CA2259282A1 - System for monitoring diaphragm pump failure - Google Patents
System for monitoring diaphragm pump failure Download PDFInfo
- Publication number
- CA2259282A1 CA2259282A1 CA002259282A CA2259282A CA2259282A1 CA 2259282 A1 CA2259282 A1 CA 2259282A1 CA 002259282 A CA002259282 A CA 002259282A CA 2259282 A CA2259282 A CA 2259282A CA 2259282 A1 CA2259282 A1 CA 2259282A1
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- CA
- Canada
- Prior art keywords
- optic
- signal
- working fluid
- diaphragm
- pump
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B43/00—Machines, pumps, or pumping installations having flexible working members
- F04B43/0009—Special features
- F04B43/0081—Special features systems, control, safety measures
- F04B43/009—Special features systems, control, safety measures leakage control; pump systems with two flexible members; between the actuating element and the pumped fluid
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B2201/00—Pump parameters
- F04B2201/02—Piston parameters
- F04B2201/0208—Leakage across the piston
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B2205/00—Fluid parameters
- F04B2205/50—Presence of foreign matter in the fluid
Abstract
A diaphragm failure monitoring system for detecting leakage in a diaphragm of a diaphragm pump. The system includes a pump (10) having an operating chamber (16) containing a working fluid (30) and a pumping chamber (14) for pumping material into and out of the pump and a diaphragm (18) separating the operating and pumping chambers. A first optic fiber (52) is joined to the operating chamber for transmitting an optic signal across the working fluid. A
second optic fiber (60) is joined to the operating chamber for receiving the optic signal from the first optic fiber. An electric signal establishing device (56) establishes a fist electrical signal when the optic signal from the first optic fiber to the second optic fiber passes through uncontaminated working fluid. The electrical signal establishing device establishes a second electrical signal when the optic signal from the first optic fiber to the second optic fiber passes through contaminated working fluid, whereby leakage of a contaminating material through the diaphragm into the operating chamber can be detected when the second electrical signal is established.
second optic fiber (60) is joined to the operating chamber for receiving the optic signal from the first optic fiber. An electric signal establishing device (56) establishes a fist electrical signal when the optic signal from the first optic fiber to the second optic fiber passes through uncontaminated working fluid. The electrical signal establishing device establishes a second electrical signal when the optic signal from the first optic fiber to the second optic fiber passes through contaminated working fluid, whereby leakage of a contaminating material through the diaphragm into the operating chamber can be detected when the second electrical signal is established.
Description
wO 98~00640 PcrluS97111489 SYSTEM FOR MONITORING DIAPHRAGM PUMP ~AILURE
This application claims the benefit of U.S. Provisional Application No.
601020,838 filed on June 28, 1996.
BACKGROUND OF THE INVENTION
This invention relates to a ~ phr~m pump for pumping slurry, and more particularly to a monitoring system for det~ ining when the diaphragm of the pump has begun to fail.
Slurry pumps are often used with gasifiers to pump slurries of coal. coke and/or carbon into the gasifier for conversion to carbon monoxide and hydrogen. A well known slurry pump includes a flexible diaphragm that is usually formed of rubber or some other, durable, flexible material. The diaphragm is deflected or pulsed by oil that is pressurized and depressurized in accordance with movement of a piston or plunger in the pump. Generally, a glycol-based oil is used as a working fluid for actuation of the diaphragm. The diaphragm shields the oil and the pump mech~ni~m from a pump chamber or transfer chamber wherein slurry passes into and out of the purnp.
Thus, when a slurry pump operates properly, the slurry is drawn into the pump chamber and pumped out of the pump chamber without encountering the ~ctll~ting mech~nj~m or working fluid of the pump. The pump diaphragm. due to the abrasive nature of the slurry as it moves in and out of the pump chamber, is subject to wear. Ultimately. the wearing action of the slurry on the diaphragm will cause the diaphragm to rupture, resulting in pump failure because of commingling of the slurry with the pump mech~ m and the working fluid of the pump. Although gradual deterioration of the pump diaphragm is expected due to the wear imposed by the slurry movement. sudden rupture of the diaphragm can occur at unpredictable times.
A typical slurry pump often includes a visual port that is usually monitored periodically by an ~ner~nt to detect visible cont~min~tion of the oil in the pump which can indicate impending rupture of the pump diaphragm. However, visual monitoring is not a reliable means of det~ctin~ impending rupture of the pump diaphragm because slight leaks in a diaphragm at the earliest stages of diaphragm failure are ~enerally not visually perceptible.
Once a slu~ry pump is rendered inoperable due to diaphragm rupture, the gasifier operation must be shut down while the slurry pump is either repaired or replaced.
.. .... ~
W O 98~K40 PCTrUS97tll489 Any shutdown of a gasifier operation is burdensome and expensive since gasifier shutdown and start-up operations, as well as pump repair and replacement operations, are time con.C~ming and expensive, and require immediate availability of skilled persormel.
