A PIPE WEAR MONITORING SYSTEM AND METHOD OF USE THEREOF

Abstract

The present invention relates to a system and method for monitoring wear in pipes, particularly irregular wear in pipelines transporting abrasive fluids. The system includes a plurality of wear sensors spaced along a length of a pipe. Each wear sensor is configured to detect wear in a wall of the pipe. The system further includes at least one remotely accessible server operatively connected to the sensors for receiving and monitoring data output from said sensors. The server is configured to alert an operator when said data received from any one of the plurality of sensors is indicative of irregular wear in the wall of the pipe.

Claims

1. A pipe wear monitoring system including: at least one base station; a plurality of wear sensors spaced along a length of a pipe and operatively connected to the at least one base station, each wear sensor configured to detect wear in a wall of the pipe; and at least one remotely accessible server operatively connected to the base station for receiving and monitoring data output from said sensors via said at least one base station, said server configured to generate an alert when said data received from any one of the plurality of wear sensors is indicative of irregular wear in the wall of the pipe.

2. A pipe wear monitoring system including: at least one base station; a plurality of sensor nodes operatively connected to the at least one base station, each sensor node operatively associated with at least one wear sensor spaced along a length of a pipe and configured to detect wear in a wall of the pipe; and at least one remotely accessible server operatively connected to the base station for receiving and monitoring data output from said sensors via said sensor nodes, said server configured to generate an alert when said data received from any one of the plurality of wear sensors is indicative of irregular wear in the wall of the pipe.

3. The system of claim 1, wherein each of the plurality of wear sensors or the at least one wear sensor is fitted or installed to a sidewall of the pipe to detect wear in an inner surface of the sidewall of the pipe.

4. The system of claim 1, wherein the wear sensors are spaced at regular intervals along a length of the pipe.

5. The system of claim 1, wherein the wear sensors are each at least partially received in a sensor inlet port defined in an outer surface of a sidewall of the pipe.

6. The system of claim 5, wherein the sensor inlet port includes an opening defined in the outer surface of the sidewall of the pipe and extends at least partially towards an inner surface of the sidewall of the pipe.

7. The system of claim 1, wherein the wear sensors are electric sensors configured to generate an electronic signal when a sidewall of the pipe thins to a predetermined thickness.

8. The system of claim 1, wherein the wear sensors are sacrificial wear sensors including a sacrificial probe configured to be at least partially destroyed in response to wear in a sidewall of the pipe, partial destruction of the probe being indicative of said wear being detected.

9. The system of claim 8, wherein the probe is an electronic sacrificial probe configured to generate an electronic signal or the absence of an electronic signal as a result of the probe being at least partially destroyed.

10. The system of claim 9, wherein the sacrificial probe includes a board having at least one electrical circuit defined thereon, said board and said at least one circuit configured to be at least partially destroyed in response to wear in a sidewall of the pipe.

11. The system of claim 9, wherein the sacrificial probe includes a board having a plurality of electrical circuits defined thereon, each individual circuit of the plurality and the board configured to be sequentially at least partially destroyed in response to wear in a sidewall of the pipe, wherein sequential at least partially destruction of each said individual circuit enables wear in the sidewall to be incrementally monitored and a wear rate to be determined.

12. The system of claim 9, wherein the at least one electrical circuit or the plurality of circuits are continuously or periodically polled by the system and wherein when the circuit or one of the plurality of circuits is intact, the circuit generates an electrical signal when polled indicative of an absence of irregular wear on the sidewall.

13. The system of claim 1, wherein the at least one base station includes a communications module for connecting the plurality of sensor or sensor nodes and the at least one remotely accessible server.

14. The system of claim 13, wherein the communications module is a modem enabling the at least one base station to connect to the at least one remotely accessible server via a wireless network.

15. A wear sensor for use in detecting irregular wear in a wall of a pipe, said sensor including: a sacrificial probe configured to be at least partially inserted into an opening defined in an outer surface of a sidewall of a pipe and be at least partially destroyed in response to irregular wear on an inner surface of the pipe, the destruction of the probe being indicative of irregular wear being detected.

16. The wear sensor of claim 15, wherein the sacrificial probe includes a board and a plurality of electrical circuits defined on the board, each individual circuit of the plurality and the board configured to be sequentially at least partially destroyed in response to wear in the sidewall of the pipe, and wherein the sequential at least partially destruction of circuits enables the wear in the sidewall of the pipe to be incrementally monitored and/or a wear rate to be determined.

