METHOD AND APPARATUS FOR DEACTIVATING A HYDRAULIC DEVICE THAT IS LEAKING HYDRAULIC OIL

Abstract

A method of deactiving an underwater hydraulic device provides a hydraulic device that is capable of being operated under water, the device having a hydraulic cylinder with a pushrod and a piston. The device is lowered below a water surface with a hose reel that is located at the water surface area such as on a marine vessel. The hose reel includes first and second hydraulic hoses that connect to the cylinder on opposing sides of the piston. Fluid flow in the first and second hydraulic hoses is continuously monitored. The ratio of the volume of fluid flowing into the cylinder from one side of the piston to the volume of fluid flowing into the cylinder from the other side of the cylinder is continuously calculated with a computer or controller. The hydraulic device is deactivated if the ratio varies from a preset value. One embodiment includes a plurality of flow meters for measuring fluid flow to and from one or more hydraulicly powered apparatuses. In one embodiment outputs of the flow meters are analyzed to determine if the hydraulic system has a leak, and if a leak is detected, a warning is issued and/or one or more of the connected hydraulically powered apparatuses are shut down, and/or the hydraulic power supply is shut down.

Claims

1. A method of deactiving an underwater hydraulic device, comprising the steps of: a) providing a hydraulic device that is capable of being operated under water, the device having a hydraulic cylinder with a pushrod and a piston; b) lowering the device below a water surface from a floating vessel with a hose reel that is located at the water surface area; c) using the device of steps a and b to cut an underwater object; d) wherein the hose reel of step b includes first and second hydraulic hoses that connect to the cylinder on opposing sides of the piston; e) providing a hydraulic pump and hydraulic fluid reservoir on the floating vessel at the water surface area for providing the hydraulic fluid under pressure to said first and second hydraulic hoses via third and fourth hydraulic hoses; f) intermittently monitoring fluid flow in the first and second hydraulic hoses; g) calculating the ratio of the volume of fluid flowing into the cylinder from one side of the piston to the volume of fluid flowing into the cylinder from the other side of the piston; h) intermittently monitoring a first and second volume of the hydraulic fluid flowing respectively in the third and fourth hydraulic hoses with a first flow meter interfaced with the third hydraulic hose, wherein the first flow meter measures fluid flow in the third hydraulic hose and a second flow meter interfaced with the fourth hydraulic hose, wherein the second flow meter measures fluid flow in the fourth hydraulic hose, said third and fourth hoses including a pressure line that transmits hydraulic fluid from the pump to the hose reel and a return flow line that returns hydraulic fluid from the hose reel to the hydraulic fluid reservoir; i) providing a control valve that is interfaced with the third and fourth hydraulic hoses at a position in between said flow meters and said hydraulic pump and reservoir, said control valve having a control that enables reversal of fluid flow in said third and fourth hydraulic hoses so that the third hydraulic hose functions as the return line and the fourth hydraulic hose functions as the pressure line; j) deactiving the hydraulic device if the ratio varies from a preset ratio or preset value; and k) using the control valve of step i to change flow direction in said third and fourth hydraulic hoses.

2. The method of claim 1 wherein the device is a hydraulic shear.

3. The method of claim 1 wherein the flow is measured with first and second flow meters in step f, one flow meter monitoring fluid flow in the first hydraulic hose, the other flow meter monitoring flow in the second hydraulic hose.

4. The method of claim 1 wherein the hydraulic device receives hydraulic fluid under pressure from a prime mover and hydraulic pump assembly and in step j, the prime mover and pump assembly is deactivated.

5. The method of claim 4 wherein the prime mover is deactivated.

6. The method of claim 5 wherein the prime mover includes an engine and in step j the engine is shut off.

7. The method of claim 1 wherein a controller continuously monitors flow in the flow meters and continuously calculates the ratio of step g.

8. The method of claim 7 further comprising providing a selector switch having multiple selectable switch positions and wherein the ratio of step g can be varied by selecting a different position of the selector switch.

9. The method of claim 7 wherein the computer uses a different ratio depending upon which switch position is selected and the dimensions of the cylinder and cylinder rod of the selected device.

10. The method of claim 1 wherein the volumes of step g are automatically calculated.

11. A method of deactiving a hydraulic device, comprising the a) providing a floating vessel with a control station, a prime mover, a hydraulic pump powered by said prime mover and a pump fluid reservoir that supplies hydraulic fluid to the pump; b) providing a hydraulic device that is capable of being operated under water, the device having a hydraulic cylinder with a pushrod and a piston; c) lowering the device below a water surface with a hose reel that is located at the water surface area; d) using the hydraulic device to cut an underwater object; e) wherein the hose reel of step c includes first and second hydraulic hoses that connect to the cylinder on opposing sides of the piston; f) intermittently monitoring fluid flow in the first and second hydraulic hoses; g) monitoring hydraulic fluid flow in third and fourth hydraulic hoses with a first flow meter and a second flow meter, wherein the first flow meter is in a third flow line that is located in between the hose reel and hydraulic pump and the second flow meter is in a fourth flow line that is located in between the hose reel and pump fluid reservoir; h) connecting each of said third and fourth flow lines to a control valve that is in between said flow meters and said pump and reservoir, said control valve having a control that enables flow reversal in said third and fourth flow lines so that the third flow line is a pressure flow line in a first control valve position and a return flow line in a second control valve position and the fourth flow line is a return flow line in a first control valve position and a pressure flow line in a second control valve position; i) calculating a ratio of a first volume of fluid in the first hydraulic hose that enters a pushrod retraction chamber section of the hydraulic cylinder to a second volume of fluid in the second hydraulic hose that enters a pushrod extension chamber of the hydraulic cylinder; and j) deactiving the hydraulic device if the ratio varies from a preset value.

12. The method of claim 11 wherein the flow is measured with first and second flow meters in step f, one flow meter monitoring fluid flow in the first hydraulic hose, the other flow meter monitoring flow in the second hydraulic hose.

