SOURCE MOUNTED MODULAR SAMPLE CONDITIONING SYSTEM

Abstract

A modular sample conditioning system formed for in-situ sampling installation, referenced herein as “source mounted”. The preferred embodiment of the present invention relates to a docking platform or substrate configured to receive multiple, diverse sampling components in various flow configurations, coupled with a unique housing/enclosure formed to engage the docking platform so as to further strengthen and stabilize the mount, the enclosure also formed to engage one or more of the mounted sampling components, so as to provide access outside of the enclosure for visibility and/or manual access of same, providing an easily installed and maintained, user-accessible, on-site modular sampling conditioning/monitoring system.

Claims

1. The method of providing a modular sample system, comprising the steps of: a. providing a substrate coupling formed to engage a fluid passage, said substrate coupling formed to selectively facilitate the passage of an extraction device therethrough; b. mounting said substrate coupling to a process isolation valve that is mounted to a conduit containing a pressurized fluid; c. mounting a substrate bracket to said substrate coupling, said substrate bracket having emanating therefrom a module mounting area having a length; d. mounting one or more modular components along the length of said module mounting area; e. providing fluid from said fluid extraction device to said modular components; f. facilitating the passage of said fluid extraction device through said substrate coupling to engage the pressurized fluid; g. facilitating the flow of fluid from said fluid extraction device to said modular components; h. using first and second enclosure components to engage said substrate coupling to enclose same, forming a housing, while i. allowing portions of said modular components to pass through said housing, providing exterior portions of said modular components outside of said housing for visibility and access.

2. The method of claim 1, wherein in step “c” there is included the added step of forming a base as part of said substrate bracket, said base having a width and depth, and in step “h” there is included the step of combining said enclosure components to provide a housing having an interior width and depth closely approximating the width and depth of said substrate bracket base, said housing having formed therethrough module component openings positioned for alignment with said modular components mounted to said substrate bracket, so as to engage same to provide a structural integration between said enclosure components, substrate bracket, module components, and substrate coupling so as to enhance stability, while increasing rigidity of the system.

3. The method of claim 1, wherein in step “d” said modular components comprise modular sample components, and wherein there is provided the added step “j” of facilitating the flow of fluid from said modular sample components to an analyzer.

4. The method of claim 3, wherein said modular sample components comprise modular sample conditioning components, and wherein in step “j” there is added the step of using said modular sample conditioning components to condition said pressurized fluid, providing conditioned sample fluid, and directing said conditioned sample fluid to said analyzer.

5. The method of claim 4, wherein in step “h” there is further included the steps of utilizing said first and second housing components to enclose said module mounting area of said substrate bracket, while allowing the passage of portions of said module components therethrough.

6. The method of claim 5, wherein in step “c” said module mounting area has module mounting apertures formed along its length to receive said module components, and in step “h” said enclosure components are formed to engage along their length and have formed there along module passages aligned with said module mounting apertures of said mounting area, so as to allow the passage of portions of said module components through said assembled enclosure components, providing access to said components exterior to a housing formed by said assembled enclosure components.

7. The method of claim 6, wherein there is provided the added step “k” of utilizing said exterior access to monitor and control the flow of fluid to said modular components.

8. The method of claim 7, wherein there is provided the added step “l” of providing openings in said housing to allow the passage of said extraction device without the need to remove said substrate bracket or substrate coupling, so as to allow each enclosure module to be removed independently without hinges.

9. The method of claim 8, wherein said fluid extraction device comprises a sample probe.

10. The method of claim 6, wherein said housing is insulated, and there is provided the added step of heating said enclosure utilizing heat trace tubing from an analyzer.

11. The method of claim 6, wherein there is provided the added step of securing said enclosure components to one another via pins to selectively form said housing.

12. The method of claim 6, wherein there is provided the added step of securing said enclosure components to one another via clips to selectively form said housing.

