11). Further, the present invention recognizes that as the
temperature of the first set of cylinders 11 decreases, the solvent
contained therewithin has a greater affinity for acetylene in the
cylinder whereby it has a tendency to hold a larger volume of
residual acetylene, thereby reducing the available capacity of
acetylene vapor in the acetylene cylinder 11. Monitoring equipment
and control systems will generally indicate to the user or operator
a so-called "false positive" improperly indicating that the
acetylene cylinders 11 are empty and need to be disengaged and
removed from the process 1 and replaced with a new acetylene
source. However, Applicants have discovered that the acetylene is
not entirely depleted at this stage. In addition to this false
positive, as mentioned hereinbefore, the continued supply of
acetylene from the first set of cylinders 11 below a predetermined
minimum pressure may cause undesirable entrainment of the solvent
with the acetylene withdrawn from the cylinders 11, resulting in
not only lower acetylene delivery pressure, but lower purity levels
that may not meet applicable purity specifications at the customer
point of use 40 for certain applications, thereby causing
conventional supply systems to abort use of the primary trailer
10.
[0038] In accordance with the principles of the present invention,
and contrary to conventional acetylene supply systems, the offline
trailer 10 is not disengaged from the process 1; nor is the offline
trailer 10 re-filled while in the "offline" or "standby" mode.
Rather, the primary trailer 10 maintains operably connected to the
skid-mounted apparatus 50 without re-filling for a certain
duration, and with the status indicator 93 indicating an "offline"
or "standby" mode. During this so-called temporary "offline" or
"standby" mode, the first set of cylinders 11 will increase in
temperature as a result of absorbing ambient heat and/or subject to
other suitable heating means, thereby causing the residual
liquefied acetylene to re-vaporize such that the partial pressure
of acetylene in the first set of cylinders 11 is increased to a
level sufficiently high enough to supply therefrom at the
predetermined delivery pressure. The pressure in the first trailer
10 is greater than the delivery pressure. In one example, the
pressure in the first trailer 10, while being temporarily offline,
increases to greater than 50 psig, such as by way of example, about
59 to about 65 psig, preferably 60 to about 62 psig, and more
preferably about 61 to about 65 psig, prior to the controller 60
switching from the second trailer 20 to the first trailer 10 and
resuming supply from the first trailer 10. The pressure in the
manifolded first set of cylinders 11 of the first trailer 10 is
preferably monitored to determine when the pressure of acetylene
has risen to above the delivery pressure, and in a more preferred
embodiment, has risen to a pressure of at least 60 to about 62
psig. Depending on the heating means and number of cylinders 10,
the duration that the first set of cylinders 11 may remain offline
is approximately 1-75 hours or in another example 10-48 hours. In
yet another example, the first set of cylinders is offline for 1-24
hours.
[0039] When the source pressure in the cylinders 11 of the first
trailer 10 has risen to a sufficient level to generate the required
delivery pressure, PLC 60 reactivates supply from the first trailer
10. In one example, supply of acetylene from the first trailer 10
increases to greater than 20% of an initial source pressure, which
can be greater than 50 psig. In this regard, PLC 60 direct signals
to activate control valve 53 along the first flow leg 90 to be set
to an open position. Valve 68 is shown as a manual valve and is set
to the open positon if previously set to the close position.
Alternatively, valve 68 may remain in the open position to simplify
operation by reducing the number of valves that must be
reconfigured between open and close positions. At minimum, control
valve 54 along the second flow leg 92 is set in the closed position
to prevent flow from the second set of cylinders 21 loaded on the
second trailer 20. In this manner, the second trailer 20 is
oriented to "standby" or "offline" mode, and the PLC 60 relays
signals to change status indicator 94 of the second trailer 20 to
standby/offline mode along with appropriate alert remote
notifications (FIG. 5). The first trailer 10 is re-activated to
online mode, and PLC 60 relays signals to change status indicator
93 of the first trailer 10 to online mode along with appropriate
alert remote notifications (FIG. 5).
[0040] With the appropriate valving for the first trailer 10
re-configured to the open position, supply of acetylene
re-initiates from the first set of cylinders 11. Specifically,
acetylene flows from each of the first set of cylinders 11 of the
first trailer 10 and into the inlet 81 of skid mounted apparatus
50. Acetylene continues to flow through the apparatus 50 and to
customer point of use 40 as previously described.