17. A method of monitoring pipe wear including: providing a plurality of wear sensors at spaced intervals along a length of a pipe, each sensor being configured to detect wear in a wall of the pipe; and receiving and monitoring data corresponding to data output from said sensors and generating an alert when data is received from any one of the plurality of wear sensors indicative of irregular wear in the wall of the pipe.

18. The method of claim 17, wherein responsive to identifying data indicative of irregular wear, the alert is generated and transmitted to a computing or mobile device of an operator or the like.

19. The method of claim 18, wherein the alert is an electronic notification and is effected by way of SMS protocol, USSD protocol, over a secure internet connection or by way of data communication enabled by a software application installed on the computing device.

20. The method of claim 17, wherein the receiving and monitoring data includes periodically or continually addressing each wear sensor and wherein the absence of a response is indicative of partially destruction of the sensor and thus irregular wear on a portion of the pipe.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0140] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0141] FIG. 1 is a photograph showing a sectional view of a pipe with irregular wear;

[0142] FIG. 2 is an illustration of a pipe wear monitoring system according to an embodiment of the present invention;

[0143] FIG. 3 is an illustration of a pipe wear monitoring system according to another embodiment of the present invention;

[0144] FIG. 4 is an illustration of a pipe wear monitoring system according to another embodiment of the present invention;

[0145] FIGS. 5A and 5B respectively show a wear sensor assembly according to an embodiment of the present invention;

[0146] FIG. 6 is a schematic showing a probe of the wear sensor shown in FIGS. 5A and 5B;

[0147] FIG. 7 is a schematic showing a probe of the wear sensor according to another embodiment of the present invention;

[0148] FIG. 8 is a screenshot of software for use in interacting with the system as shown in FIGS. 2 to 4; and

[0149] FIG. 9 is a flowchart showing steps in a method of monitoring pipe wear according to an embodiment of the present invention.

DETAILED DESCRIPTION

[0150] FIGS. 2 to 8 show embodiments of a pipe wear monitoring system (100) and parts thereof for monitoring wear along a length of a pipe (10).

[0151] Referring to FIG. 2, in this first embodiment, the system (100) includes a plurality of wear sensors (110) spaced along a length of a pipe (10). Each wear sensor (110) is configured to detect wear in a wall (12) of the pipe (10).

[0152] The system (100) further includes a remotely accessible server (1000) operatively connected to the sensors (110) for receiving and monitoring data output from said sensors (110) in a periodic basis or in real-time. The server (1000) is configured to generate an alert in the form of an electronic notification to a computing device (700) of an operator or the like when said data received from any one of the sensors (110) is indicative of irregular wear in the wall (12) of the pipe (10).

[0153] Generally, the pipe (10) is a wear resistant pipe have a thickened sidewall (12) to at least partially delay wear failure.

[0154] The wear sensors (110) are spaced at regular 1 m intervals along a length of the pipe (10) and are mounted to a lower side or portion of the pipe (10).

[0155] Each wear sensor (110) is threadingly received in a sensor inlet port (18) defined in the outer surface of the sidewall (12) of the pipe (10). The sensor inlet port (18) includes an opening defined in the outer surface and extending partially towards an inner surface of the sidewall (12) but not through the inner surface of sidewall (12). The sensor inlet port (18) includes a threaded inner surface for threadingly engaging with an outer surface of the wear sensor (110).

[0156] Referring to FIGS. 5A and 5B, the wear sensor (110) is an electronic sacrificial wear sensor. The wear sensor (110) includes a sacrificial probe (112) configured to be at least partially destroyed in response to wear in the sidewall (12; not shown) of a pipe (10; not shown). The partial destruction of the probe (112) being indicative of wear being detected.

[0157] Best shown in FIG. 6, the sacrificial probe (112) includes a board (114) having an electrical circuit (116) defined thereon. The board (114) and circuit (116) are configured to be at least partially destroyed in response to wear in the sidewall (12; not shown) of a pipe (10; not shown). As shown, the circuit (116) is printed at or near a distal outer end of the board (114) to thereby be sensitive to wear.

[0158] In use, the electrical circuit (116) is periodically polled by the system (100). When the electrical circuit (116) is intact, the circuit (116) generates a signal when polled indicative of the absence of irregular wear on the sidewall (112; not shown). When the circuit (116) is at least partially destroyed, the circuit (116) will not generate a signal when polled, thereby indicative of irregular wear on the sidewall (12; not shown).