13. The method of claim 11 wherein the hydraulic device receives hydraulic fluid under pressure from a prime mover and hydraulic pump assembly and in step j, the prime mover and pump assembly is deactivated.

14. The method of claim 13 wherein the prime mover is an engine and in step j the engine is shut off.

15. The method of claim 11 wherein a controller continuously monitors flow in the flow meters and continuously calculates the ratio of step i.

16. The method of claim 11 further comprising providing a selector switch having multiple selectable switch positions and wherein the ratio can be varied by selecting a different position of the selector switch.

17. A hydraulic power unit leak detection apparatus, comprising: a) a floating vessel having a control station that includes a storage reel, a prime mover, a pump and a pump fluid reservoir; b) a hydraulic device that is operated with a prime mover and pump, and wherein the hydraulic device includes a hydraulic cylinder having a cylinder, pushrod, and piston; c) the cylinder having a first chamber that is receptive of hydraulic fluid when extending the pushrod and a second chamber that is receptive of hydraulic fluid when retracting the pushrod; d) a first hydraulic fluid flow line that supplies hydraulic fluid to the first chamber; e) a second hydraulic flow line that supplies hydraulic fluid to the second chamber; f) the storage reel holding a first hydraulic fluid flow line that supplies the hydraulic fluid to the first chamber; g) a third flow line in between the pump and hose reel; h) a fourth flow line that is in between the hose reel and the pump fluid reservoir; i) a first flow meter in said third flow line wherein said first flow meter measures fluid flow upstream of said storage reel; j) the storage reel holding a second hydraulic flow line that supplies the hydraulic fluid to the second chamber; k) a second flow meter in said fourth flow line that measures fluid flow upstream of said storage reel; l) a computer that continuously monitors the ratio of the volume of fluid entering the first chamber to the volume of fluid entering the second chamber; m) the computer monitoring hydraulic fluid flow in the third and fourth hydraulic hoses with said first and second flow meters; and n) the computer operatively connected to the prime mover so that the computer can deactivate the prime mover when the ratio varies from a preset acceptable value of said ratio.

18. The apparatus of claim 17 wherein the hydraulic device is a power tong.

19. The apparatus of claim 17 wherein each of said first and second flow lines has a flow meter interfaced with said computer so that the flow meters continuously transmit flow data to the computer.

20. The apparatus of claim 17 further comprising a selector switch that enables the computer to compare the said ratio with a selected one of a plurality of ratios, each ratio of the plurality of ratios corresponding to different hydraulic cylinder configurations.

21. The apparatus of claim 17 further comprising a selector switch that enables the computer to compare the said ratio with a selected one of a plurality of ratios, each ratio of the plurality of ratios corresponding to different hydraulic cylinder dimensions.

22. The apparatus of claim 17 wherein the computer is programmable to designate any ratio as the acceptable value.

23. The apparatus of claim 17 wherein the acceptable value is a range.

24. The apparatus of claim 22 wherein the acceptable value is a range.

25. The method of claim 1 further comprising a hose reel that enables the device to be lowered to a sea bed area.

26. The method of claim 1 wherein multiple hydraulic flow lines are part of the hose reel.

27. The method of claim 25 wherein each of said first and second hydraulic hoses has a flow meter interfaced with a computer or controller so that the flow meters continuously transmit flow data to the computer.

28. The method of claim 27 wherein each flow meter is in a said hydraulic hose in between the hose reel and the device.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0037] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

[0038] FIG. 1 is a schematic diagram of a preferred embodiment of the apparatus of the present invention;

[0039] FIGS. 1A and 1B are partial flow diagrams of a preferred embodiment of the apparatus of the present invention wherein lines A-A on FIGS. 1A, 1B are match lines that match with lines A-A of FIG. 1;

[0040] FIG. 2 is an elevation view of a preferred embodiment of the apparatus of the present invention;

[0041] FIG. 3 is a flow diagram view of an alternate embodiment of the apparatus of the present invention providing an electrical motor drive and wherein match lines A-A of FIG. 3 match with either FIG. 1A or 1B at match lines A-A of FIG. 1A or 1B;

[0042] FIG. 4 is a partial schematic view of a preferred embodiment of the apparatus of the present invention illustrating the hydraulic device with jaws in an open position;

[0043] FIG. 5 a partial schematic view of a preferred embodiment of the apparatus of the present invention illustrating the hydraulic device with jaws in a closed position;

[0044] FIG. 6 is a schematic view of a preferred embodiment of the apparatus of the present invention;

[0045] FIG. 7 is a schematic view of a preferred embodiment of the apparatus of the present invention;

[0046] FIGS. 8-10 are diagrams of the prime mover portion of a preferred embodiment of the apparatus of the present invention; and

[0047] FIG. 11 is a schematic diagram of the hydraulic hose reel portion of a preferred embodiment of the apparatus of the present invention; and

[0048] FIG. 12 shows hydraulic tool-fitting descriptions and locations of a preferred embodiment of the apparatus of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0049] FIGS. 1-12 show a preferred embodiment of the leak detection system apparatus of the present invention designated generally by the numeral 10. In the system 10 shown in FIG. 1, the prime mover is a diesel engine 20. In system 10A of FIG. 3, the prime mover is an electric motor 50. Leak detection system 10 (or 10A) is used in a marine underwater environment when operating a hydraulic device or shear 11.

[0050] In FIG. 2, a marine vessel 1 floats on a water surface 2. A water bottom or seabed 7 has an object 47 to be removed, such as a pipe or other object embedded in or located at seabed 7. In some cases, object 47 is the remnant of a damaged or abandoned offshore marine platform (e.g., oil and gas well production platform).