Although rough forecasts can be made, based on statistical data, of when a 5 diaphragm will rupture? there are no presently known means f'or precisely predicting the earliest stages of diaphragm breakdown before severe damage occurs to the purnp mech~ni~n. Consequently. skilled personnel are often required to monitor and maintain purnp operations.
It is therefore desirable to provide a reliable method and means for detecting 10 the earliest stages of diaphragm failurc in a slurry pump so that the pump can be shut down for repairs before the diaphragm failure causes sev~re damage to the pump mechanism.
OBJECTS AND SUMMARY OF THE INVENTION
One of several objects of the invention is the provision of a novel method and 15 means of accurately detecting any deterioration in a diaphragm of a diaphragm pump that results in a slight leakage of the diaphragm. Another object of the invention is the provision of a novel mcthod and means for detectin~ an impending rupture of a diaphragm in a diaphragm pump before the rupture causes dama~e to the pumping mechanism. Another object of the invention is the provision of a novel method and means of detecting impending 20 rupturc of a diaphragm in a diaphragm pump without the need for personnel to monitor the diaphragm pump. Another object of the invention is the provision of a novel mcthod and means which employs optic signals for detectin~ deterioration or impending rupture of a diaphragm in a diaphragm purnp.
In accordance with the present invention. a diaphra~m failure monitoring 25 system is provided for automatically detectin~ leakage in a diaphra~m of a diaphragm pump The diaphragm pump includes a pumping chamber with a slurrv inlet port and a slurry outle port. The diaphragm pump also includes an operating chambcr containing a working fluid.
The diaphragm separates the pumping chamber from the operating chamber and isolates the slurry from the working fluid. A reciprocating piston pulsates the working fluid against the 30 diaphragm to deflect the diaphra~m and thereby pump the slurry into and out of the pumping charnber.
.. . .
W O 98/00640 PCTnUS97J11489 The monitoring system cooperates with the operating chamber which contains the worlcing fluid of the diaphragm pump. The monitoring system includes a first optic fiber located at the operating charnber for transmitting an optic signal across the working fluid to an oppositely disposed, second optic fiber- The monitoring system generates a first electrical 5 signal when the optic signal passes through uncont~n in~ted working fluid. and an electrical signal different from the first electrical signal when the optic signal passes through cont~min~ted working fluid. Thus, cont~min~tion of the working fluid as a first sign of diaphra~m failure can be detected when a signal other than the first electrical signal is detected by the monitoring system.
In one embodiment ofthe invention. thc monitoring system includcs a hollou~
optical cell secured to the pump at the operatin~ chamber to receive a portion of the working fluid. The first and second optic fibers are cormected to the optical cell to transmit and receive optical signals across the working fluid in the optical cell.
The invention also provides a method of detecting leakagc in a diaphragm of a 15 diaphragm pump in which the pump has an operatin~ chamber for receiving a working fluid.
The method includes transmitting an optic signal across the workin~ fluid to a signal receiver for conversion to an electrical signal. The method funher includes establishing a first electrical signal to function as a base measure when the received optic si~nal passcs through uncontaminated working fluid. and establishin~ a second electrical sienal different from the 20 first electrical signal when the received optic si~nal passes through cont~minated working fluid. ln accordance with the foregoing method when thc second electrical signal is established contamination of the working fluid due to diaphra~m failure can be detected.
The invention therefore solves the problem of detecting slight deterioration leakage and impending rupture of a pump diaphra~n . The invention achieves the foregoing 25 objects by using an optical monitoring system which relies upon changes in the absorption of light by the working fluid in the pump due to fluid contamination to indicate deterioration or impending failure of the diaphragm before thc di~phragm failure causes severe damage to thc pump mechanism.
W O 98/~C~I- PCTrUS97/11489 DESCRIPTION OF THE DRAWINGS
In the drawings, Fig. I is a simplified sç~-~m~tic sectional view of a system for monitoring diaphragm failure of a slurry pump. incorporating one embodiment of the invention;
Fig. 2 is an enlarged view of an optical cell thereof and its associated cle~llollic components: and, Fig. 3 is a perspective view of the optical cell thereof.
Corresponding reference characters indicate corresponding parts throu~hout the several views of the drawings.
DETAILED DESCRIPTION
Referring to Fig. I of the drawings. a slurry pump is L~enerally indicated by the reference number 10.
The slurry pump 10 includes a housing 12 with a pumping charnber l 4 and an operating charnber 16 and a flexible diaphra~m 18 that separatcs the pumpin~ chamber 14 from the operating chamber 16. The pumpin~ chambcr 14 receivcs an incoming flow 24 of a slurry 20 through a pump inlet 22 and provides an out~oing flow 26 of the slurry 20 throu~h a pUJSlp outlet 28 into a known partial oxidation reactor (not shown) such as the type disclosed in U.S. Patent No. 5,54~.238. The slurr~J 20 can be a slurry of'coal, coke. and/or carbon. The operatin~ chambcr 16 has a confined. fixed amount of a working fluid 30. such as any suitable, known oil.