[0159] In FIG. 7, another embodiment of the sacrificial probe (112) is shown. The probe (112) again includes a board (114) having a plurality of electrical circuits (116) defined thereon. In this embodiment, the individual circuits (116) and the board (114) are configured to be sequentially at least partially destroyed in response to wear in the sidewall (12; not shown) of a pipe (10; not shown). Like with the sacrificial probe (112) shown in FIG. 6, the circuits (116) are printed at or near a distal outer end of the board (114) to thereby be sensitive to wear.

[0160] Advantageously, the sequential destruction of the individual circuits (116) enables wear in the sidewall (12; not shown) of the pipe (10; not shown) to be incrementally monitored and/or enables a wear rate to be determined.

[0161] Referring again to FIGS. 5A and 5B, the wear sensor (110) further includes a body (120) for at least partially housing the sacrificial probe (112) and for threadingly engaging with the sensor inlet port (18; not shown) defined in the outer surface of the sidewall (12; not shown) of the pipe (10; not shown).

[0162] The body (120) includes a shank (122) having a pair of opposed ends, including a head (124) at one of the opposed ends and a tip (126) at the other of the opposed ends of the shank (122).

[0163] The shank (122) is sized and shaped to at least partially extend within a sensor inlet port (18; not shown) and position the sacrificial probe (112) at or near the inner surface of the sidewall (12) of the pipe (10) for detecting wear. The shank (122) includes an external thread (123).

[0164] The head (124) is enlarged and sized and shaped such that it cannot be received within the sensor inlet port (18; not shown) but rather abuts against an outer surface of the wall (12) of the pipe (10).

[0165] As best shown in FIG. 5B, the head (124) includes a hexagonal profile shape for engaging with a tool, such as, e.g., a wrench, for applying torque to the body (120) and turning or rotating body (120) relative to the sensor inlet port (18; not shown) for installing and removing the wear sensor (110).

[0166] The tip (126) of the body (120) is square-tipped.

[0167] Again best shown in FIG. 5B, the body (120) further includes a first internal passage (128) extending through the body (120) from the tip (126) at least partially towards the head (124). The first internal passage (128) is suitably sized and shaped for receiving and holding in place the sacrificial probe (112).

[0168] Referring to FIG. 5A, the body (120) includes a second internal passage (not visible) extending through the head (124) of the body (120) and in fluid communication with the first internal passage (128) for passage of cables connected to the sacrificial probe (112). The second internal passage (not visible) has a narrower diameter or width than the first internal passage (128; shown in FIG. 5B) to prevent passage of the sacrificial probe (112) therethrough.

[0169] When assembling, the sacrificial probe (112) inserted into the body (120) via the tip (126) prior to the sensor (110) being at least partially inserted into and threadingly engaging with the sensor inlet port (18; not shown).

[0170] Best shown in FIG. 5B, the sacrificial probe (112) includes pair of outwardly turned ends (119) for engaging with the tip (126) of the body (120) and preventing over-insertion of the probe (112) into the body (120). The ends (119) of the sacrificial probe (112) at least partially hook or clip over the tip (126) of the body (120).

[0171] Referring back to FIG. 2, in this first embodiment, each wear sensor (110) includes a communications module in the form of a cellular or radio modem for connecting the sensors (110) to the remotely accessible server (1000) via a wireless network, which may include, among others, the Internet, LANs, WANs, GPRS network, a mobile communications network, a radio network (UHF-band).

[0172] The communications module is connected to the sacrificial probe (112; not shown) by an electrical circuit extending along at least one cable extending through the head (124; not shown) of the body (120).

[0173] Each sensor (110) furthers include a power supply for powering the sacrificial probe (112; not shown), the communications module and other electrical components of the sensor (110). The power supply includes one or more rechargeable batteries.

[0174] Each sensor (110) is addressable and reports an operational status to the remotely accessible server (1000), when polled.

[0175] The remotely accessible server (1000) includes one or more processors and one or more memory units containing executable instructions/software to be executed by the one or more processors.

[0176] The server (1000) is in communication with a pipe database (1010) containing a plurality of sensor records for each pipe being monitored. The server (1000) is linked to or can maintain the pipe database (1010). Each sensor record may include a sensor identifier. Each sensor record further includes a past record of the data output for the respective sensor (110).

[0177] In addition to receiving and monitoring, the remotely accessible server (1000) additionally collects and records the data output from the sensors (110) in the pipe database (1010).