[0051] Deck area 3 on vessel 1 has a crane 4 with lifting line 5 and rigging 6 to enable lifting and lowering of hydraulic device 11. The hydraulic device shown in FIG. 1 is a hydraulic shear 11 having a jaw 14 that is moved between open and closed positions with a hydraulic cylinder 12 (see FIGS. 1A, 4-5). Device 11 can have a fixed jaw 59. Jaw 14 is pivotally attached at 60 to body 13. Cylinder 12 is attached to body 13 at pivotal connection 61 and to jaw 14 at pivotal connection 62. Jaw 14 moves from the open position of FIGS. 1A and 4 to the closed position (cutting position) of FIGS. 1B and 5 by extension of pushrod 15 and cylinder 19 relative to one another (see arrow 63, FIG. 5). Also, notice arrows 48, 49 in FIGS. 1A, 1B which illustrate such movement of jaw 14.

[0052] The hydraulic device 11 provides a body 13 that supports the moving jaw 14. Hydraulic cylinder 12 has a pushrod 15 that moves between extended (FIG. 5) and retracted (FIG. 4) positions. The hydraulic cylinder 12 provides a cylinder 19 having an interior that includes chamber sections 17 and 18 (see FIGS. 6-7). The chamber sections 17 and 18 are on opposing sides of piston 16. The chamber section 17 is on the side of piston 16 that has pushrod 15 as shown. The chamber section 18 does not have the pushrod 15 and thus is of a larger cross sectional area (see example 1 below).

[0053] Hydraulic power is provided with a hydraulic power unit or HPU which is designated generally by the numeral 28 in FIGS. 1 and 2. Hydraulic power unit 28 includes a prime mover 20 which can be for example a diesel engine (20) or electric motor (50). The prime mover 20 powers a pump 21 which can be a compensating pump. Such compensating pump are commercially avail able (e.g. from Linde Hydraulics (www.lindeamerica.com)). The pump 21 receives hydraulic fluid from reservoir 22 and flow line 27. A case drain line or recycle line 24 is provided for bypassing the hose reel 40 which is a condition that can occur with such a compensating pump 21 in some situations. Fuel is provided for the hydraulic power unit 28, for example to tank 23 which can be a diesel fuel tank for supplying diesel fuel via flow line 65 to prime mover/diesel engine 20. (See FIGS. 1-1B.) Pump 21 has a discharge flow line 25 which is a pressure line that communicates with hydraulic control valve 54. Hydraulic control valve 54 has a lever or operator handle 68 that is operated to either open or close the jaw 14. In FIG. 1A, the lever or handle 68 is in a position that transmits fluid to lines 31, 32 so that jaw 14 is opened. In FIG. 1B, the lever or handle 68 is moved to a position that transmits fluid to lines 31, 32 so that jaw 14 is closed. Valve 54 is commercially available such as from Hawe North America, Inc. of Charlotte, N.C.

[0054] From control station 30, the line 31 which supplies pressurized hydraulic fluid to hose reel 40. A first flow meter 45 is placed in flow line 31 or at the junction of flow lines 25, 31 as shown in FIGS. 1A, 1B.

[0055] Line 32 also receives flow from control station 30. Return flow line 32 communicates with hose reel 40. The flow line 32 carries a second flow meter 46. Return flow is able to travel from the hose reel 40 to the flow line 32 through the flow meter 46 and then to the control station 30. From the control station 30, the flow in line 32 communicates with the return line 26 for returning fluid to hydraulic tank or reservoir 22. Flow meters 45, 46 can be commercially available CT Series flow meters from Webster Instruments of Milwaukee, Wis.

[0056] The hose reel 40 provides flow lines 41, 42 which enable the hydraulic cylinder 12 to either open jaw 14 or close jaw 14 by either extending pushrod 15 or retracting the pushrod 15 (see FIGS. 4-5 and 6-7). This is accomplished by connecting one flow line 41 to cylinder 19 on one side of piston 16 and by connecting the other flow line 42 to cylinder 19 on the other side of the piston 16 as shown in FIGS. 6-7.

[0057] FIGS. 1 and 3 illustrate that the prime mover can be either an engine 20 or an electric motor 50. In FIG. 1, the diesel engine 20 is provided with a battery 51 for starting the engine 20. The battery 51 also provides positive and negative leads 52, 53 that communicate with controller 30 as shown in FIG. 1A. The control station 30 of 1A can include a commercially available computer or controller 33 such as a Model Plus 1 from Sauer Danfoss such as Model No. MC024-010 or MC024-012.

[0058] In FIG. 1A, the computer or controller 33 is part of the control station 30. The control station 30 can provide a key switch for enabling the control station 30 to be activated or deactivated. A rotary cam switch 55 can be provided to pre-program controller 33 for a number of different configurations (e.g., dimensional changes) of cylinder 19, pushrod 15, chamber sections 17, 18. (See FIGS. 4-7.) The cam switch enables an operator to dial in or select a particular cylinder by selecting a pre-programmed cam switch position. Such a rotary cam switch is commercially available from Control Switches International, Inc.

[0059] A start button 56 can be provided for enabling use of control station 30. Lamps 57, 58 can be provided to indicate whether or not the control station 30 has been activated or is deactivated. For the diesel engine 20, a solenoid operated valve 64 is provided in flow line 65 which supplies diesel fuel from tank 23 to engine 20. (See FIG. 1.) This solenoid operated valve 64 is closed in a situation where a leak is detected. For the electric motor 50, a solenoid operated switch 66 is provided. (See FIG. 3.) The switch 66 deactivates electric motor 50 if a leak situation is detected. For each of the diesel engine 20 and electric motor 50, a cooler 67 can be provided in the flow line 24 as shown.

[0060] In one embodiment, the method and apparatus can be provided with a display which may include a leak detection visual and/or audible alarm. A display console can be provided for controller 33 which can include a selector switch 55, on off button 56, indicator lamps 57 and 58, along with default program button. Controller 33 can be operatively connected to a computer (e.g., a notebook computer) for programming operating values into controller regarding its operations.