A piston 32 reciprocates back and forth to pulsatc the workin~ fluid 30 in the operating charnber 16 against the flexible diaphragm 18 which is preferably forrned of a suitable known flexible. durable material such as rubber.
An optical cell 34 is joined to the pump 10 at the operating chamber 16 and includes a hollow, cylindrical cell housin~ 38. 1 he cell housin~ 38 includes a securement end 40 with a neck 41 having an O-ring 42 and a clamping flange 44. The neck 41 with thc O-rin~
42 fits into an opening 46 (Fig 2) in thc pump housing 12 at the operating chamber 16 in leak-ti~h~ fashion. The clampin flange 44 is fastened to the housin~, 12 in ~ny suitable manner, such as with bolts (not shown) that extend through bolt openings 47 (Fig 3) in the flange 44 Under this arran~ement. a portion of the working fluid 30 in the operating ... . .
W 098/OU640 PCTnUS97111489 charnber 16 can distribute into the hollow portion 4X of the optical cell 34 through the opening 49 of the neck 41. An opposite end 50 of the cell housing 38 includes a suitable.
known sight plug 51.
Referring to Figs. 1 and 2, a first fiber optic cable 52 of suitable. known construction has one end referred to as an emitter end 53 connected in leak-tight fashion to one side of the cell housing 38 by a known connection plu~ 54. The emitter end 53 thus communicates with the hollow space 48 in the cell housin~ 38. An opposite end 55 of the fiber optic cable S~ is connected to an optical arnplifier 56 at a first junction 57. The optical amplifier 56 is of the type made by Tri-Tronics Co. lnc. of Tampa, Florida under the product 10 designation Model No. SALG.
A second fiber optic cable 60 similar to the first fiber optic cable 52 has one end referred to as a collector end 64 connect-od in leak-tight fashion to an opposite side of the cell housing 38 by a connection piug 61. An opposite end 62 of the fiber optic cable 60 is connected to the optical arnplifier 56 at a second junction 63. An approximate distance 15 between the emitter end 53 and the collector end 64 is 3 to 5 inches.
The optical amplifier 56 is a constituent of a detection circuit 66 that includes a known powcr supply 70 of the type sold by Astec Corporation under the designation ACB24N 1.2~ and an isolation signal conditioner 80 of the t~pe sold by Action Instruments under the desi~nation Transpak Model 2703-2000.
The optical a nplifier 56, the power suppl! 70. and the isolation signal conditioner 80 communicate with each other via the lines I 10. 1 12, 1 14. The detection circuit 66 communicates in a known manner with a known distributive control system 120 of the type sold by Honeywell Inc. under the product designation ATM.
During operation of the purnp 10~ the piston 32 reciprocates back and forth at ,~
~5 ~ c.~.lined rate. The reciprocating action of the piston 32 on the working fluid 30 forces the diaphragm 18 to deflect back and forth against the slurr!~ 20 in the pumping chamber 14 as indicated by the arrows A and B in Fig. 1. Deflection of the diaphragm 18 pumps the slurry 20 through the pumping chamber 14 into a gasifier (not shown) in a conventional manncr. During the purnping operation. an optic signal in the form of li ht is generated through the first fibcr optic cable 52 by the optical amplifier 56. The optic si~nal is emitted at the emitter end 53 and W O 98100640 PCTrUS97/1148g passes through the working fluid 30 in the optical cell 34 to the collector end 64 of the second fiber optic cable 60.
The light signal is ~,cr.,,~bly a high intensity, green light which is produced by the optical amplifier 56 and passes from the first fiber optic cable 52 through the second fiber optic cable 60 back to the optical amplifier 56 The optical amplifier 56 converts the light energy to a voltage, such as, for exarnple, a one to ten volt signal. The voltage signal can be adjusted on an analog output by the gain andJor offset of the optical amplifier 56. The voltage signal can vary in accordance with the intensity of the light. For example, a one volt signal can represent a dark intensity of light and a ten volt signal can represent a light intensity of li~ht. The amplifier 56 can be set in a known manner to anv analogous value to cp..sellt a norrnal light tr~n.~miccion, such as nine volts.
If the working fluid 30 within the operating chamber 16 becomes cont~min~ted by some portion of the sluTry 20 leaking through pin holes or through any relatively small opening in the diaphragm 18, the working fluid 30 will undergo a change in color resulting in a general darkening of the fluid 3(). When the fluid 30 darkens, the intensity of the light signal passing from the emitter end 53 to the collector end 64 decreases.
The voltage signal from the amplifier 56 in response to the li~ht signal will then decrease to indicate a darkening of the working fluid 30 as a result of entry of the slurry 20 into the c,pelaling chamber 16 due to slight leaka~e at the early deterioration or early rupture stages of the diaphragm 18, The electrical information that is analogous to the condition of thc working fluid 30 in the optical cell 34 is converted to a desirable, measurable pararneter, such as milli-amperes, and fed to the distributive control system 120 through the isolation signal conditioner 80.
