Cyclonic system for enhanced separation of fluid samples and the like, and method therefore

Abstract

A cyclonic filter separator with liquid block capabilities formed to separate liquids in a fluid stream for on-stream and spot sampling of natural gas or the like, particularly pressurized process gas having liquid entrained therein, otherwise referenced as multiphase or wet. The present invention incorporates a liquid block apparatus downstream the cyclonic separator to provide to further prevent liquid passing therethrough, ensuring a dry gas sample stream for analysis or the like. A coalescing membrane may be situated intermediate the cyclonic separator and the liquid block, which coalescing membrane may further be linked to the liquid block such that differential pressure associated with the operative state of the membrane causes the liquid block to engage, blocking the flow of fluid therethrough.

Claims

1. A device for sampling a fluid in a fluid stream, comprising: a base having an inlet formed to receive said fluid stream; a housing having first and second ends, said first end formed to engage said base, said housing containing a cyclonic separator comprising a lower, conical cyclone chamber associated with said second end of said housing, said cyclone chamber having an internal geometry formed to facilitate a cyclone to separate liquid from said fluid stream, providing a treated fluid stream, and a liquid drain; an insert having a central cavity forming a passage to said base and a cylindrical outer surface, said outer surface formed to engage said fluid stream so as to direct same to said cyclone chamber, said insert formed to receive said treated fluid stream and direct same to an outlet; said housing having a cylindrical cavity formed therein having an inner diameter formed to envelope the outer surface of said insert so as to form a clearance therebetween to form a fluid passage to receive fluid flow from said base to said cyclone chamber; a coalescing element situated downstream said cyclone chamber; a liquid block mounted downstream said coalescing element, said liquid block comprising a spring-biased arm having a seal, said seal formed to engage a retention plate associated with said coalescing element whereby, upon a said coalescing element becoming saturated with fluid, a pressure differential is created to urge said seal to engage a seat, so as to prevent the flow of said liquid therethrough.

2. The device of claim 1, wherein said housing is threadingly affixed to said base.

3. The device of claim 1, wherein there is provided a pressure reducer downstream said coalescing element.

4. The device of claim 1, wherein said seal comprises gasket material.

5. The device of claim 1, wherein said seal comprises an o-ring.

6. The device of claim 1, wherein said fluid stream is directed from a process gas stream in a pipeline, said device being situated exterior said pipeline.

7. The device of claim 1, wherein said internal geometry of said cyclone chamber is in the form of an inverted frustoconical chamber.

8. The device of claim 1, wherein said coalescing element comprises a membrane.

9. The device of claim 8, wherein said coalescing element is situated in said central cavity of said insert.

10. The device of claim 1, wherein said liquid block device operatively engages said coalescing element via said spring biased arm.

11. A method of separating a gas from a fluid stream, comprising the steps of: a. providing a device comprising: ai. a base having an inlet formed to receive said fluid stream; aii. a housing having first and second ends, said first end formed to engage said base, said housing containing a lower, conical cyclone chamber associated with said second end of said housing, said cyclone chamber having an internal geometry formed to facilitate a cyclone to separate liquid from said fluid stream, providing a treated fluid stream, and a drain for draining liquid therefrom; aiii. an insert having a central cavity forming a passage to said base, and a cylindrical outer surface, said outer surface formed to engage said fluid stream so as to direct same to said cyclone chamber, said insert formed to receive said treated fluid stream and direct same to an outlet; aiv. said housing having a cylindrical cavity formed therein having an inner diameter formed to envelope the outer surface of said insert so as to form a clearance therebetween to form a fluid passage to receive fluid flow and direct same from said base to said cyclone chamber; av. a coalescing element situated downstream said cyclone chamber; avi. a liquid block mounted downstream said coalescing element, said liquid block comprising a spring biased arm having a seal formed to engage a retention plate associated with said coalescing element whereby, upon a said coalescing element becoming saturated with fluid, a pressure differential is created to facilitate the positioning of said seal to engage a seat to selectively prevent the flow of said liquid therethrough; b. engaging said insert to said base; c. engaging said housing to said base so that said housing envelopes at least a portion of said insert, forming a clearance between said outer surface of said insert and said housing; d. flowing a fluid stream comprising gas having liquid therein from said base, about said insert via said clearance between said insert outer surface and said housing, to said cyclone chamber, e. allowing said internal geometry of said cyclonic chamber to facilitate formation of a cyclone therein; f. using said cyclone to facilitate separation of liquid from said fluid stream; g. draining said liquid, while facilitating the passage of gas therethrough.