[0178] The remotely accessible server (1000) further continuously or periodically monitors the pipe database (1010) for changes in the data output for any one of the plurality of sensors (110). The remotely accessibly server (1000) generates an alert when a change in the data output is indicative of a change in sensor operational status, such as, e.g., a sensor fail or failing sensor (imminent failure). The alert is generated to a computing device (700) of an operator or the like. The alert is an electronic notification, which will be described later.

[0179] The server (1000) is in communication with the plurality of sensors (110).

[0180] The server (1000) is configured to transmit communications to and receive communications from the sensors (110) via a wireless network, which may include, among others, the Internet, LANs, WANs, GPRS network, a mobile communications network, a radio network (UHF-band).

[0181] Responsive to the server (1000) receiving, monitoring and identifying data indicative of irregular wear, the server (1000) generates an alert to a computing device (700) of an operator or the like advising of the irregular wear.

[0182] The alert generated is an electronic notification and may be effected by way of Short Message Server (SMS) protocol, Unstructured Supplementary Service Data (USSD) protocol, over a secure Internet connection, or by way of data communication enabled by software on the computing device, for example.

[0183] The computing device can include a computer, a tablet, a smart phone, a smart watch or a PDA, for example.

[0184] Referring briefly to FIG. 8, this figure shows a screen-shot (810) of software run on a computing device (800; not shown) for controlling operation of the system (100; not shown).

[0185] As shown, the screen-shot (810) in this embodiment is reporting that the operational status of all sensors (110; not shown) is “OK”. The screen-shot also shows a satellite view of the pipe (10; not shown).

[0186] FIG. 3 shows a second embodiment of the system (100) for monitoring wear along a length of a pipe (10). For convenience, features that are similar or correspond to features of the first embodiment will again be referenced with the same reference numerals.

[0187] In this embodiment, the system (100) includes a base station (310) and a plurality of wear sensors (110) spaced along a length of a pipe (10) and operatively connected to the base station (310). Each wear sensor (110) is configured to detect wear in a wall (12) of the pipe (10).

[0188] The system (100) further includes a remotely accessible server (1000) operatively connected to the base station (310) for receiving and monitoring data output from the sensors (110) via the base station (310). The server (1000) is configured to generate an alert in the form of an electronic notification to a computing device (700) of an operator or the like when said data received from any one of the sensors (110) is indicative of irregular wear in the wall (12) of the pipe (10).

[0189] The wear sensors (110) in this embodiment are again spaced at regular 1 m intervals along a length of the pipe (10) and are mounted to a lower side or portion of the pipe (10).

[0190] Each wear sensor (110) is as previously described in respect of the first embodiment with the exception that the wear sensor (110) reports its operational status to the base station (310) when polled.

[0191] Each wear sensor (110) again includes a communication module in the form of a cellular or radio modem for wirelessly connecting the sensor (110) to the remotely accessible server (1000) via the base station (310). The base station (310) and the sensors (110) may be operatively connected via a wireless network, which may include, among others, the Internet, LANs, WANs, GPRS network, a mobile communications network or a radio network (UHF-band).

[0192] Generally, the base station (310) functions as a bridge between the plurality of sensors (110) and the remotely accessible server (1000).

[0193] The base station (310) is located at or near the pipe (10).

[0194] The base station (310) includes a body (312) sized and shaped for housing components and/or parts of the system (100), including at least one power source and a communications module. The body (312) is formed from a durable material or materials configured to withstand external environmental exposure, such as, e.g., plastic, concrete and/or metal material or materials.

[0195] The base station (310) includes a communications module in the form of a cellular or radio modem for wirelessly connecting to the sensors (110) and the remotely accessible server (1000).

[0196] The base station (310) further includes a power source in the form of one or more rechargeable batteries for powering at least the communications module.

[0197] The base station (310) also includes a microcomputer, including one or more processors and a memory, for receiving, monitoring and transmitting data between the remotely accessible server (1000) and the sensors (110). The one or more processors may be low power processors.

[0198] The processors include multiple inputs and outputs coupled to the communications module for the receiving and transmitting of data. In use, the base station (310) periodically or continuously addresses each sensor (110) and reports the operational status of the sensor (110) to the server (1000). The operational status includes whether the sensor (110) is operational, i.e., intact, an indication of any faults reported by the sensor (110), and/or an indication of the battery charge remaining.

