FLUID PRESSURE MONITORING SYSTEM USING FLOW DATA

Abstract

A fluid monitoring system is provided, which includes a control unit and at least one fluid pressure recorder. The recorder is configured for direct connection to a pipeline portion of a system to be monitored and includes upstream and downstream pressure sensors. The control unit is configured to detect, and provide for display or trigger an action, in the event that a new downstream pressure is more than a threshold number of standard deviations above or below a mean downstream pressure determined from prior readings of the downstream pressure—even though neither the minimum nor maximum pressure of the pipeline portion is reached. A fluid monitoring system for a regulator on a pipeline system is also provided.

Claims

1. A fluid monitoring system, comprising: a control unit; and at least one fluid pressure recorder configured for direct connection to a pipeline system to be monitored, the at least one recorder comprising a first pressure sensor for sensing an upstream pressure at an upstream location of a pipeline portion of the pipeline system and a second pressure sensor for sensing a downstream pressure at a downstream location of the pipeline portion, the pipeline portion at the downstream location having a known orifice size, the pipeline portion having known minimum and maximum pressures, and the at least one fluid pressure recorder configured to provide the upstream pressure and the downstream pressure to the control unit; wherein the control unit is configured to: detect a condition to be monitored in the pipeline portion, even though neither the minimum nor maximum pressure is reached, if a new downstream pressure is more than a threshold number of standard deviations above or below a mean downstream pressure determined from prior readings of the downstream pressure; and provide the condition for display or use to trigger an action.

2. The system of claim 1, wherein the control unit is further configured to detect a condition if a new flow rate is more than a threshold number of standard deviations above or below a mean flow rate determined from prior readings of the upstream pressure and downstream pressure.

3. The system of claim 1, wherein the control unit is further configured to receive and log readings from the pressure sensors over time.

4. The system of claim 3, wherein the control unit is further configured to determine flow rates from the upstream pressure and downstream pressure readings.

5. The system of claim 3, wherein the control unit is further configured to determine the mean downstream pressure from the downstream pressure readings.

6. The system of claim 4, wherein the control unit is further configured to determine the mean flow rate from the determined flow rates.

7. The system of claim 1, wherein at least one of the first or second pressure sensors is a pressure transducer.

8. The system of claim 1, further comprising a temperature sensor in connection with the pipeline system and in communication with the control unit.

9. The system of claim 8, wherein the temperature sensor is configured to sense a fluid temperature in the pipeline portion.

10. The system of claim 9, wherein the control unit is further configured to correct at least one of the upstream or downstream pressure according to the fluid temperature.

11. The system of claim 8, wherein the temperature sensor is configured to sense a temperature of a connected heating source of the pipeline system.

12. The system of claim 11, wherein the control unit is further configured to detect a failure of the connected heating source.

13. The system of claim 11, wherein the connected heating source is selected from the group consisting of: a heat tape, a transfer tape, a catalytic heater, and another heat source.

14. The system of claim 1, further comprising a display unit having one or more displays.

15. The system of claim 1, further comprising a communication interface to communicate the condition to a computing device.

16. The system of claim 1, wherein the control unit is further configured to detect an abnormal flow rate pattern given a pressure change.

17. The system of claim 16, wherein the pattern is abnormal if the downstream pressure has decreased in the absence of a change in the flow rate.

18. The system of claim 1, wherein the action is selected from the group consisting of: triggering an alarm; communicating a message to a computing device; controlling a regulator of the pipeline system; controlling a relief valve of the pipeline system; controlling a secondary regulator of the pipeline system; and controlling a compressor of the pipeline system.