12. The method of claim 11, wherein in step g said liquid comprises a liquid slug.

13. The method of claim 12, wherein following step g there is provided the added step h of flowing said gas through said coalescing element, capturing any entrained liquid therein, providing dry gas.

14. The method of claim 13, wherein following step h there is provided the added step I. of utilizing said coalescing element to close said liquid block upon said coalescing element becoming saturated with liquid.

15. A method of sampling a gas stream having entrained liquid therein, comprising the steps of: a. providing a device comprising: ai. a base having an inlet formed to receive a fluid stream; aii. a housing having first and second ends, said first end formed to engage said base, and a lower, conical cyclone chamber associated with said second end of said housing, said cyclone chamber having an internal geometry formed to facilitate a cyclone to separate liquid from said fluid stream, providing a treated fluid stream, and a drain for draining separated liquid therefrom; aiii. an insert having a central cavity forming a passage to said base, and a cylindrical outer surface, said outer surface formed to engage said fluid stream so as to direct same to said cyclone chamber, said insert formed to receive said treated fluid stream and direct same to an outlet; aiv. said housing having a cylindrical cavity formed therein having an inner diameter formed to envelope the outer surface of said insert so as to form a clearance therebetween to form a fluid passage to receive fluid flow and direct same from said base to said cyclone chamber; av. a coalescing element situated downstream said cyclone chamber; avi. a liquid block mounted downstream said coalescing element, said liquid block comprising a spring biased arm having a seal formed to engage a retention plate associated with said coalescing element whereby, upon a said coalescing element becoming saturated with fluid, a pressure differential is created to facilitate the positioning of said seal to engage a seat to selectively prevent the flow of said liquid therethrough; b. engaging said insert to said base; c. engaging said housing to said base so that said housing envelopes at least a portion of said insert, forming a clearance between said outer surface of said insert and said housing; d. receiving a flow of a said gas stream having entrained liquid into said base, providing a sample flow; e. directing a portion of said sample flow about said outer surface of said insert via said clearance to said cyclone chamber; f. allowing said sample flow to interact with said cyclonic chamber to form a cyclone; g. using said cyclone to separate liquid from said sample flow, providing a separated sample flow; h. draining said liquid into said process gas stream.

16. The method of claim 15, wherein there is further provided after step h the added step I of flowing said separated sample flow through said coalescing element, separating entrained liquid from said separated sample flow, and draining said liquid via said drain associated with said cyclone chamber, providing dry sample flow.

17. The method of claim 16, wherein there is further provided after step I the added step j of flowing said dry sample flow through said liquid block.

18. The method of claim 17, wherein there is further provided after step j the added step of utilizing said coalescing element to actuate said liquid block, sealing said liquid block, upon said coalescing element becoming saturated with liquid.

19. The method of claim 17, wherein there is further provided after step I the added step j of flowing said dry sample flow out of said insert, through said base to an analyzer.

Description

BRIEF DESCRIPTION OF DRAWINGS

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

(2) FIG. 1A is a side, partially cutaway view of the first, preferred embodiment of the present invention, illustrating a cyclone-type (also referenced as cyclonic) separator/filter, the present embodiment further illustrating a coalescing element downstream of the cyclonic separator, and a liquid block downstream the coalescing element.

(3) FIG. 1B is a side view of the second, alternative embodiment of the device of FIG. 1A, viewing through inlet 10, the second embodiment provided without the coalescing element or liquid block provided shown in the first embodiment of FIG. 1A.

(4) FIG. 2A is a side view, partially cutaway view of the invention of FIG. 1B, illustrating via arrows fluid flow/liquid separation, and draining port.

(5) FIG. 2B is a side, partially cutaway view of the invention of FIG. 2A showing inlet 10.

(6) FIG. 3 is a side, cutaway view of the first embodiment of FIG. 1A, illustrating fluid flow via inlet, outlet, bypass, and drain.

(7) FIG. 4 illustrates the second embodiment of FIG. 1B, showing threaded connections for the components, and further providing an additional, unique threaded or spiraled exterior of insert 4 to facilitate spiral or cyclonic flow about the insert from inlet to separation funnel/cyclonic chamber 3.

(8) FIG. 5 is a side, partially cutaway view of the invention of FIG. 4, illustrating via phantom internal structure of the various components shown.