13. A modular sampling system for retrieving a sample from a pressurized gas source, comprising: a coupling formed to engage a process isolation valve in fluid communication with a pressurized fluid, said coupling formed to allow the selective passage of an extraction device therethrough to engage said pressurized gas source; a mounting bracket having a base engaging said coupling, said mounting bracket having emanating therefrom a module mounting area having a length; one or more modular components mounted along the length of said modular mounting area mounting bracket, said modular components having fluid communication therebetween pursuant to a desired flow path, said modular components formed to receive fluid from said fluid extraction device; first and second enclosure components formed to engage said substrate coupling to enclose same, forming a housing, said first and second enclosure components having formed thereon opening for the passage of portions of said modular components therethrough, so as to facilitate exterior access of said modular components outside of said housing.

14. The apparatus of claim 13, wherein said housing is formed to allow portions of said modular components to be accessible exterior said housing to monitor and control same.

15. The apparatus of claim 14, wherein said modular components comprise modular sample components are configured to provide a sample for an analyzer.

16. The apparatus of claim 14, wherein said modular sample components comprise modular sample conditioning components configured to condition said pressurized fluid.

17. The apparatus claim 14, wherein said first and second enclosure components enclose said module mounting area of said substrate bracket, forming a housing, while allowing the passage of portions of said module components for access exterior said housing.

18. The apparatus of claim 15, wherein said module mounting area has module mounting apertures formed along its length to receive said module components, and said enclosure components are formed to engage along their length and have formed there along module passages aligned with said module mounting apertures of said mounting area, so as to allow the passage of portions of said module components mounted to said mounting area through said assembled enclosure components, so as to provide access to said components exterior to said housing formed by said assembled enclosure components.

19. The apparatus of claim 18, said components exterior to said housing are positioned to be monitored as well as condition fluid flowing to said modular components.

20. The apparatus of claim 17, wherein said housing is formed to allow the passage of said extraction device through said coupling without the need to remove said mounting bracket or said coupling, as well as allow each enclosure module to be removed independently without hinges.

21. The apparatus of claim 17, wherein said fluid extraction device comprises a sample probe.

22. The apparatus of claim 16, wherein said housing is insulated, and a heater for selectively heating fluid passing through said module components.

23. The apparatus of claim 17, wherein said enclosure components are secured to one another via pins to selectively form said housing.

24. The apparatus of claim 17, wherein said enclosure components are secured to one another via clips to selectively form said housing.

25. The apparatus of claim 18, wherein said base of said mounting bracket has a width and depth, and said housing has an interior width and depth closely approximating the width and depth of said mounting bracket base, said housing further having formed therein module component openings positioned for alignment with said modular components mounted to said mounting bracket to engage same, said enclosure components, module components, and substrate coupling formed to engage one another so as to provide a structural integration therebetween, said integration enhancing stability, while increasing rigidity of the system.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0026] For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:

[0027] FIGS. 1A-1C are partially cut-away, isometric, side, and end views, respectively, of a pressurized source contained in a pipeline an isolation valve mounted thereto.

[0028] FIGS. 2A-2C are isometric, side, and end views of the device of FIGS. 1A-1C, respectively, with the substrate coupling (3) mounted thereto.

[0029] FIGS. 3A-3C are isometric, side, and end views of the device of FIGS. 2A-2C, respectively, with the extraction device (4) mounted thereto.

[0030] FIG. 4A-4B shows opposing perspective views of modular sample components forming a modular sample conditioning system (5), the components mounted to the substrate bracket or, alternatively referenced, mounting bracket.

[0031] FIG. 5 is an upper, isometric view of the substrate bracket (6) (a/k/a mounting bracket) of the present system.

[0032] FIGS. 6A and 6b are front and side views, respectively, of the first, preferred embodiment of the present invention, illustrating various exemplary modular sample components forming an exemplary modular sample conditioning system using the substrate bracket (6) or mounting bracket of FIG. 5.

[0033] FIGS. 7A-7C are isometric, side, and end views of the exemplary modular sample conditioning system of FIGS. 6A-6B, with the substrate bracket (6) or mounting bracket mounted to the substrate coupling (3) of FIGS. 2A-2C with the extraction device as shown in FIGS. 3A-3C.