19. The system of claim 1, wherein the fluid is natural gas.

20. The system of claim 1, wherein the fluid is a mixed concentration of various fluids.

21. A fluid monitoring system for a regulator on a pipeline system, comprising: a control unit; and at least one fluid pressure recorder configured for direct connection to a pipeline portion of the pipeline system to be monitored, the at least one recorder comprising a first pressure sensor for sensing an upstream pressure at a location on the pipeline portion upstream of the regulator and a second pressure sensor for sensing a downstream pressure at a location on the pipeline portion downstream of the regulator, the regulator having a known orifice size, the pipeline portion having known minimum and maximum pressures, and the at least one fluid pressure recorder configured to provide the upstream pressure and the downstream pressure to the control unit; wherein the control unit is configured to: detect a condition to be monitored in the pipeline portion, even though neither the minimum nor maximum pressure is reached, if a new downstream pressure is more than a threshold number of standard deviations above or below a mean downstream pressure determined from prior readings of the downstream pressure; and provide the condition for display or use to trigger an action.

22. The system of claim 21, wherein the control unit is further configured to detect a condition if a new flow rate is more than a threshold number of standard deviations above or below a mean flow rate determined from prior readings of the upstream pressure and downstream pressure.

23. A fluid monitoring system, comprising: a control unit; and at least one fluid pressure recorder configured for direct connection to a pipeline system to be monitored, the at least one recorder comprising a first pressure sensor for sensing an upstream pressure at an upstream location of a pipeline portion of the pipeline system and a second pressure sensor for sensing a downstream pressure at a downstream location of the pipeline portion, the pipeline portion at the downstream location having a known orifice size, the pipeline portion having known minimum and maximum pressures, and the at least one fluid pressure recorder configured to provide the upstream pressure and the downstream pressure to the control unit; wherein the control unit is configured to: detect a condition to be monitored in the pipeline portion, even though neither the minimum nor maximum pressure is reached, if a new downstream pressure-related variable is more than a threshold number of standard deviations above or below a mean of a downstream pressure-related variable determined from prior readings of the downstream pressure.

24. The system of claim 23, wherein the downstream pressure-related variable and the new downstream pressure-related variable are selected from the group consisting of: downstream pressure, and flow rate.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0033] FIG. 1 is an illustration of a system for pressure recording the volume of a fluid, wherein the system uses serial overpressure protection.

[0034] FIG. 2 is an illustration of a system for pressure recording the volume of a fluid, wherein the system uses monitored overpressure protection.

[0035] FIG. 3 is an illustration of a system for pressure recording the volume of a fluid, wherein the system uses relief valve overpressure protection.

[0036] FIG. 4 is an illustration of a system for pressure recording on a piping system, wherein the system has no regulators and/or overpressure protection.

[0037] FIG. 5 is an illustration of possible positions for pressure recorder/monitors within a gas distribution system.

[0038] FIG. 6 is a sample graph showing conversion of specific gravity to energy units.

[0039] The present concept is best described through certain embodiments thereof, which are described herein with reference to the accompanying drawings, wherein like reference numerals refer to like features throughout. It is to be understood that the term invention, when used herein, is intended to connote the inventive concept underlying the embodiments described below and not merely the embodiments themselves. It is to be understood further that the general inventive concept is not limited to the illustrative embodiments described below and the following descriptions should be read in such light.

DETAILED DESCRIPTION

[0040] The general inventive concepts described herein are not limited to any single context and may apply to various contexts or applications. In particular, while a natural gas context is described herein, a person of ordinary skill in the art will appreciate that other fluid distribution contexts may apply including other gases, water and oils.

[0041] Natural gas or fossil gas is an odorless naturally occurring hydrocarbon gas mixture consisting primarily of methane, but can include varying amounts of other higher alkanes, and sometimes a small percentage of carbon dioxide, nitrogen, hydrogen sulfide, or helium. Natural gas is used as a source of energy for heating, cooking, electricity generation, fuel for vehicles, as well as other processes in various industries.

[0042] A pressure measuring apparatus measures the pressure, and calculates the flow, of natural gas and may come in the form of a pressure recorder.

