FIBRE OPTIC MONITORING INSTALLATION AND METHOD

Abstract

The invention relates to installations for fibre optic monitoring of articles, and apparatus and methods for forming such installations, including a modular system and components for forming a fibre optic monitoring installation. Applications of the invention include the monitoring of vessels, chambers, and fluid conduits in industrial processing plants, and the invention has particular application to monitoring large vessels, for example temperature monitoring of vessels used in catalytic reforming processes. Convenient installation on or removal from the article being monitored is achieved by providing a support structure for the fibre optic length, which presents the fibre optic length in a preconfigured orientation suitable for monitoring the article. In a particular embodiment of the invention, the fibre optic length is disposed on a panel in a plurality of dense spiral patterns.

Claims

1.-66. (canceled)

67. A fibre optic monitoring installation comprising: an article having an outer surface to be monitored; a fibre optic support structure arranged to support a fibre optic length, wherein the support structure comprises a frame defining a monitoring area which corresponds to a part of the outer surface of the article, and the fibre optic length is arranged in a predetermined pattern or orientation on a first surface of the frame such that the fibre optic length is located over the monitoring area defined by the frame; means for locating the fibre optic support structure in relation to the article such that, in use, the fibre optic length is sensitive to a condition of the outer surface of the article; and fibre optic instrumentation coupled to the fibre optic length, wherein the support structure is configured to be located in relation to the article to form an in situ support for subsequent installation of the fibre optic length onto the support structure.

68. The fibre optic monitoring installation according to claim 67, wherein the means for locating the fibre optic support structure in relation to the article is arranged such that, in use, the first surface of the frame faces the outer surface of the article such that the fibre optic length is presented to the outer surface of the article.

69. The fibre optic monitoring installation according to claim 67, wherein the frame further comprises a plurality of attachment points spaced along the frame for attaching the fibre optic length to the first surface.

70. The fibre optic monitoring installation according to claim 67, wherein the frame further comprises a channel for receiving the fibre optic length.

71. A fibre optic monitoring installation comprising: an article having an outer surface to be monitored; a plurality of modules, each module comprising: a fibre optic length, and a fibre optic support structure arranged to support the fibre optic length, wherein the support structure comprises a frame defining a monitoring area which corresponds to a part of the outer surface of the article, and the fibre optic length is arranged in a predetermined pattern or orientation on a first surface of the frame such that the fibre optic length is located over the monitoring area defined by the frame; means for locating the fibre optic support structure in relation to the article such that, in use, the fibre optic length is sensitive to a condition of the outer surface of the article; and fibre optic instrumentation coupled to the fibre optic length, wherein the installation further comprises a connector for connecting each module directly to an adjacent module.

72. The fibre optic monitoring installation according to claim 71, wherein the connector comprises a rod clamp, the frame of each module further comprising a first channel arranged to receive the rod clamp.

73. The fibre optic monitoring installation according to claim 71, wherein the means for locating the fibre optic support structure in relation to the article is arranged such that, in use, the first surface of the frame faces the outer surface of the article such that the fibre optic length is presented to the outer surface of the article.

74. The fibre optic monitoring installation according to claim 71, wherein the frame further comprises a plurality of attachment points spaced along the frame for attaching the fibre optic length.

75. The fibre optic monitoring installation according to claim 71, wherein the frame further comprises a second channel for receiving the fibre optic length.

76. A fibre optic monitoring installation comprising: an article having an outer surface to be monitored; fibre optic instrumentation; a fibre optic loop coupled to the fibre optic instrumentation, wherein the fibre optic instrumentation is coupled to the loop at both ends of the loop; one or more modules, each module comprising a fibre optic length coupled to the fibre optic loop and a fibre optic support structure arranged to support the fibre optic length, wherein the support structure comprises a frame defining a monitoring area which corresponds to a part of the outer surface of the article, and the fibre optic length is arranged in a predetermined pattern or orientation on a first surface of the frame such that the fibre optic length is located over the monitoring area defined by the frame; and means for locating the fibre optic support structure of each module in relation to the article such that, in use, the corresponding fibre optic length is sensitive to a condition of the outer surface of the article.

77. The fibre optic monitoring installation according to claim 76, wherein the fibre optic length of each module is coupled to the fibre optic loop at both ends.