(9) FIG. 6 is a side, exploded view illustrating the various components of first, preferred embodiment of the cyclonic device of FIG. 1A, illustrating in phantom the internal structure of same.

(10) FIG. 7 is a side, exploded view of the device of FIG. 1A with the added feature shown of the incorporation of the unique threaded or spiraled exterior of insert utilized with the device to facilitate spiral or cyclonic flow about the insert from inlet to separation funnel/cyclonic chamber 3, the insert further containing a coalescing element 5 and liquid block 6 therein, formed for fluid passage therethrough to outlet 7.

DETAILED DISCUSSION OF THE INVENTION

(11) Referring to the drawings, the present invention comprises a cyclone separator in the form of a separation funnel/cyclone chamber 3 (may also be referenced as cyclone filter) the first embodiment 1 further incorporating a coalescing/membrane filter or element 5 downstream the cyclone chamber 3, so that the coalescing element 5 is situated to receive and capture, via coalescence, entrained mist or very fine aerosol droplets flowing through cyclone chamber 3, the coalescing element formed to capture any remaining aerosol droplets in the fluid stream beyond the cyclone filter, and preventing same from being introduced into the sample stream downstream the coalescing filter.

(12) In both the first 1 and second 2 embodiments of the invention, if a slug of liquid is present in the sample stream entering the cyclone filter, said fluid flow passes through separation funnel/cyclone chamber 3 which can (within limits) separate said slug of liquid (or any residual liquid therefrom) and prevent same from passing through outlet port 7 leading to the sample system.

(13) The cyclonic separator/filter of the present invention comprises a base 33 to which a housing 34 (alternatively referenced as a sleeve) is removably affixed thereto. An outlet 7 is provided (shown formed in base 33) to engage an outflow passage leading to a sample analyzer, container, etc.

(14) Base 33 engages said housing 34 via threaded connection 41 or the like, said housing 34 formed to house insert 4 shown being cylindrical and formed to be enveloped by a cylindrical inner walls 35, 35 formed in base 33 and housing 34, respectively, forming a clearance 17 therebetween for passage therethrough, as will be further discussed herein.

(15) Insert 4 includes an extension 27 emanating therefrom formed to engage the base at receiver 27 so as to provide a passage to outlet 7. The outer surface of extension 27 may be threaded to threadingly engage receiver 27 formed in base. An o-ring or other seal may be provided to sealingly connect the two components and insure a fluid seal therebetween.

(16) Housing 34 may also be threaded at its first end 30 so as to threadingly engage base 33, and a seal such as an O-ring or the like may be provided as required for a fluid-tight connection.

(17) Formed within housing 34 is a conical cavity forming a tunnel/cyclone chamber 3 tapering from its widest point to an end or apex having a drain 9 in the vicinity of the second end 30 of housing.

(18) Continuing with the figures, the present invention is shown having an inlet 10 and bypass 11 port associated with base 33, the inlet formed to receive a process flow or the like via a conduit or such so as to facilitate fluid flow 24 tangentially therein and about the passage formed by clearance 17.

(19) A portion of the fluid flowing via inlet 10 passes through clearance 17 and exits via the bypass 11, the remaining flow 24 spiraling via clearance 17 between insert 4 and inner wall 35, 35 formed by base 33 and housing 34, spirally about and down along the outer surface 19 of insert 4 to the inverted cone-shaped portion forming the separation funnel/cyclone chamber 3, said chamber 3 formed to further facilitate cyclonic action within the chamber forming a vortex 22 to facilitate fluid-liquid separation as the gas of the sample flow is drawn upward 22 through the lower pressure center of the vortex, the liquid is separated via cyclonic action and gravity, and flows to drain 9.

(20) Most or all liquid particulates in the fluid stream are thereby cyclonically extracted from the stream and drain through drain port 9, with any residual liquid taken out by coalescing element 5 downstream therefrom (in the first embodiment 1 of the invention where such element 5 feature is provided).

(21) Note again that the coalescing element 5 may be situated within insert 4 at the mouth of the separation funnel/cyclone chamber 3. The present configuration allows excess liquid coalesced into the membrane to collect and drip back into the funnel/cyclone chamber, where it is separated via the cyclonic action and drained via drain 9.

(22) Further, the described stacking or nesting of the coalescing element 5 within insert 4 in the first embodiment of the invention 1 decreases the amount of space required when compared to prior art systems. In the present system, an exemplary coalescing element may comprise, for example, A+ Manufacturing LLC's AVENGER Brand Coalescing membrane filter Model 33(M) and 38(M).