[0043] A pressure recorder is a precision measuring instrument that is manufactured to record various pressures. As natural gas flows through regulators, control valves, and pipes, variances in pressure can change with variances of flow rates. A pressure recorder can determine the changes in pressure relative to flow rate.

[0044] The pressure being recorded by the recorder can fluctuate depending on the amount the fluid flowing within the system.

[0045] Pressure recording can be used as a reliable and efficient means for determining the safe operating pressure of the system.

[0046] To accurately record and monitor the pressure of a single concentration of a particular fluid or a mixed concentration of various fluids through a regulator station the following parameters are used: inlet pressure of the regulator, flow coefficient of the regulator, and the universal gas regulator sizing constant 1.29. The flow rate is calculated in cubic feet per hour (f.sup.3/h), calculated from the following Equation 1:

[00001]$\begin{array}{cc}Q=\sqrt{\frac{520}{\mathrm{GT}}}{C}_g{P}_{1\mathrm{abs}}\mathrm{SIN}\left(\frac{3417}{C_1}\sqrt{\frac{\Delta P}{P_{1\mathrm{abs}}}}\right)\mathrm{DEG}& \left(1\right)\end{array}$ [0047] Where: [0048] Q=gas flow rate, SCFH [0049] P.sub.1abs=absolute inlet pressure, psia (P.sub.1 gauge+14.7) [0050] C.sub.g=regulating or wide-open gas sizing coefficient [0051] G=specific gravity of the gas [0052] T=absolute temperature of gas at inlet, °Rankine [0053] C.sub.1=flow coefficient (C.sub.g/C.sub.v) [0054] ΔP=pressure drop across the regulator, psi

[0055] An example of the equation in Equation 1 is: [0056] Q=gas flow rate, SCFH [0057] P.sub.1abs=314.7 psia [0058] C.sub.g=680 [0059] G=0.54 [0060] T=520 [0061] C.sub.1=35 [0062] ΔP=160 psi

[0063] Solving for “Q”:

[00002]$$\begin{gathered} Q=\sqrt{\frac{520}{\left(520x054\right)}}\times 680\times 314.5\times [\sin \frac{3417}{35}\times \sqrt{\left(\frac{160}{314.7}\right)]} \\ Q=1.361\times 680\times 314.7\times 0.937 \end{gathered}$$

[0064] Thus, Q=272,726 SCFH. This can also be expressed in cubic meters per hour (m.sup.3/h).

[0065] In addition, solving the above equation for “G” (Specific Gravity) the heating value (BTU, Joules, etc) can be calculated.

[0066] An example of solving for “G” is: [0067] Q=163,065 SCFH [0068] P.sub.1abs=314.7 Asia [0069] C.sub.g=680 [0070] G=Specific Gravity [0071] T=520 [0072] C.sub.1=35ΔP=160 psi

[0073] Solving for “G” the answer is “0.54”

[0074] The specific gravity can then be converted to energy units by use of a lookup table or equation. For example, as shown in the graph in FIG. 6, if the equation: y=−21667x.sup.2+28883x−8480 is used with the specific gravity of “0.54” the BTU content is calculated to be 799.

[0075] To accurately record and monitor the pressure of a fluid through a pipe within the distribution system, pressure samples are turned into other data points. Fluid pressure samples will determine the mean pressure. From these, standard deviations in the fluid pressure will be calculated. The mean and standard deviation will be calculated in pounds per square inch (PSI). The following Equations 2, 3, 4 are used to calculate mean, variance and standard deviation, respectively:

[00003]$\begin{array}{cc}\mathrm{Mean}=\frac{\mathrm{Sum}\mathrm{of}\mathrm{Pressures}}{N\mathrm{umber}\mathrm{of}\mathrm{Pressure}\mathrm{Readings}}& \left(2\right)\end{array}$$\begin{array}{cc}\mathrm{Variance}=\frac{\begin{array}{c}\mathrm{Sum}\mathrm{of}\mathrm{the}\\ {\left(\begin{array}{c}\mathrm{Difference}\mathrm{between}\mathrm{Mean}\mathrm{and}\\ \mathrm{each}\mathrm{Actual}\mathrm{Pressure}\mathrm{Reading}\end{array}\right)}^2\end{array}}{\mathrm{Number}\mathrm{of}\mathrm{Pressure}\mathrm{Readings}}& \left(3\right)\end{array}$$\begin{array}{cc}\mathrm{Standard}\mathrm{Deviation}=\sqrt{\mathrm{Vari}ance}& \left(4\right)\end{array}$

[0076] For example, given a set point on a regulator of 160 psig.

[0077] Fifteen sample pressures readings P.sub.i, i=1 to 15, are taken: 164, 163, 162, 161, 160, 160, 159, 158, 157, 155, 155, 155, 155, 159, 162. The mean is the Σ.sub.i=1.sup.15P.sub.i/15=159.

[0078] The variance is: Σ.sub.i=1.sup.15(P.sub.i−159).sup.2/159 or

(164−159).sup.2=(5).sup.2=25

(163−159).sup.2=(4).sup.2=16

(162−159).sup.2=(3).sup.2=9

(161−159).sup.2=(2).sup.2=4

(160−159).sup.2=(1).sup.2=1

(160−159).sup.2=(1).sup.2=1

(159−159).sup.2=(0).sup.2=0

(158−159).sup.2=(−1).sup.2=1

(157−159).sup.2=(−2).sup.2=4

(155−159).sup.2=(−4).sup.2=16

(155−159).sup.2=(−4).sup.2=16

(155−159).sup.2=(−4).sup.2=16

(155−159).sup.2=(−4).sup.2=16

(159−159).sup.2=(0).sup.2=0

(162−159).sup.2=(3).sup.2=9

25+16+9+4+1+1+0+1+4+16+16+16+16+0+9=134 [0079] Variance=134/15 [0080] Variance=8.9 [0081] Standard Deviation=√{square root over (8.9)} [0082] Standard Deviation=2.98 . . . =˜3

[0083] To accurately record temperature, in an embodiment, a sensor (e.g. temperature transducer) is used on the piping to determine the temperature of the gas. The equation of Charles Law is used to calculate the corrected flow of gas through the regulator/s or piping system in an embodiment.

[0084] The Charles Law equation is calculated using the following Equation 5:

V.sub.o=V(520/(T+460))  (5) [0085] Where: [0086] V.sub.o=Corrected Volume [0087] V=Uncorrected Volume [0088] 520=Absolute Zero @ 60° F. [0089] (Temperature drop from base temperature of 60° F. to Absolute Zero) [0090] T=Gas Temperature (in ° F.) [0091] 460=Absolute Zero (in ° F.) [0092] (All temperatures expressed in absolute values.)

Example

[0093] V=100 CFH [0094] T=30° F. [0095] V.sub.o=100 [520/490]=100×1.0612=106 CFH

[0096] Temperature can also be used to monitor the use of various heating elements on a regulator station. By monitoring the temperature of heat tape, transfer tape, catalytic heaters, etc. the operators can be notified of a failure of these devices.

[0097] FIG. 1 shows an illustration of a fluid pressure recorder/monitoring system according to an example. In this type of configuration, serial overpressure protection is provided. The system 100 uses at least two pressure recorders 107A and 107B. First pressure recorder 107A receives pressure at a first position from first pressure transducer 101A and at a second position from second pressure transducer 101B and at a third position from third pressure transducer 101C. Likewise, second pressure recorder 107B receives pressure at a first position from first pressure transducer 101D and at a second position from second pressure transducer 101E and at a third position from third pressure transducer 101F. Temperature data is received from temperature transducers 103A, 103B, which are used to determine the corrected flow of gas recorded at each pressure regulator 102A, 102B. Temperature data may also include readings from connected heating sources, such as heat tape, transfer tape, catalytic heaters, etc., and failures of such devices may also be recorded for use with trend analysis and to indicate for general maintenance. These two pressure recordings can then be used determine flow rate, inlet and outlet pressure, mean outlet pressure, and standard deviation outlet pressure as the fluid flows between 104 and 106 in the pipeline. In the event of an overpressure, the system can failover from the first regulator to the second. As shown, recorder data can be communicated to cloud 110 or other network storage for retrieval and further processing or analysis.