Thus, when the diaphragm 18 does not leak, the working fluid 30 will be clear and the light signal received by the second optic cable 60 will be relatively strong based on the known clarity of uncontaminated workin~ fluid 30 and because of minim~l absorption of the light signal by the clear working fluid 30. A corresponding voltage signal will be generated by the optical amplifier 56 to represent the uncons~min~ted working fluid 30.
When the diaphragm 18 begins to fail due to the development of a leakage condition in the diaphragm 18 because of pin holes, cracks or any other manifestation of early breakdown of the diaphragm 18, the working fluid 30 will be less clear or cont~min~t~d .. . ..
WO 98/00640 PCl'lUSg7111489 because a portion of the slurry 20 will have leaked through the diaphragm 18 into the working fluid 30. In such a case, a weaker light signal will be received by the second fiber optic cable 60 from the first fiber optic cable 52 for tr~n~mi~sion to the optical arnplifier 56. The light signal is weaker because the darker, cont~n in~ted working fluid 30 will absorb more of the 5 light signal transmitted by the first optic cable 52. A correspondingly weaker voltage signal will be generated by the optical amplifier 56 to l~resent cont~min~ted wor~ing fluid 30.
From the foregoing description~ it can be seen that low levels of cont~min~tion of the working fluid 30 can be detected to indicate the earliest stages of deterioration that result in diaphragm leakage which leakage signals an impending rupture of the diaphragm I X.
10 Once the cont~min~tion of the working fluid 30 is detected before severe pump darnage occurs, remedial measures can be taken which do not require a complete shutdown of the purnp 10 and the associated gasifier. Moreover, the slurry pump 10 can be repaired by simply replacing the diaphragrn 18 without the need to overhaul the working mech~ni~m of the pump 10. Thus, early detection of a leak in the diaphragm 18 in accordance with the instant 15 invention results in substantial cost savings and mininl~l interruption to a gasifier operating system.
Although the present invention has been described in terms of a single, preferred embodiment. it is anticipated that various modifications and alterations thereof will be appalent to those skilled in the art.
.
This application claims the benefit of U.S. Provisional Application No.
601020,838 filed on June 28, 1996.
BACKGROUND OF THE INVENTION
This invention relates to a ~ phr~m pump for pumping slurry, and more particularly to a monitoring system for det~ ining when the diaphragm of the pump has begun to fail.
Slurry pumps are often used with gasifiers to pump slurries of coal. coke and/or carbon into the gasifier for conversion to carbon monoxide and hydrogen. A well known slurry pump includes a flexible diaphragm that is usually formed of rubber or some other, durable, flexible material. The diaphragm is deflected or pulsed by oil that is pressurized and depressurized in accordance with movement of a piston or plunger in the pump. Generally, a glycol-based oil is used as a working fluid for actuation of the diaphragm. The diaphragm shields the oil and the pump mech~ni~m from a pump chamber or transfer chamber wherein slurry passes into and out of the purnp.
Thus, when a slurry pump operates properly, the slurry is drawn into the pump chamber and pumped out of the pump chamber without encountering the ~ctll~ting mech~nj~m or working fluid of the pump. The pump diaphragm. due to the abrasive nature of the slurry as it moves in and out of the pump chamber, is subject to wear. Ultimately. the wearing action of the slurry on the diaphragm will cause the diaphragm to rupture, resulting in pump failure because of commingling of the slurry with the pump mech~ m and the working fluid of the pump. Although gradual deterioration of the pump diaphragm is expected due to the wear imposed by the slurry movement. sudden rupture of the diaphragm can occur at unpredictable times.
A typical slurry pump often includes a visual port that is usually monitored periodically by an ~ner~nt to detect visible cont~min~tion of the oil in the pump which can indicate impending rupture of the pump diaphragm. However, visual monitoring is not a reliable means of det~ctin~ impending rupture of the pump diaphragm because slight leaks in a diaphragm at the earliest stages of diaphragm failure are ~enerally not visually perceptible.
Once a slu~ry pump is rendered inoperable due to diaphragm rupture, the gasifier operation must be shut down while the slurry pump is either repaired or replaced.
.. .... ~
W O 98~K40 PCTrUS97tll489 Any shutdown of a gasifier operation is burdensome and expensive since gasifier shutdown and start-up operations, as well as pump repair and replacement operations, are time con.C~ming and expensive, and require immediate availability of skilled persormel.
Although rough forecasts can be made, based on statistical data, of when a 5 diaphragm will rupture? there are no presently known means f'or precisely predicting the earliest stages of diaphragm breakdown before severe damage occurs to the purnp mech~ni~n. Consequently. skilled personnel are often required to monitor and maintain purnp operations.
It is therefore desirable to provide a reliable method and means for detecting 10 the earliest stages of diaphragm failurc in a slurry pump so that the pump can be shut down for repairs before the diaphragm failure causes sev~re damage to the pump mechanism.