[0061] FIGS. 1A and 1B are schematic block diagrams of leak detection system 10 connected to two hydraulic systems(a) hydraulic shears 11 and (b) the reel drive motor 38 for hose reel 40. Leak detection system 10 can detect undesirable conditions in one or both of these two connected hydraulic systems.

[0062] A plurality of flow meters 45 and 46 can be used to measure flow to and from the monitored hydraulic systems (e.g., shears 11 and reel drive motor 38). The flow meter 45 sends a signal to controller 33 which is proportional to the rate of fluid flow in flow line 31. The flow meter 46 sends a signal to controller 33 which is proportional to the rate of fluid flow in flow line 32.

Pre-Leak Detection Testing

[0063] Leak detection 10 system can go through various pre-leak detection monitoring checks which are designed to ensure that the connected hydraulic systems (e.g., shears 11 and reel drive motor 38) are operating correctly. In one embodiment leak detection system 10 will shut off hydraulic power to the hydraulic pump 21 if one or more pre-monitoring exceptions are found.

[0064] Pre-monitoring exceptions can include, but are not limited to: [0065] (a) powering hydraulic pump 21 not operating such as not rotating between a predefined rotational range; [0066] (b) the level of hydraulic fluid in reservoir tank 22 not being above a predefined reservoir tank level; [0067] (c) the pressure in flow line 31 not being above a predefined pressure for such flow line; [0068] (d) the pressure in flow line 32 not being above a predefined pressure for such flow line [0069] (e) the pressure in flow line 41 not being above a predefined pressure for such flow line; and [0070] (f) the pressure in flow line 42 not being above a predefined pressure for such flow line.

[0071] If one or more of the above pre-monitoring exceptions are found, leak detection system 10 can turn off power to pump 21, and issue a warning signal indicating the identification of a pre-monitoring exception. The pressure exerted by the hydraulic fluid can be monitored by pressure transducers in flow lines 31, 32, 41, and 42.

[0072] If an exception condition is found, including satisfaction of the time periods for existence of such exception, the leak detection system 10 shuts down the identified leaking hydraulic system (e.g., shears 11 and/or reel drive motor 38). Shutting down a hydraulic system can include shutting off the flow of hydraulic fluid from the reservoir tank 22 to pump 21 and shutting off power to pump 21. The hydraulic fluid flow can be shut off at reservoir tank 22 by turning a valve in line 27 to a closed position.

[0073] If a leaking exception condition satisfying leaking parameters has been found, the leaking hydraulic system (e.g., shears 11 or reel drive motor 38) causing the leaking event to be identified may be shut down and the indicator or display signals are sent to console to warn that a leaking event has been identified. The leak detected light 58 can be turned on and optionally an auditory alarm can also be issued.

Leak Detection Monitoring

[0074] In one embodiment, following the completion of the various pre-leak detection monitoring checks, leak detection system 10 can monitor one or both connected hydraulic systems (shears 11 and/or reel drive motor 38) by monitoring flow though flow meters 45 and 46 and comparing such monitored flow to certain predefined flow amounts for the particular hydraulic system being monitored.

[0075] In one embodiment leak detection system 10 provides a predefined startup period of time from activation of a hydraulic system to beginning of monitoring operations of flow meters 45 and 46. Such predefined start up period of time allows the monitored hydraulic system time to stabilize before leak detection system 10 begins looking for leaking exceptions in monitoring conditions. In one embodiment such predefined start up period of time can be at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, and/or 50 seconds. In various embodiments such predefined period of time can be a range between any two of the specified time periods.

[0076] Exceptions for leak detection can be identified by leak detection system 10 where a measured parameter falls outside of the predefined allowed ranged for such measured parameter. Additionally, preferably leak detection system 10 requires that the exception be present for a predetermined period of time before considering that an identified leaking exception is considered a leaking event and acting accordingly, such as by shutting down pump 21 and/or the hydraulic system (e.g., shears 11 or reel drive motor 38) causing the identified leaking exception to be present.

Frequency of Sampling Flow Meter Readings

[0077] In one embodiment leak detection system 10 can be user programmed regarding the frequency of sampling of which the system accepts signals from the plurality of flow meters 45 and 46. Although continuous is used in this specification it is anticipated that, in any given time period, only a finite number sampling of measurements can be taken by leak detection system 10.

[0078] In various embodiments embodiment sampling rates can be at least 1, 5, 10, 50, 100, 120, 150, 200, 300, 500, 1000, 2000, or 3000 Hertz. In various embodiments sampling rates can be a range between any two of the specified sampling rates.

Time Period For Existence of Leaking Exception

[0079] In one embodiment leak detection system 10 responds or reacts rapidly to an identified leaking event, such as by shutting off power to pump 21 along with shutting off fluid flow from reservoir 22 to pump 21. With the occurrence of such an event, leak detection system 10 can also issue a warning signal such as be lighting lamp 57 or lamp 58, along with possibly issuing a audible warning signal such as a siren.

[0080] In one embodiment, after a leaking event is determined, leak detection system 10 will shut down the flagged hydraulic system (shears 11 or reel drive motor 38). This can occur after determining a leaking exception exists for a predetermined time. In one embodiment such predefined period of time that the leaking exception must exist before a leaking event can be identified, can be at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, 50, and/or 60 seconds. In various embodiments such predefined period of time can be a range between any two of the specified time periods. In various embodiments the user can program this predefined period of time and/or range into leak detection system 10.

Programming Based on Actual Operating Conditions of Hydraulic Systems in a Non-Leaking Condition

[0081] In one embodiment benchmark conditions in a known non-leaking conditions to be expected when taking sampling measurements can be automatically programmed into the method and apparatus. In one embodiment predefined exception conditions can be programmed into leak detection system 10 based on actual operating conditions of the hydraulic system being monitored (e.g., shears 11 and/or reel drive motor 38). In one embodiment, the default predefined button can be provided in leak detection system 10, and a method of programming predefined conditions for flow meters 45 and 46 can be as follows:

(1) Shear System

[0082] With hydraulic shear system 11, hydraulic power can be suppled by pump 21 though lines 31 and 32 which respectively flow through lines 41 and 42. The ratio of flow measured by flow meter 45 to compared to flow meter 46 (or vice versa) can be calculated by controller 33 and such ratio be set in the method and apparatus as the ideal predefined ratio in a non-leaking condition.