[0199] FIG. 4 shows a third embodiment of the system (100) for monitoring wear along a length of a pipe (10). For convenience, features that are similar or correspond to features of the first and second embodiments will again be referenced with the same reference numerals.

[0200] In this embodiment, the system (100) include a base station (310) and a plurality of sensor nodes (410) operatively connected to the base station (310). Each sensor node (410) is operatively associated with a plurality of wear sensors (110) and configured to detect wear in a wall (12) of the pipe (10).

[0201] The system (100) further includes a remotely accessible server (1000) operatively connected to the base station (310) for receiving and monitoring data output from the sensors (110) via the sensor nodes (410). The server (1000) is configured to generate an alert in the form of an electronic notification to a computing device (700) of an operator or the like when said data received from any one of the sensors (110) is indicative of irregular wear in the wall (12) of the pipe (10).

[0202] The wear sensors (110) in this embodiment are again spaced at regular 1 m intervals along a length of the pipe (10) and are mounted to a lower side or portion of the pipe (10).

[0203] Each wear sensor (110) is as previously described in respect of the first and second embodiments with the exception that the wear sensor (110) reports its operational status to the sensor node (310) when polled.

[0204] The sensor nodes (410) relay data between the sensors (110) and the server (1000), via the base station (310).

[0205] Like with the base station (310), each sensor node (410) includes a body (412) sized and shaped for housing components and/or parts of the system (100), including a power source and a communications module. The body (412) is formed from a durable material or materials configured to withstand external environmental exposure, such as, e.g., plastic, concrete and/or metal material or materials.

[0206] As shown, each sensor node (410) is operatively associated with four wear sensors (110) via a wired connection. Accordingly, each sensor node (410) is located at or near the pipe (10) in the immediate vicinity of the wear sensors (110) to which it is connected.

[0207] As indicated above, each sensor node (410) includes communication module for communicating with both the sensors (110) and the sever (800) via the base station (310). The communication module includes a port or access point for connecting the sensors (110) via a cable.

[0208] The communications module is in the form of a cellular or radio modem for wirelessly connecting to the base station (310).

[0209] Each sensor node (410) further includes a power source in the form of one or more rechargeable batteries for powering at least the communication module and polling the sensors (110).

[0210] Again and like with the base station (310), each sensor node (410) further includes a microcomputer, including one or more processors and a memory, for receiving, monitoring and transmitting data between the base station (310) and the sensors (110). The one or more processors are low power processors.

[0211] Again, the processors include multiple inputs and outputs coupled to the communications module for the receiving and transmitting of data. In use, each sensor node (410) periodically or continuously address each sensor (110) operatively associated with the node (410) and report the operational status of the sensor (110) and the node (410) to the remotely accessible server (1000) via the base station (310). The operational status again includes whether the sensor (110) is operational, i.e., intact, an indication of any faults reported by the sensor (110), and/or an indication of the battery charge remaining.

[0212] A method (900) of using the system (100) as shown in FIGS. 2 to 4 is now described in detail with reference to FIG. 9.

[0213] At step 910, the providing includes the forming of senor inlet ports (18; not shown) in the sidewall (12) of the pipe (10) at spaced intervals corresponding to the desired spaced intervals for the sensor (110). The threaded openings coinciding as the sensor inlet ports (18; not shown) can be thrilled into the sidewall (12) of the pipe (10).

[0214] Once the senor inlet ports (18; not shown) are formed in the sidewall (12) of the pipe (10), a sensors (110) can be threadingly received in each senor inlet port (18; not shown).

[0215] At step 920, the receiving and monitoring of data output from the sensors (110) includes addressing each sensor (110) to verify that the sensor probe (112; not shown) is intact. The verifying includes transmitting an electrical current through the electrical circuit (116; not shown) provided on the sensor probe (112; not shown), wherein a closed circuit is indicative that the sensor (110) is intact and wherein an interrupted or open circuit is indicative that the sensor (110) has been partially destroyed and thus irregular wear has occurred on a portion of the pipe (10) at least adjacent the sensor (110).

[0216] At step 930, responsive to the remotely accessible server (1000) identifying data indicative of irregular wear, the server (1000) generates an alert in the form of an electronic notification advising of the irregular wear to a computing or mobile device of an operator or the like.

[0217] The electronic notification can be effected by way of Short Message Server (SMS) protocol, Unstructured Supplementary Service Data (USSD) protocol, over a secure Internet connection, or by way of data communication enabled by software installed on the computing device.

[0218] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0219] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0220] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.