[0098] FIG. 2 shows an illustration of a fluid pressure recorder/monitoring system according to an example. In this type of configuration, monitored overpressure protection is provided. The system 200 comprises at least two pressure recorders 207A and 207B. First pressure recorder 207A receives pressure at a first position from first pressure transducer 201A and at a second position from second pressure transducer 201B and at a third position from third pressure transducer 201C. Likewise, second pressure recorder 207B receives pressure at a first position from first pressure transducer 201D and at a second position from second pressure transducer 201E and at a third position from third pressure transducer 201F. Temperature data is received from temperature transducers 203A, 203B, which is used to determine the corrected flow of gas. These two pressure recordings can then be used to determine flow rate, inlet and outlet pressure, mean outlet pressure, and standard deviation outlet pressure as the fluid flows between 204 and 206 in the pipeline. The system is monitored generally for overpressure and various corrective steps can be taken with respect to regulators 202A, 202B.

[0099] FIG. 3 shows an illustration of a fluid pressure recorder/monitoring system according to an example. In this type of configuration, relief valve overpressure protection is provided. The system 300 comprises at least one pressure recorder 307A. First pressure recorder 307 receives pressure at a first position from first pressure transducer 301A and at a second position from second pressure transducer 301B and at a third position from third pressure transducer 301C. The pressure recorder will record flow rate, inlet and outlet pressure, mean outlet pressure, and standard deviation outlet pressure as the fluid flows between 304 and 306 in the pipeline. In the event of an overpressure, a relief valve can be triggered.

[0100] FIG. 4 shows an illustration of a fluid pressure recorder/monitoring system according to an example. In this type of very simple configuration on a piping system, there are no regulators and no overpressure protection. The system 400 comprises at least one pressure recorder 407. First pressure recorder 407 receives pressure at a first position from first pressure transducer 401. Temperature data is received from temperature transducer 402, which is used to determine the corrected flow of gas. The pressure recorder will record outlet pressure, mean outlet pressure, and standard deviation outlet pressure as the fluid flows along at 404 in the pipeline.

[0101] In the present system, pressure, temperature, flow rate, mean pressure, and standard deviation are all preferably being continuously recorded and monitored. By monitoring and recording multiple variables, condition-based monitoring and maintenance can be employed without waiting for a maximum or minimum pressure threshold to be reached otherwise triggering an alarm condition. Trend analysis is employed to determine and flag unexpected conditions. For example, if the pressure decreases and the flow rate increases, the decrease in pressure is normal. Conversely, if the pressure decreases and there is no change in flow this indicates a situation might exist that warrants investigating. In addition, the information monitored and recorded can be transmitted to a remote monitoring station.

[0102] On distribution regulator stations the pressure recorder will monitor and record pressure before and after each regulator and temperature after the regulator then calculate the flow rate through the regulator. If the outlet pressure of the regulator changes, there should be a corresponding change in the flow rate. If the outlet pressure of the regulators changes and there is no corresponding change in flow rate a problem is indicated and the distribution regulator station's operator will be notified. This allows the operator to perform maintenance before a failure occurs.

[0103] On various points of the distribution system piping, the pressure recorder will monitor and record pressure on the distribution piping. Samples of pressure will be recorded, and the mean pressure and standard deviation will be determined. If the pipeline pressure changes within a predetermined number of standard deviations the operator of the distribution pipeline will be notified. This allows the operator to perform maintenance before a failure occurs.