[0034] FIGS. 8A-8B are side and end views of opposing halves, respectively, of the common substrate/mounting bracket housing/enclosure with pre-drilled holes formed therethrough of the preferred embodiment of the present invention.

[0035] FIGS. 9A-9C are isometric, side and end views, respectively, of the mounted sample conditioning system comprising modular sample conditioning components substrate bracket (6) or mounting bracket of FIGS. 7A-7C, with the bracket housing/enclosure of FIGS. 8A-8B mounted thereto.

[0036] FIGS. 10A-10C are frontal, close-up and perspective views of the housing for the modular sample conditioning components of FIGS. 9A-9C, with user viewable and control components accessible via openings in said housing/enclosure, as well as pins (17) used for alignment of the enclosure components with gaskets (18) therebetween and held in place via clasps (15), as well as retaining of the enclosure component(s) when same is opened for access.

[0037] FIG. 10D illustrates a rear view of the modular sample conditioning components of FIG. 10A, illustrating the flow path of the pressurized fluid out of the extraction device, through an elbow to a tube (coiled to allow positioning) leading to a regulator, then out through a valve to the modular components.

[0038] FIGS. 11A-11B are illustrate perspective and end views, respectively, of the housing enclosure enclosing the modular sample system of FIGS. 10A-10C, in a completed installation.

[0039] FIGS. 12A and 12B are perspective and frontal views, respectively, of a second, alternative embodiment of the present invention, illustrating the housing enclosure enclosing the modular sample system as a stand-alone location situated between the source and the analyzer.

[0040] FIG. 13 is a frontal view of a third, alternative embodiment of the present invention, wherein the modular conditioning mounted on the substrate bracket/mounting bracket and enclosed by the housing/enclosure, at the location of and just prior to a stationary analyzer.

[0041] FIG. 14 illustrates a side view of still other embodiments of the present invention illustrating the modular sample system of the present invention integrated with a portable analyzer.

[0042] FIG. 15 is an isometric view of the invention of FIG. 14.

[0043] FIG. 16 is an end, partially exploded view of the invention of FIGS. 3A-3C.

[0044] FIG. 17 is a perspective, partially exploded view of the invention of FIG. 16

[0045] FIG. 18 is an end, exploded view of the invention of FIGS. 7A-7C.

[0046] FIG. 19 is a side, partial, cut-away view of the system of FIGS. 3A-3C.

[0047] FIG. 20 is a side, perspective close-up, cut-away view, of the invention of FIG. 3A.

[0048] FIG. 21 is an isometric, cut-away, close-up, view of the substrate coupling mounted to the isolation valve.

[0049] FIG. 21A is a cross-sectional view of the device of FIG. 21.

DETAILED DISCUSSION OF THE INVENTION

[0050] Referring to FIGS. 1A-11B, the preferred embodiment of the present invention contemplates a self-contained, modular sample/conditioning system mounted at the source of the sample, such as, for example, a pressurized source 1 with process isolation valve 2 (FIGS. 1A-1C).

[0051] A substrate coupling 3 (FIGS. 2A-2C) is mounted to the process isolation valve 2. The coupling 3 connects the process source 1 to the modular sample system of the present invention (discussed in detail infra) while also allowing for the installation/utilization of an independent, insertable extraction device such as Mayeaux U.S. Pat. No. 8,522,630 probe, the contents of which are incorporated herein by reference thereto.

[0052] In the present system, the modular sample/conditioning system cooperatively engages the isolation valve so as to allow for the passthrough of an extraction device 4 (FIGS. 3A-3C), and allows both components to operate independently of one another. An enclosure (14a and 14B in FIGS. 9A-11B) is provided to house the modular components (as further discussed herein), but does not require direct connection or engagement to extraction device 4, as is the case with prior art.

[0053] FIGS. 3A-3C and FIGS. 16-20 illustrate the extraction device 4 passthrough ability through the substrate coupling 3 and threaded connection thereto.