78. The fibre optic monitoring installation according to claim 76, wherein the fibre optic instrumentation comprises an optical switch such that, in use, the fibre optic instrumentation is arranged to monitor the fibre optic loop via both ends.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] There will now be described, by way of example only, various embodiments of the Invention with reference to the drawings, of which:

[0052] FIG. 1 is a perspective view of a typical vessel used in a catalytic reforming process;

[0053] FIG. 2 is a side view of a module according to an embodiment of the invention;

[0054] FIG. 3 is a schematic view of a fibre optic monitoring system according to an embodiment of the invention;

[0055] FIG. 4 is a perspective view of a fibre optic monitoring installation according to an embodiment of the invention;

[0056] FIG. 5 shows an initial installation step according to an embodiment of the invention;

[0057] FIG. 6A to 6C show schematically steps of an installation method according to an embodiment of the invention;

[0058] FIG. 7 shows schematically a step of an installation method according to an alternative embodiment of the invention;

[0059] FIGS. 8A to 8B show schematically steps of an installation method according to an alternative embodiment of the invention;

[0060] FIG. 9A is a perspective view of a fibre optic monitoring installation according to an alternative embodiment of the invention;

[0061] FIG. 9B is an enlarged view of the support structure of the embodiment of FIG. 9A;

[0062] FIG. 10A is a perspective view of a fibre optic monitoring installation according to an alternative embodiment of the invention;

[0063] FIG. 10B is an enlarged view of the support structure of the embodiment of FIG. 10A; and

[0064] FIG. 11A is a side view of a module according to an alternative embodiment of the invention.

[0065] FIG. 11B shows a cross-section through line X of FIG. 11A according to an alternative embodiment of the invention.

[0066] FIG. 11C shows an enlarged view of a portion of one of the spirals in FIG. 11A according to an alternative embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0067] Referring firstly to FIG. 1, there is shown generally depicted at 10 a catalytic reforming process vessel having a cylindrical outer wall 12. The vessel 10 is oriented vertically on a concrete support 14 which surrounds a lower part 16 of the vessel. An annular space 19 of a few centimetres (3 to 10 cm) is provided between the concrete support 14 and the outer wall 12. However, the concrete support 14 prevents visual assessment of the vessel, and restricts manual access to the lower part 16 of the vessel.

[0068] FIG. 2 shows generally at 20 a module forming a part of a first embodiment of the invention. The module 20 is suitable for use as a component of a fibre optic monitoring system for the vessel 10. This embodiment of the invention is suitable for a wide range of industrial applications, and includes benefits in installation, removal, and monitoring inaccessible surfaces of the vessel.

[0069] The module 20 comprises a fibre optic length 21 supported by and attached to a support structure in the form of frame 22. The frame 22 is formed from a panel 23 of a thermally conductive metal material (for example stainless steel, aluminium or an alloy thereof). The panel 23 has preformed windows 24 between horizontal and vertical members 25, 26. Edges of the frame 22 comprise corresponding attachment features 27, 28 which are configured to attach the module 20 to an adjacent module (not shown) or other attachment feature of the installation. The fibre optic length 21 is attached to the frame 22 by attachment points 29 spaced along the frame, and follows a convoluted path over the areal extent of the frame to define a monitoring area. It will be appreciated that the pattern followed by the fibre optic length 21 can be varied according to the application (such as in the alternative embodiment shown in FIGS. 11A-11C and described in further detail below).

[0070] In this embodiment, the module is pre-assembled from the frame and the fibre optic to allow easy installation on the vessel 10. The frame 20 is planar, but has sufficient flexibility and compliance to allow it to be curved around the outer surface of the vessel. In alternative embodiments, the frame may have an intrinsic curvature to match the shape of the vessel.

[0071] Ceramic insulating material (not shown) is placed between the fibre optic cable 21 and the frame 23 to insulate the fibre optic from the effects of the environment.