OBJECTS AND SUMMARY OF THE INVENTION
One of several objects of the invention is the provision of a novel method and 15 means of accurately detecting any deterioration in a diaphragm of a diaphragm pump that results in a slight leakage of the diaphragm. Another object of the invention is the provision of a novel mcthod and means for detectin~ an impending rupture of a diaphragm in a diaphragm pump before the rupture causes dama~e to the pumping mechanism. Another object of the invention is the provision of a novel method and means of detecting impending 20 rupturc of a diaphragm in a diaphragm pump without the need for personnel to monitor the diaphragm pump. Another object of the invention is the provision of a novel mcthod and means which employs optic signals for detectin~ deterioration or impending rupture of a diaphragm in a diaphragm purnp.
In accordance with the present invention. a diaphra~m failure monitoring 25 system is provided for automatically detectin~ leakage in a diaphra~m of a diaphragm pump The diaphragm pump includes a pumping chamber with a slurrv inlet port and a slurry outle port. The diaphragm pump also includes an operating chambcr containing a working fluid.
The diaphragm separates the pumping chamber from the operating chamber and isolates the slurry from the working fluid. A reciprocating piston pulsates the working fluid against the 30 diaphragm to deflect the diaphra~m and thereby pump the slurry into and out of the pumping charnber.
.. . .
W O 98/00640 PCTnUS97J11489 The monitoring system cooperates with the operating chamber which contains the worlcing fluid of the diaphragm pump. The monitoring system includes a first optic fiber located at the operating charnber for transmitting an optic signal across the working fluid to an oppositely disposed, second optic fiber- The monitoring system generates a first electrical 5 signal when the optic signal passes through uncont~n in~ted working fluid. and an electrical signal different from the first electrical signal when the optic signal passes through cont~min~ted working fluid. Thus, cont~min~tion of the working fluid as a first sign of diaphra~m failure can be detected when a signal other than the first electrical signal is detected by the monitoring system.
In one embodiment ofthe invention. thc monitoring system includcs a hollou~
optical cell secured to the pump at the operatin~ chamber to receive a portion of the working fluid. The first and second optic fibers are cormected to the optical cell to transmit and receive optical signals across the working fluid in the optical cell.
The invention also provides a method of detecting leakagc in a diaphragm of a 15 diaphragm pump in which the pump has an operatin~ chamber for receiving a working fluid.
The method includes transmitting an optic signal across the workin~ fluid to a signal receiver for conversion to an electrical signal. The method funher includes establishing a first electrical signal to function as a base measure when the received optic si~nal passcs through uncontaminated working fluid. and establishin~ a second electrical sienal different from the 20 first electrical signal when the received optic si~nal passes through cont~minated working fluid. ln accordance with the foregoing method when thc second electrical signal is established contamination of the working fluid due to diaphra~m failure can be detected.
The invention therefore solves the problem of detecting slight deterioration leakage and impending rupture of a pump diaphra~n . The invention achieves the foregoing 25 objects by using an optical monitoring system which relies upon changes in the absorption of light by the working fluid in the pump due to fluid contamination to indicate deterioration or impending failure of the diaphragm before thc di~phragm failure causes severe damage to thc pump mechanism.
W O 98/~C~I- PCTrUS97/11489 DESCRIPTION OF THE DRAWINGS
In the drawings, Fig. I is a simplified sç~-~m~tic sectional view of a system for monitoring diaphragm failure of a slurry pump. incorporating one embodiment of the invention;
Fig. 2 is an enlarged view of an optical cell thereof and its associated cle~llollic components: and, Fig. 3 is a perspective view of the optical cell thereof.
Corresponding reference characters indicate corresponding parts throu~hout the several views of the drawings.
DETAILED DESCRIPTION
Referring to Fig. I of the drawings. a slurry pump is L~enerally indicated by the reference number 10.
The slurry pump 10 includes a housing 12 with a pumping charnber l 4 and an operating charnber 16 and a flexible diaphra~m 18 that separatcs the pumpin~ chamber 14 from the operating chamber 16. The pumpin~ chambcr 14 receivcs an incoming flow 24 of a slurry 20 through a pump inlet 22 and provides an out~oing flow 26 of the slurry 20 throu~h a pUJSlp outlet 28 into a known partial oxidation reactor (not shown) such as the type disclosed in U.S. Patent No. 5,54~.238. The slurr~J 20 can be a slurry of'coal, coke. and/or carbon. The operatin~ chambcr 16 has a confined. fixed amount of a working fluid 30. such as any suitable, known oil.
A piston 32 reciprocates back and forth to pulsatc the workin~ fluid 30 in the operating charnber 16 against the flexible diaphragm 18 which is preferably forrned of a suitable known flexible. durable material such as rubber.