[0083] As best can be seen in FIGS. 6 and 7, for any particular movement of piston 16 inside of cylinder 19, the amount of hydraulic fluid entering/leaving chamber section 17 is less than the amount of hydraulic fluid entering/leaving chamber section 18. The difference is a result of pushrod 15 taking up part of the volume of chamber section 17. Although not expected to be a 1:1 ratio, because pushrod 15 has a substantially uniform cross sectional area the ratio of the amount of fluid exchange between the two chamber sections is expected to be constant regardless of the position of piston 16 in cylinder 19. In a preferred embodiment the ratio can be 1:2.28 and measured variations from this ratio can be used by leak detection system 10 to identify leaking exceptions for shear 11, and if such identified leaking exception persists, a leaking event for shear 11.

(2) Driving Motor for Hose Reel

[0084] For reel drive motor 38 hydraulic power can be suppled by pump 21 though lines 31 and 32 which power reel drive motor 38 to outlay or take up lines 41 and 42. The ratio of flow measured by flow meter 45 to 46 can be calculated by controller 33 and such ratio be set as a predefined ratio in a non-leaking condition. However, this ratio in a non-leaking situation is expected to be 1:1 and this step can be omitted for programming the leak detection parameters for reel drive motor 38.

[0085] Unlike shears 11, reel drive motor 38 operably connected to hose reel 40 (and rotating reel 40 to outlet and take up of flow lines 41 and 42) will have input and output lines which, in a non-leaking condition, are expected to have a 1:1 ratio of hydraulic fluid entering and exiting driving motor 38.

Use of Physical Dimensional Parameters to Calculate Predefined Ratios

[0086] As best can be seen in FIGS. 6 and 7, for any particular movement of piston 16 inside of cylinder 19, the amount of hydraulic fluid entering/leaving chamber section 17 is less than the amount of hydraulic fluid entering/leaving chamber section 18. The difference is a result of pushrod 15 taking up part of the volume of chamber section 17. Although not expected to be a 1:1 ratio, because pushrod 15 has a substantially uniform cross sectional area the ratio of the amount of fluid exchange between the two chamber sections is expected to be constant regardless of the position of piston 16 in cylinder 19. In a preferred embodiment the ratio can be 1:2.28 and measured variations from this ratio can be used by leak detection system 10 to identify leaking exceptions for shear 11, and if such identified leaking exception persists, a leaking event for shear 11.

[0087] In one embodiment, where the push rod has a diameter D.sub.r and the piston has a diameter D.sub.P the ratio between the two flow rates will be the same as the ratio of the cross sectional areas on either side of the piston, and can be calculated by the formula:

[00001]$\frac{\left[D_p^2-D_r^2\right]}{D_p^2}$

In this embodiment a user can enter the diameter of the rod D.sub.rand the diameter of the piston D.sub.P and the method and apparatus can calculate the ideal predefined ratio in a non-leaking condition from which allowable variations can be looked for by the method and apparatus.
Customizing Allowable Variations from Predefined Non-Leaking Ratios

[0088] In various embodiments a user can custom program leak detection system 10 to allow a variation of a selected amount from the predefined ratio in a non-leaking condition for either the hydraulic shear system 11 and/or reel drive motor 38. In various embodiments such can be a symmetrical variation from the initial predefined ratio can be an allowable percentage variation from the initial predefined ratio. In various embodiments this allowable percentage can be at least about 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, and/or 50 percent. In various embodiments such exception variations can differ from variations above compared to variations below the user selected value in a non-leaking condition (e.g., the initial predefined ratio).

[0089] In various embodiments the lower limit can be one of the specified allowable variations, and the upper limit can be a different one of the specified allowable variations.

[0090] In various embodiments such user selected predefined parameters may be changed from time to time as the user desires.

[0091] At different points in time the user can use the default program button to calculate another predefined ratio for either hydraulic system (shear 11 or drive motor 38) as either hydraulic system's non-leaking characteristics may change over time. In one embodiment such predefined variations can be numerically entered into controller 33 by a computer.

[0092] As disclosed herein it is anticipated that leak detection system 10 can have programmed multiple sets of ratios for flow in flow meters 45 and 46 based on the different hydraulic systems which flow meters 45 and 46 are measuring flow in relation to. For example, when reel drive motor 38 is operating to lay out or take up hoses 41 and 42 (respectively lowering or raising shears 11), hydraulic shears 11 will not be operating. Accordingly, the values programmed for reel drive motor 38 are used by leak detection system 10.

Catastrophic Leak Detection Testing

[0093] During operations leak detection system 10 system can go through various checks for catastrophic leaking events which are designed to ensure that the connected hydraulic systems (e.g., shears 11 and reel drive motor 38) do not suffer a catastrophic leaking event. In one embodiment leak detection system 10 will shut off hydraulic power to the hydraulic pump 21 and/or hydraulic systems if one or more pre-monitoring exceptions are found.

[0094] Catastrophic monitoring exceptions can include, but are not limited to: [0095] (a) no flow read by flow meter 45 while flow is read by flow meter 46; [0096] (b) no flow read by flow meter 46 while flow is read by flow meter 45; [0097] (c) the pressure in flow line 31 not being above a predefined pressure for such flow line; [0098] (d) the pressure in flow line 32 not being above a predefined pressure for such flow line [0099] (e) the pressure in flow line 41 not being above a predefined pressure for such flow line; and [0100] (f) the pressure in flow line 42 not being above a predefined pressure for such flow line.