[0041] The process 1 recognizes that acetylene is being supplied a
second time from the first trailer 10. As such, when the source
pressure of the first set of cylinders 11 has reduced to a final
pressure (e.g., less than delivery pressure of, by way of example,
15 psig), the cylinders 11 are considered depleted, at which point
the PLC 60 send signals to abort supply from the first set of
cylinders 11 and configure at least control valve 53 to the off
position. Valves 68 and 88 can remain in the open position or also
be set to the closed position.
[0042] Trailer 10 is disconnected from connection 102 to allow the
trailer 10 to be removed from the inlet 81 of skid mounted
apparatus 50. Status indicator 93 for the first trailer 10 may
indicate "depleted" or "permanently depleted" and further indicate
that a new trailer is required. Alert remote notifications to this
effect are also relayed (FIG. 5). At this point in the process 1,
trailer 10 can be replaced with a new trailer with adequate levels
of acetylene, and the new trailer is operably connected to the skid
50. Alternatively, the second trailer 20 can become the primary
trailer and a new secondary trailer can be operably connected to
the skid mounted apparatus 50 in place of the first trailer 10 that
has been depleted. The depleted first trailer 10 can be refilled at
a suitable acetylene filling station, as known in the art.
[0043] PLC 60 may reconfigure the valves along second flow leg 91
to allow flow to resume from the second trailer 20 such that it
becomes the new primary trailer, while the previously depleted
trailer 10 is disconnected from the skid mounted apparatus 50 and
re-filled or replaced with a new trailer, to ensure uninterrupted
flow is provided to the customer point of use 40 at substantially
constant delivery pressure. Alternatively, PLC 60 may activate
another trailer to serve as the primary trailer and the second
trailer 20 continues to function as a secondary trailer as defined
hereinbefore. Status indicators 93 and 94 are updated accordingly.
Remote notifications can also be sent via a cellular network or
secure internet connection to one or more remote units (e.g., cell
phone, pager or computer) to alert customers, users and/or
operators that the primary trailer 10 has been depleted and needs
to be disconnected from the skid mounted apparatus 50 and replaced
with a new acetylene source.
[0044] The present invention offers numerous benefits unprecedented
within the context of acetylene supply systems. For example, the
ability to regulate delivery pressure and monitor when switchover
from a primary acetylene source to a second acetylene source occurs
can prevent the temperature of the cylinder from reducing to a
level where unacceptable amounts of solvent begin to be entrained
with the withdrawn acetylene, thereby reducing the purity of the
acetylene to the customer point of use 40. Applicants have
discovered that lower temperature increases solvent affinity for
acetylene and increases the tendency for solvent to be entrained
with the acetylene that is withdrawn from its respective acetylene
source. The present invention can minimize, reduce or eliminate the
amount of solvent that is entrained with the acetylene that is
withdrawn from the first set of cylinders 11, by switching to a
secondary acetylene source when the pressure in the primary
acetylene source is reduced to a predetermined minimum pressure.
The predetermined minimum pressure defines the minimum pressure to
be delivered to a customer point of use 40 before solvent
impurities are introduced. In a preferred embodiment, the minimum
pressure level is no more than 80% of the initial pressure.
Specifically, when the pressure of the primary acetylene source is
reduced from 250 psig to 50 psig, supply form the primary acetylene
source stops, and the supply resumes from a secondary acetylene
source, thereby avoiding solvent entrainment into the acetylene
that is supplied to the customer point of use 40. As such, the
purity level of acetylene is substantially maintained; the need to
replenish the first set of cylinders 11 to the required solvent
level is significantly reduced; and the utilization of the primary
acetylene source 10 is increased in comparison to conventional
acetylene supply systems.
[0045] As an additional means to ensure purity of the supplied
acetylene, the skid-mounted apparatus 50 includes a condensate leg
69 for removal of moisture and/or other contaminants that may
inadvertently accumulate in the conduits. The present invention
recognizes that moisture in particular can accumulate in the flow
legs 90 and/or 91 despite the flow legs 90 and 91 being purged with
nitrogen prior to acetylene supply, during acetylene supply; and
after acetylene supply from one of the trailers 10 and 20.
Alternatively or in addition thereto, the impurities can arise if
the connections to the trailers 10 and 20 are not clean or when the
connections 81 and 82 to the trailers 10 and 20, respectively, are
disconnected and re-connected to the skid-mounted apparatus 50. As
such, the condensate leg 69 can be periodically opened to remove
any moisture or contaminants entrapped within the process 1 of FIG.
1.