An optical cell 34 is joined to the pump 10 at the operating chamber 16 and includes a hollow, cylindrical cell housin~ 38. 1 he cell housin~ 38 includes a securement end 40 with a neck 41 having an O-ring 42 and a clamping flange 44. The neck 41 with thc O-rin~
42 fits into an opening 46 (Fig 2) in thc pump housing 12 at the operating chamber 16 in leak-ti~h~ fashion. The clampin flange 44 is fastened to the housin~, 12 in ~ny suitable manner, such as with bolts (not shown) that extend through bolt openings 47 (Fig 3) in the flange 44 Under this arran~ement. a portion of the working fluid 30 in the operating ... . .
W 098/OU640 PCTnUS97111489 charnber 16 can distribute into the hollow portion 4X of the optical cell 34 through the opening 49 of the neck 41. An opposite end 50 of the cell housing 38 includes a suitable.
known sight plug 51.
Referring to Figs. 1 and 2, a first fiber optic cable 52 of suitable. known construction has one end referred to as an emitter end 53 connected in leak-tight fashion to one side of the cell housing 38 by a known connection plu~ 54. The emitter end 53 thus communicates with the hollow space 48 in the cell housin~ 38. An opposite end 55 of the fiber optic cable S~ is connected to an optical arnplifier 56 at a first junction 57. The optical amplifier 56 is of the type made by Tri-Tronics Co. lnc. of Tampa, Florida under the product 10 designation Model No. SALG.
A second fiber optic cable 60 similar to the first fiber optic cable 52 has one end referred to as a collector end 64 connect-od in leak-tight fashion to an opposite side of the cell housing 38 by a connection piug 61. An opposite end 62 of the fiber optic cable 60 is connected to the optical arnplifier 56 at a second junction 63. An approximate distance 15 between the emitter end 53 and the collector end 64 is 3 to 5 inches.
The optical amplifier 56 is a constituent of a detection circuit 66 that includes a known powcr supply 70 of the type sold by Astec Corporation under the designation ACB24N 1.2~ and an isolation signal conditioner 80 of the t~pe sold by Action Instruments under the desi~nation Transpak Model 2703-2000.
The optical a nplifier 56, the power suppl! 70. and the isolation signal conditioner 80 communicate with each other via the lines I 10. 1 12, 1 14. The detection circuit 66 communicates in a known manner with a known distributive control system 120 of the type sold by Honeywell Inc. under the product designation ATM.
During operation of the purnp 10~ the piston 32 reciprocates back and forth at ,~
~5 ~ c.~.lined rate. The reciprocating action of the piston 32 on the working fluid 30 forces the diaphragm 18 to deflect back and forth against the slurr!~ 20 in the pumping chamber 14 as indicated by the arrows A and B in Fig. 1. Deflection of the diaphragm 18 pumps the slurry 20 through the pumping chamber 14 into a gasifier (not shown) in a conventional manncr. During the purnping operation. an optic signal in the form of li ht is generated through the first fibcr optic cable 52 by the optical amplifier 56. The optic si~nal is emitted at the emitter end 53 and W O 98100640 PCTrUS97/1148g passes through the working fluid 30 in the optical cell 34 to the collector end 64 of the second fiber optic cable 60.
The light signal is ~,cr.,,~bly a high intensity, green light which is produced by the optical amplifier 56 and passes from the first fiber optic cable 52 through the second fiber optic cable 60 back to the optical amplifier 56 The optical amplifier 56 converts the light energy to a voltage, such as, for exarnple, a one to ten volt signal. The voltage signal can be adjusted on an analog output by the gain andJor offset of the optical amplifier 56. The voltage signal can vary in accordance with the intensity of the light. For example, a one volt signal can represent a dark intensity of light and a ten volt signal can represent a light intensity of li~ht. The amplifier 56 can be set in a known manner to anv analogous value to cp..sellt a norrnal light tr~n.~miccion, such as nine volts.
If the working fluid 30 within the operating chamber 16 becomes cont~min~ted by some portion of the sluTry 20 leaking through pin holes or through any relatively small opening in the diaphragm 18, the working fluid 30 will undergo a change in color resulting in a general darkening of the fluid 3(). When the fluid 30 darkens, the intensity of the light signal passing from the emitter end 53 to the collector end 64 decreases.
The voltage signal from the amplifier 56 in response to the li~ht signal will then decrease to indicate a darkening of the working fluid 30 as a result of entry of the slurry 20 into the c,pelaling chamber 16 due to slight leaka~e at the early deterioration or early rupture stages of the diaphragm 18, The electrical information that is analogous to the condition of thc working fluid 30 in the optical cell 34 is converted to a desirable, measurable pararneter, such as milli-amperes, and fed to the distributive control system 120 through the isolation signal conditioner 80.
Thus, when the diaphragm 18 does not leak, the working fluid 30 will be clear and the light signal received by the second optic cable 60 will be relatively strong based on the known clarity of uncontaminated workin~ fluid 30 and because of minim~l absorption of the light signal by the clear working fluid 30. A corresponding voltage signal will be generated by the optical amplifier 56 to represent the uncons~min~ted working fluid 30.
When the diaphragm 18 begins to fail due to the development of a leakage condition in the diaphragm 18 because of pin holes, cracks or any other manifestation of early breakdown of the diaphragm 18, the working fluid 30 will be less clear or cont~min~t~d .. . ..