[0072] FIG. 3 shows schematically a fibre optic monitoring system 30 comprising multiple modules 20′. The modules 20′ are similar to modules 20, and will be understood from FIG. 2 and the accompanying description. The module 20′ differs from the module 20 in the layout of the frame and the orientation of the fibre optic length, but functions in the same way. The system 30 comprises multiple (in this case four) modules 20′ which, each of which define a monitoring area. In use, the modules 20′ are located against the surface of the vessel 10 to be sensitive to a condition of the vessel 10. The system 30 is configured as a Distributed Temperature Sensor (DTS) system for monitoring the temperature of the outer wall of the vessel 10, and the fibre optic lengths 21′ are selected for high temperature operation. The system 30 comprises a DTS instrument 31 located remote from the vessel 10 in a control room (not shown). A surface cable 32 with a multiple fibre optic core is routed from the control room to the vessel 10. The surface cable 32 is selected to meet fire and safety standards.

[0073] The ends of the fibre optic lengths 21′ are connected in series by splicing them together in a junction box 33 via interconnecting cable 34 to form a loop. The interconnecting cable 34 is protected by a metal tube (not shown) to provide additional protection during routine maintenance work. Access to both ends of the fibre optic lengths 21′ is provided by splicing the two ends of the loop to two separate fibres in the surface cable 32.

[0074] An optical switch 35 is incorporated at the optical output of the DTS instrument 31 which enables the monitoring of the fibre loop from both ends. This has two advantages. The first advantage is that the temperature accuracy can be improved by combining the two measurements. The second advantage is that the whole length of the fibre can be monitored if there is a break in the fibre.

[0075] Although the system 30 is configured for monitoring one vessel 10, the system can be extended to monitor additional vessels. For example, the fibre optic lengths of additional modules may be spliced in series with the fibre optic lengths 21′ to form a part of the loop. Alternatively, they may be routed separately back to the DTS instrument via additional fibres in the surface cable 32, used in conjunction with a multichannel optical multiplexer (not shown) to sequentially monitor the additional vessels.

[0076] FIG. 4 shows the system 30 in a fibre optic monitoring installation 40 on a vessel 10. The installation 40 comprises four modules 20 installed on the vessel 10, in the annular space 10 between the vessel 10 and the concrete support 14. The modules 20 are arranged to present their respective fibre optic lengths to the surface, such that they are sensitive to the temperature conditions of the vessel. Each module can be installed individually on the vessel to cover a monitoring area or zone. The modules 20 are connected together by connectors 41 and placed under tension to ensure good thermal conduct between the fibre and the vessel and accommodate thermal expansion and contraction of the vessel. Examples of installation methods are described in more detail below.

[0077] In use, the system monitors the surface of the vessel 10 to provide quantitative temperature data. The installation 40 also optionally comprises a visual and audible indicator 42 which is activated in response to the detection of an undesirable temperature condition. When a hotspot is detected an alarm signal is sent to the local indicator 42 via the surface cable to draw immediate attention to the detected condition. The surface cable may therefore be a hybrid electrical and optical cable. In an alternative embodiment the warning signal may be transmitted optically, which is advantageous if it is undesirable to provide electrical cables in the vicinity of the vessels.

[0078] Methods of forming the monitoring installation 40 will now be described. The frames allow convenient installation of the system on parts of the surface which are difficult to reach due to the geometry of the installation. However, it will be appreciated that the invention also has benefits when the modules are installed in accessible areas of the vessel, including ease of installation and removal. Furthermore, the invention allows the system to be installed and/or removed without interrupting the operation of the vessel.

[0079] In the embodiment of FIG. 4, lower part of the vessel beneath the concrete support is more accessible from below than from above. The individual modules are pre-assembled, and are positioned against the surface of the vessel by raising the modules up into the annular space between the concrete support 14 and the vessel from below. FIG. 5 shows an initial stage of installation, in which a module 20′ is vertically supported in the annulus by a bracket 52. The bracket 52 is an “L-shaped” bracket fitted to the concrete support (not shown in FIG. 5), and comprises a pin 53 which supports the module 20′ vertically in the space. Additional modules are positioned against the surface of the vessel sequentially around the vessel, and supported vertically by similar brackets.

[0080] FIGS. 6A to 6C show schematically a mechanism by which the system is installed according to one embodiment. For clarity, these drawings show a pair of frames 54a, 54b which make up a pair of modules, with the fibre optic lengths omitted and outside of the installation 40. It will be appreciated that same mechanism may be used in the annular space between the vessel and the concrete support.