[0046] The portability of the skid-mounted apparatus 50 can be
better appreciated by FIGS. 2 and 3. The portability of the
skid-mounted apparatus 50 avoids the need to assemble on-site the
extensive conduit, valving, and flash arrestors, PLC and data
acquisition system which is required for optimizing the delivery of
acetylene from multiple acetylene sources. FIG. 2 shows a top-down
view of the skid mounted apparatus 50 of FIG. 1 whereby the
required components are self-contained and pre-assembled as a
unitary skid-mounted or portable apparatus 50. Acetylene gas flow
through the skid-mounted apparatus 50 is indicated by the various
arrows. The components (i.e., the conduit, PLC, first and second
flow legs, control valves, manual valves, status indicators,
nitrogen cylinders, etc.) of skid mounted apparatus 50 in FIG. 2
are intended to correspond to those shown in FIG. 1. FIG. 2 shows a
majority of the components shown and described in FIG. 1 to be
mounted directly onto the platform 49. However, for purposes of
clarity, some of the components shown in FIG. 1 have been omitted
from FIG. 2. One end of the skid-mounted apparatus 50 is operably
connected by hose 71 to primary trailer 10 via connection 102; and
the other end of the skid mounted apparatus 50 is operably
connected by hose 72 to the secondary trailer 20 via connection
103. FIG. 2 shows that the pressure regulator 52 situated along the
connection 102 and the pressure regulator 53 situated along the
connection 103. However, it should be understood that the pressure
regulators 52 and 53 can be situated anywhere, including connected
directly or indirectly onto the platform 49.
[0047] FIG. 3 illustrates a perspective view of the skid-mounted
apparatus 50 of FIG. 1 (indicated by dotted line in FIG. 1) showing
the various components responsible for automatically controlling
supply of acetylene from multiple acetylene sources, including
trailers and reserve banks (FIG. 4). The compactness of the
skid-mounted apparatus 50 provides a modular "plug and operate"
capability for delivery of acetylene from multiple acetylene
sources in an optimized manner at substantially constant delivery
pressure, while increasing utilization of acetylene from the
trailers. In a preferred embodiment, the modular platform of the
skid-mounted apparatus 50 is characterized by a footprint having an
area of no more than about 32 ft2. The modularity allows for ease
of transportability to a customer site with convenient plug and
operation to the acetylene sources along one side of the apparatus
50 at inlets 81 and 82 and plug and operation to the customer point
of use 40 along another side of the apparatus 50.
[0048] FIG. 4 shows an alternative process 2 whereby the secondary
trailer 20 of FIG. 1 is replaced with a reserve bank 401, which is
shown in FIG. 4 as a cluster of 12 interconnected cylinders. A
primary acetylene trailer 10 is shown in FIG. 4. The primary
acetylene trailer 10 includes a first set of interconnected
cylinders 11 that supplies acetylene in a manner similar to the way
shown and described with the primary trailer 10 of FIG. 1 and
incorporates similar components as shown in FIG. 1, including the
skid-mounted apparatus 50. For purposes of clarity, some of the
components (e.g., valving, control box, flow legs and conduit)
shown in FIG. 1 have been intentionally omitted from FIG. 4. In
operation, the process 2 is similar to that of FIG. 1. The
difference in the process 2 of FIG. 4 occurs when the source
pressure in the primary acetylene trailer 10 reduces to a
predetermined minimum pressure (preferably, no more than 80% of the
initial source pressure), the supply of acetylene switches from the
primary trailer 10 to the reserve bank 401 instead of a secondary
trailer 20. The reserve bank 401 is a cluster of a certain number
of cylinders permanently deployed at the customer site. FIG. 4
shows a cluster of 12 cylinders. However, it should be understood
that any number of cylinders can be utilized to form the reserve
bank 401. Preferably, the reserve bank 401 is designed to have
enough capacity to provide acetylene flow at the required delivery
pressure until a new primary trailer 10 is delivered to the
customer site and connected to the skid-mounted apparatus 50. In
one example, supply from the reserve bank can last 2-3 days; in
other example, the reserve bank 401 is configured to provide supply
for 1 week or more. In a preferred embodiment, the reserve bank 401
is configured to provide a 2-3 week supply of acetylene. The
process 4 also can include remote alert notifications when
automatic switchover occurs from the primary trailer 10 to the
reserve bank 401. Other remote alert notifications as described in
FIG. 1 can also occur.