[0101] If one or more of the above catastrophic leak detection monitoring exceptions are found, leak detection system 10 can turn off power to pump 21, shut down the hydraulic systems, and issue a warning signal indicating the identification of a catastrophic leak detection event. The pressure exerted by the hydraulic fluid can be monitored by pressure transducers in flow lines 31, 32, 41, and 42.

[0102] The following example illustrates the continuous calculation of a ratio of one chamber section 17 and the other chamber section 18. In the Example 1 below, the computer or controller 33 of control station 30 continuously calculates the ratio of fluid that enters or departs from the chamber 18 and compares that volume of fluid with the volume of fluid that enters or departs from the chamber section 17. The flow meters 45, 46 provide data to the controller or computer 33. If the computer 33 calculates that the ratio of the volume of fluid entering and exiting the cylinders differs from a ratio for example of 2.28:1 in the following example, the computer knows that a leak has occurred and it sends a signal to the solenoid valve 64 to shut off the flow of diesel fuel to the engine 20 thus deactiving the engine 20. In the case of an electric motor 50, the computer or controller 33 sends a signal to the solenoid operated switch 66 which deactivates the electric motor 50.

Example 1

[0103] An exemplary hydraulic cylinder could have the following dimensions:

[0104] Cylinder bore=8 inches (20 cm), cylinder rod=6 inches (15 cm), cylinder stroke=20.5 inches (52 cm)

[0105] For this system, shutdown occurs when the difference in volume entering and exiting the cylinder is different from the ratio between the cylinder piston area and the cylinder annulus area. The annulus area is equal to the piston area minus the rod area. The computer or controller 33 which is part of the control system 30 compensates for this difference in volume, continuously calculating the ratio based upon input from the flow meters 45, 46. The computer or controller 33 can be a commercially available Plus +1 controller available from Sauer-Danfoss (e.g. models MC024-010 or MC024-012).

[0106] The piston end volume is equal to the Cylinder Piston Area times the Cylinder Stroke

[0107] Cylinder piston area=Piston Diameter squared times a constant of (0.7845)

[0108] 8 (20 cm) squared () 0.7854=50.26 sq. in. (324.26 sq. cm)

[0109] Piston End Volume=50.26 sq. in. (324.26 sq. cm) () 20.5 in. (52 cm)=1030.33 cu. in.or 4.46 gallons (16,884.1 cu. cm)

[0110] The Rod end volume is equal to the Cylinder Annulus Area times the Cylinder Stroke

[0111] Rod Area=6 (15 cm) squared () 0.7854=28.27 sq. in. (182.39 sq cm)

[0112] Cylinder Annulus=50.26 sq. in. (324.26 sq. cm) () 28.27 sq. in. (182.39 sq cm)=21.99 sq. in. (141.87 sq. cm)

[0113] Rod End Volume=21.99 sq. in. (141.87 sq. cm) () 20.5 in. (52 cm)=450.79 cu. in. or 1.95 gallons (7,381.6 cu. cm)

[0114] The ratio between the Piston End volume and the Rod End volume is (2.28:1)

[0115] Under normal operations with no leak present, the volume entering and exiting the cylinder will differ by the ratio of (2.28:1). If a leak occurs, the computer or controller 33 will then calculate a ratio that is not 2.28:1 and stop the prime mover, 20 or 50.

[0116] Thus, if at any time the ratio of volume entering and exiting the cylinder is a value that is different from the ratio of (2.28:1) the controller or computer 33 will send a signal to shut down the diesel engine or electric motor and thus the hydraulic device 11. FIGS. 8-11 are schematic diagrams of the prime mover 20 and hose reel 40. FIG. 12 shows examples of hydraulically operated devices and components 70, 71, 72, 73, 74.

[0117] The following is a list of parts that correspond to FIG. 8:

TABLE-US-00001 QTY Parts # Description 1 2 FM TEE NPT Brass 1 3 FM FM NPT 90* Brass 2 4 M JIC M NPT 90* Brass 1 6 M M NPT Hex Nip. Brass 1 7 NPT100 PSI Murphy gauge(oil pres.) 1 8 Oil Pressure Switch 1 9 M M NPT Hex Nip 6K 1 10 M Jic Boss w/Jam Nut 90* 6K 4 11 M Jic M NPT Hex Nip 6K 7 12 M Jic M NPT 90* 6K 2 13 FM FM Collar NPT 6K 1 18 M FM NPT Needle Valve (102 FMG) 1 20 NPT 10000 PSI gauge (Flush Mount) 2 23 Bushing NPT 6K 1 29 M M NPT Hex Nip 6K 1 31 FM FM NPT Gate Valve Brass 4 39 1 M M NPT Hex Nip 6K 1 40 1 M Jic 1 M NPT 45* 6K 5 41 1 M Jic 1 M NPT Hex Nip 6K 2 44 1 Tee NPT 6K 2 51 1 NPT Bushing 6K 6 55 1 M NPT 1 M Jic 90* 6K 1 56 1 M NPT 1 M Jic Hex Nip 6K 1 57 1 M NPT 1 M Jic 90* 6K 3 58 1 1 NPT Bushing 6K 1 63 1 1 NPT Bushing 6K 2 64 1 1 NPT Bushing 6K 1 65 3 1 Bushing NPT 2 66 3 All thread Sch. 80 NIP. 1 67 3 Hydraulic Oil Strainer FM FM NPT 1 68 3 FM FM NPT Gate Valve Brass 3 71 FM FM Jic 6K JJ Crimp 2 6 3 73 FM FM Jic Fuel line 7 5 81 1 FM FM Jic 6K JJ crimp 4 1 83 1 FM FM Jic 6K JJ crimp 11 1 88 1 FM FM Jic 6K JJ crimp 14 1 89 BT 216 Oil filter (Baldwin) 1 90 BT 387 Hydrauic return filter (Baldwin) 1 91 BF-7681-D Fuel filter primary (Baldwin) 1 92 BF-7674-D Fuel filter secondary (Baldwin) 1 95 R20P Racor filter 1 101 RS3542 Outer air filter (Baldwin) 1 102 RS3543 Inner air filter (Baldwin) 1 103 Relief valve CT 10 F 30 1 104 M Jic FM Compression 1 105 1 M M NPT Hex Nip 1 106 2 1 NPT Bushing 6K 2 107 Gates 9525