[0054] FIGS. 4A-4B illustrate an exemplary the modular sample system 5, comprising multiple diverse sampling and/or conditioning components mounted to a mounting bracket, also referenced as the substrate bracket. The modular sample system 5 can be pre-configured independent of the operation of the extraction device 4, and also independent of the enclosure 14a and 14B, on-site, as required.

[0055] FIG. 5 illustrates the substrate bracket 6 before the individual modular sample system components are attached and configured on it. The bracket is configured to allow multiple, diverse components to be installed thereto for cooperative flow therebetween, or otherwise, as required. The bracket holes of the substrate bracket 6 are shown as spaced evenly so that sample system components can be placed and configured in any desired order.

[0056] The substrate bracket 6 is formed to readily attach to the free end of the substrate coupling 3 (FIG. 2C). A typical modular sample system configuration is shown in FIG. 6A-6B. This exemplary system is shown incorporating a temperature indicator 7, with tubing and fittings 8 connecting the various components in the desired configuration. A relief valve 9, a pressure gauge 10, an outlet NPT connection 11, a conduit junction box 12, and a self-limiting heater block 13 are shown.

[0057] Each of these components are attached to the substrate bracket 6 (FIG. 5), and each of them are configured in this example to operate independent of the extraction device 4 (FIG. 7C) and the enclosure 14a and 14b (FIG. 8A, 8B).

[0058] Continuing with FIGS. 1-11B, the substrate bracket 6 with sample components is enveloped by the housing formed by enclosure 14a, 14b components to provide a modular sample system which is 100% accessible for service or replacement, with the visible portion of the components as well as those parts of the components for manual control pass through the housing or are otherwise exposed by apertures formed to receive same, as will be further discussed herein.

[0059] FIGS. 7A-7C shows the pressurized source 1 with the process isolation valve 2 and the substrate coupling 3 and the extraction device 4 and the modular sample system 5. Also shown are the rubber gaskets 18 situated on the components to engage each hole of the bracket. The rubber gaskets 18 (“rubber” is an exemplary material, others may likewise be used), are positioned to engage the edges of one or both enclosures 14A, 14B when brought together at the housing component apertures, and are formed to seal the enclosure 14A, 14B about the components upon which the subject gaskets 18 are mounted, allowing a portion to pass through or other wise be visible/accessible outside of the housing, as well as to help the enclosure slide onto and off of the substrate bracket.

[0060] FIGS. 8A and 8B shows the common substrate enclosure with pre-drilled holes 24A. The holes are evenly spaced so that sample components can be arranged in different order or configurations. The holes coincide with the substrate bracket. The enclosure slides onto and off of the rubber gaskets 18 at the substrate bracket. The enclosure is shown using alignment pins 17 to align with the bracket, and then held in place with clasps 15 shown in FIGS. 10A-10C.

[0061] FIGS. 9A-9C shows one half of the enclosure 14a engaging the substrate bracket 6, modular components and substrate coupling 3, with the other enclosure 14b not yet installed, revealing the system being half enclosed. Each half of the enclosure is completely independent and is held in alignment with the substrate bracket using the pin 17 for that half. The other half of the enclosure 14b can hang from the substrate bracket using its pin 17 as shown in FIGS. 10A-10C.

[0062] The pins 17 are used for alignment when the enclosure is in place or to hold the enclosure temporarily as shown in FIGS. 10A-10C, when service or maintenance is required. Both halves of the enclosure 14a and 14b may be removed at the same time or installed at the same time or used one at a time independently, thereby allowing 100% access to the modular sample system for service or replacement.

[0063] The modular sample system can be completely replaced with a spare unit (another modular sample system 5) in the field as required, or worked on at a component level with the component being repaired or replaced. This innovation allows a less skilled technician to operate in the field and a more skilled technician to operate back at the company home base or central service location.

[0064] FIGS. 10A-10C shows the enclosure halves 14a and 14b on the substrate bracket fitting around the gaskets 18 aligned to the substrate bracket with pins 17 and held in place with clasps 15. As shown, pins 17 are attached to enclosure halves (14a and 14b) with cables 16.