[0049] When the new primary acetylene trailer 10 arrives to the
customer site 40, it is connected as shown in FIG. 4 to the
apparatus 50 and the reserve bank 401. Suitable valving and conduit
extends between the new primary acetylene trailer 10 and the
reserve bank 401. When the new primary acetylene trailer 10 is
connected as shown in FIG. 4, it initially provides flow to the
reserve bank 401 until all the cylinder clusters of the reserve
bank 401 have been re-filled. Specifically, the reserve bank 401 is
automatically and continuously filled by the primary trailer 10,
such as, for example, from a port on the upstream side of the
pressure regulator of the primary trailer 10. Other suitable means
for establishing fluid connectivity between the primary trailer 10
and the reserve bank 401 can be employed as would be known and
recognized in the art. After having re-filled the cylinder clusters
of reserve bank 401, the primary acetylene trailer 10 can resume
supply of acetylene, as has been previously described. Because the
depleted primary trailer 10 is replaced within 1-2 days of reaching
the predetermined minimum pressure, the reserve bank 401 has
sufficient capacity during this time period, and therefore is never
depleted. In this manner, the reserve bank 401 can permanently be
maintained at the customer site 40 to provide back-up supply of
acetylene while a new acetylene trailer is transported to the
customer site and operably connected to the process 4.
[0050] In an alternative embodiment, the depleted primary trailer
10 can remain connected to the process 2 and be allowed to absorb
heat and increase in temperature as described hereinbefore in
connection with the embodiment of FIG. 1. In such a scenario,
acetylene supply would switch back from the reserve bank 401 to the
primary trailer 10, thereby increasing utilization of the primary
trailer 10. In one example, supply of acetylene is resumed from the
primary trailer 10 when the pressure of the primary trailer 10
increases to greater than 20% of an initial source pressure of the
primary trailer (e.g., greater than 50 psig). Only when the source
pressure has fallen a second time to the predetermined minimum
pressure would the primary trailer 10 be considered permanently
depleted, at which point flow from reserve bank 401 would resume
until a new acetylene trailer 10 is transported to the customer
site and connected to the process 2. Upon removal of the
permanently depleted trailer 10 and connection of the new trailer
to serve as the new primary trailer 10, the reserve bank 401 is
replenished by the new primary trailer 10, before supply from the
new primary trailer 10 to the customer point of use 40 is
re-initiated. Because this mode of operation requires longer usage
from the reserve bank 401, the reserve bank 401 must be capable of
providing supply for a longer duration in comparison to the mode of
operation in which the primary trailer 10 is removed and replaced
upon its pressure falling to a predetermined minimum pressure for
the first time (i.e., and not given time to heat up and increase to
a sufficient pressure level capable of supplying acetylene a second
time at the desired delivery pressure to the customer point of use
40, as described with reference to the process 1 of FIG. 1). A
longer-lasting supply from the reserve bank 401 prior to being
replenished may require a higher number of cylinders clustered
together to form the bank 401, and/or the use of larger cylinders
or larger bulk vessels.
[0051] In accordance with another embodiment, the present invention
is configured to provide remote alert and fault notifications to
registered remote devices 517, as shown in the communication
infrastructure and system 500 of FIG. 5. The system 500 has the
ability to remotely transmit alarms or shutdowns as it manages,
monitors and stores process and operational data for multiple
acetylene processes carried out in FIG. 1 and FIG. 4 at the
multiple customer sites. Each customer site is provided with the
supply of acetylene in accordance with the principles of the
present invention of FIG. 1 or 4 which have been in detail
hereinbefore. FIG. 5 shows multiple control systems are provided as
part of the control process. Control system 60a is situated at
acetylene customer location "a". Control system 60b is situated at
acetylene customer location "b". Other control systems at various
customer sites can also be provided. Each control system 60a and
60b includes a PLC 115a and 115b, respectively (as described in
connection with the embodiment of FIG. 1), and data collection
device 114a and 114b, respectively, and a secured device 112a and
112b, respectively.
[0052] The PLC 115a at customer location "a" is programmed to look
for an alarm or shutdown of its respective acetylene process 1 or
2. Similarly, the PLC 115b at customer location "b" looks for an
alarm or shutdown of its respective acetylene process 1 or 2. When
the PLC 115a and 115b finds a fault, the process of notification
begins whereby the respective PLC's 115a and 115b send a signal via
the internet or local area network (LAN) to a Supervisory Data
Control and Data Acquisition (SCADA) Server 507. The SCADA server
507 is a supervisory control system that collects all the
information, including all the alarms and shutdowns at each
customer site "a" and "b" from the multiple different on-site
acetylene supply processes 1 and 2. In order words, the SCADA
server 507 is a warehouse of information and monitors all the
alarms for all the different systems and processes 1 and 2 (FIGS. 1
and 4) that are deployed at multiple customer sites. For example,
the various PLC's 60a/60b at their respective customer sites
receive and gather data from their respective pressure transmitters
57a/57b and then communicate such data to the SCADA server 507.