[0104] FIG. 5 illustrates examples of possible locations for pressure recorders or monitors 510 within such a distribution system 500. As illustrated, the recorders 510 (which may be configured as shown in any of FIGS. 1-4) may be located at transitional locations, such as: between extraction and storage or processing facilities; before and after treatment plants, compressor stations, city gates, local distribution companies; and in transit to industrial, commercial or residential customers.

[0105] Preferably, the pressure recorders communicate with a control unit. Calculations on the pressure and flow data may be carried out on a continuous basis, at intervals, or request triggered through the control unit. Frequency of sampling and calculating can be increased on detection in the system of a threshold event.

[0106] The control unit is preferably in communication with one or more display units. All of the various devices herein (pressure recorders, transducers, and display units) comprise respective communication components and may communicate via one or more protocols as is known. The networks may include a public network such as the Internet. Control unit, by way of example, may be provided as a cloud-based service, which may be configured as a service (SaaS) model.

[0107] It will be understood that control unit comprises a computing device having various components coupled for communication including at least some of: processor(s) (e.g. CPU, GPU, etc.), storage device(s), one or more communication subsystems or devices, display(s), input device(s), output device(s), etc. Displays may be touch or gesture enabled. Input devices may include a pointing device such as a mouse, a microphone, a camera, a keyboard, button(s), etc. Communication devices may couple to a location device such as to provide satellite based location services. Output devices may include a speaker, lights, vibration/haptic devices. The various components may be coupled via one or more communication buses or other structures.

[0108] The storage devices may store instructions and data for example, which instructions when executed configure the operation of the computing device. The instructions may define an operating system, applications, etc. The computing device for the control unit may be configured as a server or other device configuration.

[0109] Any of the processing units may be computing devices such as described. Other computing devices (e.g. other processing unit types) may be used such as programmable logic devices, which may be field programmable such as field programmable gate array (FPGA), etc.

[0110] Pressure data communicated from the/each pressure recorder may be raw pressure data, or the data may be preprocessed (e.g. corrected using temperature data).

[0111] Control unit that receives pressure data may then output as output data to one or more display units, for instance, in the form of a chart or graph or dashboard. In some embodiments, the output includes pressures or flow rates over a given time period. Further thresholds may be set and alerts may be activated when those thresholds are surpassed. Standardized messages may be triggered depending on threshold. Alerts may be directed to separate devices than the display units. For example, illuminated or auditory signals may be triggered on devices other than standard I/O devices. Further, thresholds may be used to control other actuators (e.g. opening or closing regulators, relief valves or compressors, or actuating secondary regulators in a series). Thresholds may be preset or they may be user-configurable and/or configurable based on averages already detected.

[0112] In addition to computing device aspects, a person of ordinary skill will understand that computer program product aspects are disclosed, where instructions are stored in a non-transitory storage device (e.g. a memory, CD-ROM, DVD-ROM, disc, etc.) to configure a computing device to perform any of the method steps, act as modules of the system, or provide other aspects of the invention described herein.

[0113] Practical implementation may include any or all of the features described herein. These and other aspects, features and various combinations may be expressed as methods, apparatus, systems, means for performing functions, program products, and in other ways, combining the features described herein. A number of embodiments have been described. Nevertheless, it will be understood that various modifications can be made without departing from the spirit and scope of the processes and techniques described herein. In addition, other steps can be provided, or steps can be eliminated, from the described process, and other components can be added to, or removed from, the described systems. Accordingly, other embodiments are within the scope of the following claims.

[0114] Throughout the description and claims of this specification, the word “comprise”, “include” and “contain” and variations of them mean “including but not limited to” and they are not intended to (and do not) exclude other components, integers or steps. Throughout this specification, the singular encompasses the plural unless the context requires otherwise. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0115] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example unless incompatible therewith. All of the features disclosed herein (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of the features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing examples or embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings) or to any novel one, or any novel combination, of the steps of any method or process disclosed.