WO 98/00640 PCl'lUSg7111489 because a portion of the slurry 20 will have leaked through the diaphragm 18 into the working fluid 30. In such a case, a weaker light signal will be received by the second fiber optic cable 60 from the first fiber optic cable 52 for tr~n~mi~sion to the optical arnplifier 56. The light signal is weaker because the darker, cont~n in~ted working fluid 30 will absorb more of the 5 light signal transmitted by the first optic cable 52. A correspondingly weaker voltage signal will be generated by the optical amplifier 56 to l~resent cont~min~ted wor~ing fluid 30.
From the foregoing description~ it can be seen that low levels of cont~min~tion of the working fluid 30 can be detected to indicate the earliest stages of deterioration that result in diaphragm leakage which leakage signals an impending rupture of the diaphragm I X.
10 Once the cont~min~tion of the working fluid 30 is detected before severe pump darnage occurs, remedial measures can be taken which do not require a complete shutdown of the purnp 10 and the associated gasifier. Moreover, the slurry pump 10 can be repaired by simply replacing the diaphragrn 18 without the need to overhaul the working mech~ni~m of the pump 10. Thus, early detection of a leak in the diaphragm 18 in accordance with the instant 15 invention results in substantial cost savings and mininl~l interruption to a gasifier operating system.
Although the present invention has been described in terms of a single, preferred embodiment. it is anticipated that various modifications and alterations thereof will be appalent to those skilled in the art.
.
Claims (16)
1. A diaphragm failure monitoring system and apparatus, for detecting leakage in a diaphragm of a diaphragm pump, comprising:
a) a pump having an operating chamber containing a working fluid and a pumping chamber for pumping material into and out of the pump and a diaphragm separating the operating chamber and the pumping chamber;
b) a first optic fiber joined to said operating chamber for transmitting an optic signal across said working fluid;
c) a second optic fiber joined to said operating chamber, in spaced arrangement from said first optic fiber, and without being connected to said first optic fiber at said operating chamber, for receiving said optic signal from said first optic fiber;
d) means for establishing a first electrical signal, corresponding to a minimum optic signal level of light attenuation, when the optic signal from said first optic fiber to said second optic fiber passes through the working fluid in an uncontaminated state; and e) means for establishing a second electrical signal different from the first electrical signal, and corresponding to a higher optic signal level of light attenuation than the minimum optic signal level of light attenuation, when the optic signal from said first optic fiber to said second optic fiber passes through working fluid in a contaminated state, whereby leakage of a contaminating material, that is part of the material being pumped, into said working fluid through said diaphragm into said operating chamber can be detected when said second electrical signal is established.
a) a pump having an operating chamber containing a working fluid and a pumping chamber for pumping material into and out of the pump and a diaphragm separating the operating chamber and the pumping chamber;
b) a first optic fiber joined to said operating chamber for transmitting an optic signal across said working fluid;
c) a second optic fiber joined to said operating chamber, in spaced arrangement from said first optic fiber, and without being connected to said first optic fiber at said operating chamber, for receiving said optic signal from said first optic fiber;
d) means for establishing a first electrical signal, corresponding to a minimum optic signal level of light attenuation, when the optic signal from said first optic fiber to said second optic fiber passes through the working fluid in an uncontaminated state; and e) means for establishing a second electrical signal different from the first electrical signal, and corresponding to a higher optic signal level of light attenuation than the minimum optic signal level of light attenuation, when the optic signal from said first optic fiber to said second optic fiber passes through working fluid in a contaminated state, whereby leakage of a contaminating material, that is part of the material being pumped, into said working fluid through said diaphragm into said operating chamber can be detected when said second electrical signal is established.
2. The apparatus of claim 1, wherein said diaphragm comprises rubber.
3. The apparatus of claim 1, wherein said working fluid comprises oil.
4. The apparatus of claim 1, additionally comprising a hollow, optical cell secured to said operating chamber for receiving a portion of the working fluid, wherein said cell includes first means for connecting with said first optic fiber and second means for connecting with said second optic fiber.
5. The apparatus of claim 4, wherein said first and second connecting means arelocated at opposite sides of said optical cell.
6. The apparatus of claim 5, wherein said first optic fiber includes an emitter end connected to said first connecting means and said second optic fiber includes a collector end connected to said second connecting means, and wherein said means for establishing said first electrical signal and said means for establishing said second electrical signal comprise an optical amplifier connected to the other ends of said first and second optic fibers.
7. The apparatus of claim 6, wherein said optic signal comprises a high intensity, green light.
8. The apparatus of claim 7, additionally comprising an isolation signal conditioner connected to said optical amplifier, and a distributive control system connected to said isolation signal conditioner, wherein said electrical signals are fed from said amplifier to said distributive control system through said isolation signal conditioner.
9. The apparatus of claim 8, additionally comprising a power supply communicating with said optical amplifier and said isolation signal conditioner.