[0065] FIGS. 11A, 11B show the completed modular sample system in the preferred embodiment, at the site of the pressurized gas source. The alignment pins (FIGS. 10A-10C) ensure the each housing half is properly aligned with the docking platform. This feature also helps to ensure that the enclosure halves will not move due to pipeline vibrations. The same alignment pins are used to hang the enclosure halves when service or maintenance is performed (FIG. 10C). This feature is useful to keep the enclosure half handy (within reach) and off the ground but also out of the technicians way.

[0066] The housing formed by the joined enclosure halves (14A, 14B) with the openings are positioned and formed to engage the modular components where access outside the housing of parts of the modular components is desirable, providing visible components. Most components utilized in analyzer sample conditioning applications may be adapted for exterior use, even those not necessarily specific to natural gas or gas chromatography.

[0067] The visible components can be placed in any order that the application would require. The hole spacing (the holes formed in the housing by enclosures (14A, 14B) are preferably evenly spaced so the visible components may be placed in any order that makes sense for the particular application.

[0068] Exemplary components wherein visibility exterior the housing would be advantageous analyzer sample conditioning, for example, might comprise as follows: pressure gauge, temperature gauge, outlet fitting, relief valve, and conduit connection, and the present system allows technician/operator access without having to open/disassemble the housing.

[0069] By allowing visibility access exterior the housing, the technician is able to read the pressure gauge, temperature gauge and other important data readings, as well as access the outlet fitting and inspect the conduit wiring and know that the relief valve is not activated. Other components such as tubing, fittings, valves, and any other conditioning components needed are not visible, remaining in the housing formed by enclosure components 14a, 14b, since they only need to be accessed for service or maintenance.

[0070] The present invention thereby provides visibility of components such as pressure gauge, temperature gauge, relief valve, outlet fitting, and conduit fitting without having to open or disassemble the enclosure (housing). This feature is in contrast with the prior art, which teaches a housing enclosure with pressure gauge and sight glass inside the enclosure as previously discussed. Unlike the prior art, the modular components in the present case can be arranged on the mounting bracket in any order using the substrate bracket design and matching enclosure design (housing) of the preferred embodiment of the invention.

[0071] Accordingly, with the housing formed by the enclosure components 14a, 14b (FIG. 11A) the preferred embodiment of the present invention, the modular sample system 5 (FIG. 9) is protected from the environment (via the housing) and can be temperature regulated or controlled, and yet the gasketed openings of the housing are formed to engage the periphery of desired components to provide exterior access/visibility of said components that require said access for operation.

[0072] This arrangement can accommodate a diverse selection of components such as electronic, electrical, flow control, etc. mounted into a non-customized substrate (the substrate bracket or mounting bracket) and housing (formed via enclosure components 14a, 14b), while allowing the components to be easily mounted into a customizable configuration along with protection from the environment and visibility of certain components, while providing 100% access to all components AND tubing when one or both enclosure components 14a, 14b forming housing are removed, while maintaining the rigidity of the system and not having to break any fittings or connection, or disassemble the system.

[0073] The present design is unique in that the substrate/mounting bracket is designed to structurally integrate with the two enclosure halves forming the housing and the mounted modular components so that, when assembled together, the structure integrated to substantially enhance rigidity, allowing mounting to the pressurized source via the unique substrate coupling 3, while allowing the extraction device 4 to pass through, in a stable overall structure.

[0074] To accomplish this enhanced structural rigidity, the configuration of the substrate bracket 6 is formed to have base 6A width 22 and depth 22a dimensions (FIG. 5) to closely approximate the interior width 20a and depth 20b of the base 20 of the enclosure formed by the combining of enclosure components 14a, 14b (FIG. 11A).

[0075] Further continuing with FIGS. 5, 11A, and 8A-9C, emanating from the base 6A of the substrate bracket is module mounting area 23, which has formed therethrough multiple module component mounting apertures 17, shown in generally uniform spacing along its length, said module mounting area having a length 23a formed to generally span the longitudinal length 21 of the housing formed by assembled enclosure components 14a, 14b, so that the module component mounting apertures 17 are aligned with the mounting apertures 17a formed by the enclosure halves 14a, 14b.