Each of the pressure transmitters 57 at the various customer sites
is registered with the SCADA server 507. The SCADA server 507
collects all the pressure information from the remoter PLC's 60a/b
through a cyber-secure network 509/510 thereby enabling the
information to be securely transferred to a central location where
the SCADA server 507 is located. One of the secure networks goes
through a LAN network and the other secure network goes thru the
Internet (cloud). As such, in this aspect of the present invention,
there can be primarily two ways by which information is remotely
transmitted from the on-site customer location 60a and 60b to the
SCADA server 507, thereby allowing the present invention to
implement a completely autonomous switchover acetylene supply
system.
[0053] If there is a fault (for example, an overpressure situation
during delivery where the delivery pressure is 5 psig or higher
than set point; the flash arrestors absorb a flash; or a clog
exists in the process 1 or 4 that creates a sudden pressure rise
above a certain safety threshold level), the PLC 115a and/or 115b
at that particular site where the fault occurs will register an
alarm at the customer location 60a/b, such as by way of the status
indicators 93 and 94 (FIG. 1). The SCADA 107 also transmits
specific alerts to remote devices 517, such as cell phones or
pagers as shown in FIG. 5.
[0054] In addition to such faults, the communication infrastructure
500 of FIG. 5 can send out an alarm that the primary trailer 10 is
temporary depleted or permanently empty as described hereinbefore.
The alarm is sent from the respective PLC 60a/b located at that
particular customer site 60a/b. The alarm can be transmitted via a
communications network such as the internet or LAN to the SCADA
Server 507, which is generally based remotely and located away from
the customer sites 60a/b. By way of example, when the pressure of
the first set of cylinders 11 of first trailer 10 at customer site
60a (i.e., plant a) has reduced to 50 psig, the PLC 60a at plant a
will transmit a signal to the status indicators 93 and 94 at site
a; transmit a signal back to the SCADA Server 507 by either the
Internet or LAN through its respective secured network, as shown in
FIG. 5, which can then send remote alert notifications to remote
devices 517.
[0055] FIG. 5 also shows that an end-user 501 can dial into the
operations. A remote access terminal server 503 acts as a firewall
that allows end users 501 with proper security and recognized
passwords to log onto the communication infrastructure and system
500 to enable the access of the warehouse of certain information at
the SCADA sever 507. As a further means for security, the Secured
Devices 112a/b only allows secured (encrypted) communications to
occur from its corresponding customer site 60a or 60b to the SCADA
server 507. Each of the Secured Devices 112 a/b at its respective
customer site 60a or 60b has a specific IP address that is only
recognized by the SCADA server 107. In this regard, when an
end-user 501 logs onto the Office Network, and then access the
Terminal Server and looks at the SCADA server 507, the SCADA server
507 goes out to the corresponding Secured Devices 112a/b that only
that particular end-user 501 is linked with and recognizes is
present at that customer site 60a/b that the registered end-user
501 can access.
[0056] While it has been shown and described what is considered to
be certain embodiments of the invention, it will, of course, be
understood that various modifications and changes in form or detail
can readily be made without departing from the spirit and scope of
the invention. It is, therefore, intended that this invention not
be limited to the exact form and detail herein shown and described,
nor to anything less than the whole of the invention herein
disclosed and hereinafter claimed. For example, suitable
modifications for carrying out the process 1 and 4 for delivery of
acetylene are contemplated. In particular, although the various
embodiments have been described with regards to cylinders, it
should be understood that any type of container for acetylene
source can used, including, by way of example and not intending to
be limiting, bulk vessels and ISO containers. Further, although the
modularity of the apparatus 50 has been defined as skid-mounted, it
should be understood that any other suitable portable apparatus or
platform 49 may be utilized, having modularity and compactness.
Still further, various components may be assembled in close
proximity to the skid-mounted apparatus 50. For example, although
the PLC 60 has been shown and described in the embodiments as
located onto the platform 49 of the skid-mounted apparatus 50 for
purposes of conforming to certain regulatory approvals, the PLC 60
and associated control panel can be configured so as to be, one
example, 5-15 ft away from the edge of platform 49 when deployed in
a nonclassified area. Further, although the embodiments have
utilized pressure as the basis for switching between a primary
source and a secondary source, it should be understood that other
manipulated variables may be employed to serve as the basis for
switchover, including temperature and flow rate.
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