[0081] Each frame 54a, 54b comprises connector formations 56 along opposing adjacent edges 55a, 55b. The formations 56 are located along the edges and extend from the plane of the frames to form abutment surfaces. The formations are arranged in corresponding pairs which are designed to be brought together during installation. As most clearly shown in FIGS. 6B and 6C, a pivoting clamp 58 is located around the formations 56, opened against the force of a spring 59. The open ends of the clamp 58 are brought together to engage the abutment surfaces of the formations 56 and bring the edges 55a, 55b of the frames together, as shown in FIG. 6C. An additional spring 57 connects the lower ends of the clamp 58.

[0082] For the installation of the monitoring system 40, the method takes place inside the annular Space 19 between the vessel and the concrete support 14. The frames are located in the annular space and vertically supported by the brackets 52. The clamp 58 is located in the annular space 19 and positioned around the formations 56. The ends of the clamp 56 are brought together to engage the abutment surfaces of the formations 56 and bring the edges 55a, 55b of the frames together, and an additional spring 57 connects the lower ends of the clamp 58. The attachment mechanism applies tension to the modules in the installation to maintain good physical contact between the fibre optic lengths and the vessel and therefore maintain sensitivity to the vessel condition. In addition, it allows the modules to be brought together from an access position located above or below the modules, enabling the modules to be assembled over areas which are difficult to reach such as behind structural elements.

[0083] Each of a plurality of modules may be brought together and attached in the manner described above. Alternatively, some of the modules may be mechanically fixed to one another with only one (or some) of the interfaces between adjacent modules having a tensioned connection.

[0084] Variations to the described embodiment are within the scope of the invention. In one alternative, the clamp is provided with hooks which engage with slots in the frames. In another, as shown in FIG. 7, the clamp 68 is a scissor-type clamp with a pivot 69 located part-way along its length. This arrangement operates similarly to the arrangement of FIGS. 6A to 6C, although it does not require the clamp to be located around the formations on the frames. Instead, the clamp 68 operated from below can be positioned on the outside of the formations on the frames from below (as shown in the drawing), and is not required to manipulated over the uppermost formations. This facilitates positioning of the clamp in narrow access areas, and the minimal extent of the clamp above the frames may allow them to be positioned higher up in a restricted space. It will be appreciated that this configuration can be inverted for operation from above.

[0085] A further alternative embodiment is illustrated in FIGS. 8A and 8B. In this embodiment, the frames 80 are provided with channels 82 formed by bending the material of the frame. The channels are shaped to receive a rod clamp 84, which is inserted into the channels 82 to allow the frames to be positioned in relation to the vessel. After positioning of the panels, high strength springs 84 are installed around the rods to maintain the modules under sufficient tension to accommodate for thermal expansion of the vessel in operation.

[0086] FIGS. 9A and 9B show a fibre optic monitoring installation 90 according to another embodiment of the invention. FIG. 9A shows the system formed from modules 91a, 91b, located on the vessel. Each module comprises a custom-fabricated aluminium channel structure 92 welded to supports 93. The channel structure 92, most clearly shown in FIG. 9B, comprises a channel for receiving the fibre optic length 94. The depth of the channel is less than 50% of the cable diameter to ensure that sufficient fibre is upstanding from the channel to provide good contact with the vessel. The channel structure 92 is shaped to follow the curve of the surface of the vessel to which it is attached. This allows firm pressure to be applied over the entire surface using L-shaped brackets secured to the concrete support.

[0087] The fibre optic length is secured to the channel structure 92 using cable ties, which are held in place along the length of the channel by notches 96. In addition, ceramic insulating material (not shown) is placed between the fibre optic cable and the channel structure 92 to insulate the fibre optic from the effects of the environment.

[0088] FIGS. 10A and 10B show an alternative embodiment 100 of the invention, in which the support structure for the fibre optic cable is a flexible sleeve 101 of fibrous material. FIG. 10A shows the installation system 100, having a part of the concrete support 14 removed to show the sleeve 101 beneath. FIG. 10B shows the sleeve 101 and fibre optic assembly prior to installation.

[0089] The sleeve 101 is approximately 3 to 7 mm thick and supports the fibre optic length in a preformed orientation. The insulating material of the sleeve reduces the effect of ambient temperature on the monitoring operation, and also prevents conduction of heat from the vessel to the concrete support. The internal structure of the sleeve 101 is supported by a steel mesh (not shown). In order to allow installation behind the concrete collar, the blanket is fitted around the vessel by opening the sleeve at edges 103a, 103b and placing the sleeve around the vessel. The sleeve is positioned vertically on the vessel and the edges 103a, 103b are attached to one another at points above and below the concrete support using by spring-loaded attachment mechanisms 104. The mechanism tension the sleeve to maintain close contact between the vessel and the fibre optic lengths.