(23) In addition, in the preferred, first embodiment 1 of the present invention, a liquid block device 6 can be provided downstream and interfacing the coalescing element, shown in the first embodiment 1 situated within insert 4, the liquid block device 6 being configured to activate to prevent passage of liquid therethrough in the event the coalescing element is over-saturated with liquid, resulting in excessive pressure differential, or in the event of pass-through of low surface tension liquids which might be unaffected by the coalescing element.

(24) In the present, first 1 embodiment illustrated embodiment, a liquid block device 6 is provided, the preferred, exemplary embodiment thereof includes a spring 16 biased arm 12 having first 13 and second ends 13, the second end 13 having a seal 23 such as an o-ring associated therewith.

(25) The second end 13 of arm 12 and associated seal 23 is configured to engage membrane retention plate 25 situated on the exit or downstream side 14 of the coalescing element 5. While seal 23 is biased to a default open, flow position, said bias can be overcome to reposition said seal 23 to engage a seat 21 into a sealing position, blocking the outlet flow passage therethrough. Particularly, upon coalescing element 5 becoming oversaturated with fluid, a pressure differential build-up 26 can occur to urge said coalescing element to apply pressure to a retention plate 25 associated with the downstream side of coalescing element 5, which retention plate 25 applies pressure to the second end 13 of arm 12.

(26) Sufficient differential build 26 and associated pressure associated with a clogged coalescing element 5 will overcome the spring bias 16 to urge said seal 23 to engage seat 21 to a sealing position, blocking further flow and thereby preventing liquid from passing therefrom.

(27) Thus, flow is cut off and any sensitive equipment (i.e. analyzer) downstream the system is protected from liquid contamination. Further, the liquid block device would ideally also activate in the event of pass-through of low surface tension liquids which might be unaffected by the coalescing element.

(28) In both the first 1 and second 2 embodiments of the present invention, it is noted that the configuration of the cylindrical insert 4 can vary depending upon the application and associated needs, including, for example, a linear or blade configuration, a triangular or polygonal configuration as well as others, which may be interchangeably changed as the need arises.

(29) To facilitate the desired downwardly descending spiral flow as the fluid flows along from inlet about the outer surface of insert 4, threads 20 can be provided about the outer diameter of the cylinder insert 4. The sizes and scales of the inserts may vary depending upon the application to vary the clearance between said insert and the outer housing, which forms the passage for the fluid stream flowing thereabout and therethrough.

(30) The inlet opening size and the length and diameter of the conical section and internal barrier as well as the outlet and drain diameters may need to be sized for the flow to filter ratio of the cyclone filter/separator. This ratio must be sized correctly so that under normal analytical flow rates in a gas or vapor only single phase sample, the cyclone filter supplies the appropriate flow of sample.

(31) In addition, the passageways must also be sized so that when liquid slugs are present, the cyclone filter can remove the liquid in sample intended for the analyzer. The material of construction of the coalescing element of the first embodiment 1 may be application dependent (i.e. may depend on process fluid, analytical flow rate, the properties of the type of liquid entrained, etc.).

(32) Continuing with FIGS. 1B, 2A-2B, 4 and 5, the second embodiment of the present invention would utilize a cyclone separator/filter formed in a housing engaging a base similar in concept to that taught in the first embodiment, but without the coalescing element (5) or liquid block (6) as shown in the insert of the first embodiment, as such components may only be required when there exists substantial liquid in the flow stream and accordingly would not be provided in the second embodiment. Accordingly, the second embodiment can provide an effective, compact, low maintenance, and reliable liquid filter using cyclonic separation, providing filtered gas therefrom to outlet port 7 in flow streams without excessive liquids present therein and in installations where such separation is compliant with the desired operational specification.

ELEMENTS OF THE INVENTION

(33) 1 first embodiment of cyclone separator 2 second embodiment 3 separation funnel/cyclone chamber 4 insert 5 coalescing element/membrane filter 6 liquid block 7 outlet port 8 outlet 9 drain port 10 inlet port 11 bypass port 12 biased armliquid block 13, first, second ends 14 exit side coalescing element 15 passage 16 spring 17 clearance 19 outer surface of insert 4 20 threads 21 seat 22, vortex, upward 23 seal 24 fluid flow 25 retention plate 26 build up 27, extension, receiver 29 body 30, 30 first second ends of housing 33 base 34 housing 35, cylindrical inner walls 41 connection

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