[0118] The following is a list of parts that correspond to FIG. 9:

TABLE-US-00002 QTY Parts # Description 1 2 FM TEE NPT Brass 1 3 FM Fm NPT 90* Brass 2 4 M JIC M NPT 90* Brass 1 6 M M NPT Hex Nip. Brass 1 7 NPT100 PSI Murphy gauge(oil pres.) 1 8 Oil Pressure Switch 3 9 M M NPT Hex Nip 6K 3 11 M Jic M NPT Hex Nip 6K 8 12 M Jic M NPT 90* 6K 1 13 FM FM Collar NPT 6K 2 17 M Stucci FM NPT 1 19 FM NPT Shuttle Valve 1 20 NPT 10000 PSI gauge (Flush Mount) 2 23 Bushing NPT 6K 1 26 FM NPT 14 mm M thread 6K 1 27 M Jic 22 1.5 mm M thread 6K 1 29 M M NPT Hex Nip 6K 1 30 Jic NPT 90* 6K 1 31 FM FM NPT Gate Valve Brass 9 39 1 M M NPT Hex Nip 6K 1 40 1 M Jic 1 M NPT 45* 6K 9 41 1M Jic 1 NPT Hex Nip 6K 1 42 1 FM Jic M NPT Hex Nip 6K 3 44 1 Tee NPT 6K 1 45 1 FM NPT 4-Way 1 48 1 Ball Valve 306-S 6K 2 49 1 M Stucci FM NPT 2 50 1 FM Stucci FM NPT 1 51 1 NPT Bushing 6K 1 53 1 NPT Bushing 6K 3 55 1 M NPT 1 M Jic 90*6K 1 56 1 M NPT 1 M Jic Hex Nip 6K 1 57 1 M NPT 1 M Jic 90* 6K 1 58 1 1 NPT Bushing 6K 1 63 1 1 NPT Bushing 6K 2 64 1 1 NPT Bushing 6K 1 65 3 1 Bushing NPT 2 66 3 All thread Sch. 80 NIP. 1 67 3 Hydraulic Oil Strainer FM FM NPT 1 68 3 FM FM NPT Gate Valve Brass 1 70 FM FM Jic 6K Blue Fuel line 1 2 3 71 FM FM Jic 6K JJ Crimp 2 6 3 73 FM FM Jic Fuel line 7 1 77 FM FM Jic 6K JJ Crimp 7 5 81 1 FM FM Jic 6K JJ crim p 4 1 83 1 FM FM Jic 6K JJ crimp 11 1 88 1 FM FM Jic 6K JJ crimp 14 2 89 BT 216 Oil filter (Baldwin) 1 90 BT 387 Hydrauic return filter (Baldwin) 1 91 BF-7681-D Fuel filter primary (Baldwin) 1 92 BF-7674-D Fuel filter secondary (Baldwin) 1 93 RS3544 Outer air filter (Baldwin) 1 94 RS3545 Inner air filter (Baldwin) 1 95 R20P Racor filter 1 104 M Jic FM Compression

[0119] The following is a list of parts that correspond to FIG. 10:

TABLE-US-00003 QTY Parts # Description 1 2 FM TEE NPT Brass 1 3 FM FM NPT 90* Brass 3 4 M JIC M NPT 90* Brass 1 5 M JIC M NPT 45* Brass 1 6 M M NPT Hex Nip. Brass 1 7 NPT100 PSI Murphy gauge(oil pres.) 3 9 M M NPT Hex Nip 6K 7 11 M Jic M NPT Hex Nip 6K 12 12 M Jic M NPT 90* 6K 1 13 FM FM Collar NPT 6K 2 17 M Stucci FM NPT 1 19 FM NPT Shuttle Valve 1 20 NPT 10000 PSI gauge (Flush Mount) 2 23 Bushing NPT 6K 7 24 Banjo FM NPT 2 25 M Jic M NPT 90* 6K 1 26 FM NPT 14 mm M thread 6K 1 27 M Jic 22 1.5 mm M thread 6K 1 29 M M NPT Hex Nip 6K 1 30 Jic NPT 90* 6K 1 31 FM FM NPT Gate Valve Brass 9 39 1 M M NPT Hex Nip 6K 1+ 40 1 M Jic 1 M NPT 45* 6K 9 41 1 M Jic 1 M NPT Hex Nip 6K 1 42 1 FM Jic M NPT Hex Nip 6K 3 44 1 Tee NPT 6K 1 45 1 FM NPT 4-Way 1 48 1 Ball Valve 306-S 6K 2 49 1 M Stucci FM NPT 2 50 1 FM Stucci FM NPT 1 51 1 NPT Bushing 6K 1 53 1 NPT Bushing 6K 3 55 1 M NPT TM Jic 90* 6K 1 56 1 M NPT 1 M Jic Hex Nip 6K 1 57 1 M NPT 1 M Jic 90* 6K 1 58 1 1 NPT Bushing 6K 1 63 1 1 NPT Bushing 6K 2 64 1 1 NPT Bushing 6K 1 65 3 1 Bushing NPT 2 66 3 All thread Sch. 80 NIP. 1 67 3 Hydraulic Oil Strainer FM FM NPT 1 68 3 FM FM NPT Gate Valve Brass 4 70 FM FM Jic 6K Blue Fuel line 1 2 3 71 FM FM Jic 6K JJ Crimp 2 6 3 72 FM FM Jic Fuel Line 3 6 2 73 FM FM Jic Fuel line 7 1 77 FM FM Jic 6K JJ Crimp 7 5 81 1 FM FM Jic 6K JJ crimp 4 1 82 1 FM FM Jic 6K JJ Crimp 94 1 88 1 FM FM Jic 6K JJ crimp 14 1 90 BT 387 Hydrauic return filter (Baldwin) 1 95 R20P Racor filter 1 96 0118-1749 Oil filter (Deutz) 1 97 0118-1917 Fuel filter primary (Deutz) 1 98 0131-9257 Outer Air filter (Deutz) 1 99 01180-0870 Inner Air filter (Deutz) 1 100 Duetz Fuel Pump