[0090] In FIG. 11A, an alternative module 200 is shown in which a very high density of fibre 221 is accommodated on a panel 222. The dashed portions 221b of the fibre 221 indicate where the fibre 221 is passed behind the panel 222 (via apertures 222a) to avoid having the fibre 221 physically cross itself. In this way, a series of dense spirals 230 is able to be provided without risking the fibre 221 being bent, crushed or otherwise damaged when, for example, the module 200 is pressed onto a vessel to be monitored. Of course, a number of alternative patterns may be achieved in this way. FIG. 11B shows a cross-section through line X illustrating the location of the fibre 221 on opposite sides of the panel when in one of the spirals 230, or behind 221b the panel 222 between spirals 230. FIG. 11C shows an enlarged view of a portion of one of said spirals 230.

[0091] In this particular embodiment, the panel 222 may be pre-shaped to correspond, for example, to the shape of a vessel to be monitored such that it may be installed directly. Of course, similarly to previously described embodiments, the panel 222 may be planar and able to conform to the shape of a vessel to be monitored as it is installed.

[0092] The front face of the panel 222 (i.e. that facing out of the drawing in FIG. 11A and to the right of the drawing in FIG. 11B and that which is applied to the vessel surface) is provided with a number of fibre guide portions 229a which define and arrange the fibre 221 in a spiral path and a number of attachment points 229b which hold the fibre 221 in place. The attachment points 229b shown herein are short panel pass-throughs corresponding to the spiral path defined by the fibre guide portions 229a and ensure the fibre 221 is held in this configuration. Alternative attachment points may take the form of clips, studs, loops or other attachment means that would be apparent to the skilled person as suitable for this purpose.

[0093] The fibre guide portions 229a are shown in a concentric or quasi-concentric arrangement, and the attachment points 229b in a radial arrangement, however the skilled person will readily understand that a number of variations on and of these arrangements can be employed to effect and maintain a spiral (or other shaped) fibre configuration.

[0094] The provision of a series of dense spirals 230 also provides significant measurement and processing enhancements. For example, when a DTS is employed (such as described in relation to FIG. 3) the measurement density is vastly increased over previously described module embodiments, and the spirals themselves can be treated in processing as an array of virtual point sensors. Similarly, a number of said modules 200 may be connected to one another for further enhanced measuring and monitoring capability.

[0095] The invention provides a fibre optic monitoring installation and method of installation for an article such as a catalytic reforming process vessel. The installation comprises a fibre optic support structure arranged to support a fibre optic length in a predetermined orientation, which corresponds to a part of a surface of the article. The fibre optic support structure is located in relation to article such that in use the fibre optic length is sensitive to a condition (such as a temperature) of the surface of the article. Fibre optic instrumentation is coupled to the fibre optic length. Preferably the installation is a modular system of modules which allow convenient fitting of the fibre optic lengths to the article.

[0096] The present invention in its various aspects and embodiments offers a number of advantages over previously proposed fibre optic monitoring installations, apparatus and methods. Firstly, the invention allows convenient and fast installation and removal of fibre optic lengths by providing a support structure which orientates the fibre optic in a desired pattern. The invention enables fibre optic installation and/or removal while an article is in operation in an industrial process, and protects the fibre optic from mechanical damage.

[0097] The invention allows installation of fibre optic lengths over difficult-to-reach surfaces of an article to be monitored, such as parts of catalytic reforming process vessels which are obscured by structural elements. The installation methods and apparatus allow tensioning of the monitoring apparatus to maintain good contact between the fibre optic and the vessel (and therefore good sensitivity). Modular systems of embodiments of the invention facilitate removal and replacement of parts of the monitoring system without interfering with the operation and/or monitoring of other parts of the article.

[0098] Various modifications may be made within the scope of the invention as herein intended, and embodiments of the invention may include combinations of features other than those expressly disclosed herein. In particular it will be appreciated that many features of the various embodiments of the invention can be interchanged with one another or used in combination in alternative installation designs.