[0076] When assembled, referring to FIG. 9A, the modular sample components pass through and engage via threaded connectors or the like the module component mounting apertures and enclosure apertures, which, with the engaged enclosure halves 14a,14b provides a structural integration which enhances stability as well as the rigidity of the mount.

[0077] The base substrate (bracket) mounts to the substrate coupling via substrate coupling engagement slots 19, which are formed to align with threaded passage 3b formed in base 3a of substrate coupling 3.

[0078] Accordingly, in the preferred embodiment of the invention, the horizontal portion of the base substrate (rectangular base) has dimensions that approximate the interior base of the enclosure. Also, the vertical portion of the base substrate spans the length of the enclosure. This design makes the sample system rigid and independent of the enclosure (i.e. able to “stand alone”) allowing 100% access to all components and tubing for service, maintenance, and replacement.

[0079] Conversely, the prior art has used a backplane or panel that was fastened to the back of the enclosure. Components were fastened to the panel and were only accessible if the cover was unbolted or opened. The present invention overcomes these issues.

[0080] A second embodiment is shown in FIGS. 12A-12B, where the modular sample system is not at the pressurized source but is instead at a stand-alone location between the source and the analyzer. All of the benefits and features described above would apply to this location as well. It may be desirable to have one modular sample system at the pressurized source with one configuration and a second modular sample system with a different configuration between the source and the analyzer.

[0081] A third embodiment is shown in FIG. 13, where the modular sample system is used at the same location as the stationary analyzer.

[0082] Other embodiments could include the modular sample system integrated into a portable analyzer as shown in FIGS. 14-15.

[0083] Based upon the above and foregoing, a method of providing a modular sample conditioning utilizing the present system may comprise, for example, the steps of:

[0084] a. providing a substrate coupling formed to engage a fluid passage, said substrate coupling formed to selectively facilitate the passage of an extraction device therethrough;

[0085] b. mounting said substrate coupling to a process isolation valve that is mounted to a conduit containing a pressurized fluid;

[0086] c. mounting a substrate bracket to said substrate coupling, said substrate bracket having emanating therefrom a module mounting area having a length;

[0087] d. mounting one or more modular components along the length of said module mounting area;

[0088] e. providing fluid from said fluid extraction device to said modular components;

[0089] f. facilitating the passage of said fluid extraction device through said substrate coupling to engage the pressurized fluid;

[0090] g. facilitating the flow of fluid from said fluid extraction device to said modular components;

[0091] h. using first and second enclosure components to engage said substrate coupling to enclose same, forming a housing, while

[0092] i. allowing portions of said modular components to pass through said housing, providing exterior portions of said modular components outside of said housing for visibility and access.

ELEMENTS

[0093] 1 pressurized source [0094] 2 process isolation valve [0095] 3,a,b substrate coupling, base, b [0096] 4 extraction device (as probe) [0097] 5 modular sample system [0098] 6, a substrate bracket, base [0099] 7 temperature indicator [0100] 8 fittings [0101] 9 relief valve [0102] 10 pressure gauge [0103] 11 NPT connection [0104] 12 conduit junction box [0105] 13 block heater [0106] 14a,b enclosure halves [0107] 15 clasps [0108] 16 cables [0109] 17 pins [0110] 18 gaskets [0111] 19,a substrate coupling engagement slot [0112] 20, a,b enclosure base width, depth [0113] 21 enclosure length [0114] 22 base width, depth [0115] 23, a module mounting area, length [0116] 24,a module component mounting apertures, enclosure apertures

[0117] The embodiments listed are not intended to be an exhaustive list of applications, but only intended to show the need and some of the practical applications of the invention. Further, the invention embodiments herein described are done so in detail for exemplary purposes only, and may be subject to many different variations in design, structure, application and operation methodology. Thus, the detailed disclosures therein should be interpreted in an illustrative, exemplary manner, and not in a limited sense.