[0120] The following is a list of parts that correspond to FIG. 11:

TABLE-US-00004 QTY Item # Description 1 9 M M NPT Hex Nip 6K 2 10 M Jic Boss w/Jam Nut 90* 6K 1 11 M Jic M NPT Hex Nip 6K 1 14 M NPT . M Jic Bulkhead Fit 6K 1 15 Tee NPT 6K 3 16 M Stucci FM NPT 2 17 FM Stucci FM NPT 2 18 M FM NPT Needle Valve (102 FM G) 1 20 10000 PSI gauge NPT (Flush Mount) 6 33 M Jic Boss #10 Hex Nip 6K 4 34 M Jic M NPT Hex Nip 6K 2 35 M Jic FM Jic 90* 6K 1 37 1 M Jic Boss Hex Nip 6K 1 38 1 M Jic M Boss w/Jam Nut 90* 6K 2 39 1 M M NPT Hex Nip 6K 4 40 1 M Jic 1 M NPT 45* 6K 2 43 1 M JIC 1 M Type M Hex Nip 6K. 6 46 1 M M Type-M Hex Nip 6K 2 47 1 M Type-M M NPT Hex Nip 6K 4 49 1 M Stucci FM NPT 6K 4 50 1 FM Stucci FM NPT 2 54 1 M NPT M Jic Hex Nip 6K 2 59 1 3 SS XXH NPT Nipple 2 62 1 Sw iv. 90 w/grease cert style 60 6K 2 71 FM FM Jic 6K JJ Crimp 2 6 1 74 FM FM Jic 6K JJ crimp 11 1 75 M M NPT 6000 PSI hose 25 1 77 FM FM Jic 6K JJ crimp 7 4 78 FM FM Jic 6K JJ crimp 2 6 1 80 FM FM Jic 6K JJ crimp 11 1 82 1 FM FM Jic 6K JJ crimp 9 4 3 83 1 FM FM Jic 6K JJ crimp 11 2 84 1 M M NPT 6000 PSI hose 25 2 86 1 FM FM Type M Hose 25 6 87 1 FM FM Type M Hose 150 1-A Flow Meter 1-B 2-A 2-B 3-A 3-B 4-A 4-B

[0121] The following is a list of parts that correspond to FIG. 12:

TABLE-US-00005 QTY Parts # Description SHEAR 70 1 49 1 M Stucci FM NPT 1 50 1 FM Stucci FM NPT 2 52 1 3 XXH NPT Nipple 6K 2 58 1 to 1 Bushing NPT 6K 2 60 1 5 XXH NPT Nipple 6K 2 62 Swivel Style 60 6K SHEAR 72 1 49 1 M Stucci FM NPT 1 50 1 FM Stucci FM NPT 2 52 1 3 XXH NPT Nipple 6K 2 58 1 to 1 Bushing NPT 6K 2 60 1 5 XXH NPT Nipple 6K 2 62 Swivel Style 60 6K SHEAR 71 1 49 1 M Stucci FM NPT 1 50 1 FM Stucci FM NPT 2 52 1 3 XXH NPT Nipple 6K 2 58 1 to 1 Bushing NPT 6K 2 59 1 3 XXH NPT Nipple 6K 2 62 Swivel Style 60 6K SHEAR 73 1 49 1 M Stucci FM NPT 1 50 1 FM Stucci FM NPT 2 52 1 3 XXH NPT Nipple 6K 2 58 1 to 1 Bushing NPT 6K 2 60 1 5 XXH NPT Nipple 6K 2 62 Swivel Style 60 6K GRAPPLE 74 2 47 1 M NPT 1 M Type-M Nipple 6K 1 49 1 Male Stucci 6K 1 50 1 Female Stucci 6K 2 58 1 to 1 Bushing NPT 6K 2 61 1 7 XXH NPT Nipple 6K 2 62 Swivel Style 60 6K

[0122] The following is a list of parts and materials suitable for use in the present invention:

TABLE-US-00006 PARTS LIST: PART NUMBER DESCRIPTION 1 marine vessel 2 water surface area 3 deck area 4 crane/lifting device 5 lifting line 6 rigging 7 seabed 10 leak detection system 10A leak detection system 11 hydraulic device/shear 12 hydraulic cylinder 13 body 14 jaw 15 pushrod 16 piston 17 chamber section 18 chamber section 19 cylinder 20 prime mover/diesel engine 21 pump 22 reservoir/hydraulic fluid 23 diesel fuel tank 24 case drain line/recycle line 25 flow line (pressure) 26 flow line (return) 27 flow line 28 hydraulic power unit 30 control station 31 flow line 32 flow line 33 computer/controller 38 drive motor for hose reel 40 hose reel 41 flow line 42 flow line 45 flow meter 46 flow meter 47 object/pipe 48 arrow 49 arrow 50 prime mover/electric motor 51 battery 52 positive lead 53 negative lead 54 hydraulic control valve 55 rotary cam switch 56 start button 57 lamp 58 lamp 59 jaw 60 attachment 61 pivotal connection 62 pivotal connection 63 arrow 64 solenoid operated valve 65 flow line 66 switch/solenoid operated switch 67 cooler 68 lever 70 shear 71 shear 72 shear 73 shear 74 grapple

[0123] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.

[0124] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.