10. The apparatus of claim 9, wherein said first and second connecting means each comprises a plug.
11. A method of detecting leakage in a diaphragm of a diaphragm pump, said pumphaving an operating chamber containing a working fluid and a pumping chamber for pumping material into and out of the pump and a diaphragm separating the operating chamber and the pumping chamber, comprising:
a) transmitting an optic signal through said working fluid from one optic fiber to a second optic fiber that receives the transmitted optic signal;
b) maintaining the first and second optic fibers spaced and unconnected to each other at the working fluid;
c) establishing a first electrical signal corresponding to a minimum optic signal level of light attenuation when the received optic signal passes through the working fluid in an uncontaminated state; and d) establishing a second electrical signal corresponding to a higher signal level of light attenuation than the minimum optic signal level of light attenuation when the received optic signal passes through the working fluid in a contaminated state, whereby leakage of a contaminating material, that is part of the material being pumped, through said diaphragm into said operating chamber can be detected when said second electrical signal is established.
a) transmitting an optic signal through said working fluid from one optic fiber to a second optic fiber that receives the transmitted optic signal;
b) maintaining the first and second optic fibers spaced and unconnected to each other at the working fluid;
c) establishing a first electrical signal corresponding to a minimum optic signal level of light attenuation when the received optic signal passes through the working fluid in an uncontaminated state; and d) establishing a second electrical signal corresponding to a higher signal level of light attenuation than the minimum optic signal level of light attenuation when the received optic signal passes through the working fluid in a contaminated state, whereby leakage of a contaminating material, that is part of the material being pumped, through said diaphragm into said operating chamber can be detected when said second electrical signal is established.
12. Canceled
13. The method of claim 11, wherein a hollow, optical cell is connected to said first and second optic fibers for receiving a portion of said working fluid, and said optic signal is transmitted across said optical cell.
14. The method of claim 13, wherein said first and second electrical signals areestablished by an optical amplifier connected to said first and second optic fibers.
15. The method of claim 14, wherein said optic signal comprises a high intensity, green light.
16. The method of claim 15, wherein said working fluid comprises oil.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US2083896P | 1996-06-28 | 1996-06-28 | |
| US08/869,644 | 1997-06-05 | ||
| US08/869,644 US5883299A (en) | 1996-06-28 | 1997-06-05 | System for monitoring diaphragm pump failure |
| US60/020,838 | 1997-06-05 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2259282A1 true CA2259282A1 (en) | 1998-01-08 |
Family
ID=26693936
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002259282A Abandoned CA2259282A1 (en) | 1996-06-28 | 1997-06-26 | System for monitoring diaphragm pump failure |
Country Status (7)
| Country | Link |
|---|---|
| US (2) | US5883299A (en) |
| EP (1) | EP0907828A1 (en) |
| JP (1) | JP3223511B2 (en) |
| CN (1) | CN1114040C (en) |
| AU (1) | AU702633B2 (en) |
| CA (1) | CA2259282A1 (en) |
| WO (1) | WO1998000640A1 (en) |
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| US5883299A (en) * | 1996-06-28 | 1999-03-16 | Texaco Inc | System for monitoring diaphragm pump failure |
| US6041801A (en) * | 1998-07-01 | 2000-03-28 | Deka Products Limited Partnership | System and method for measuring when fluid has stopped flowing within a line |
| US6190136B1 (en) * | 1999-08-30 | 2001-02-20 | Ingersoll-Rand Company | Diaphragm failure sensing apparatus and diaphragm pumps incorporating same |
| US6361281B1 (en) * | 2000-08-22 | 2002-03-26 | Delphi Technologies, Inc. | Electrically driven compressor with contactless control |
| US7662139B2 (en) * | 2003-10-30 | 2010-02-16 | Deka Products Limited Partnership | Pump cassette with spiking assembly |
| US8158102B2 (en) * | 2003-10-30 | 2012-04-17 | Deka Products Limited Partnership | System, device, and method for mixing a substance with a liquid |
| US7632080B2 (en) * | 2003-10-30 | 2009-12-15 | Deka Products Limited Partnership | Bezel assembly for pneumatic control |
| US6941853B2 (en) * | 2003-12-02 | 2005-09-13 | Wanner Engineering, Inc. | Pump diaphragm rupture detection |
| US20080260551A1 (en) * | 2007-01-26 | 2008-10-23 | Walter Neal Simmons | Rolling diaphragm pump |
| US8654338B2 (en) * | 2011-07-11 | 2014-02-18 | Abb Technology Ag | Optics sensor structure for detecting water or oil leakage inside a conservator having a bladder or membrane |
| EP3640321B1 (en) | 2015-10-09 | 2022-04-06 | DEKA Products Limited Partnership | Method for generating a tissue for transplant |
| US11299705B2 (en) | 2016-11-07 | 2022-04-12 | Deka Products Limited Partnership | System and method for creating tissue |
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1997
- 1997-06-05 US US08/869,644 patent/US5883299A/en not_active Expired - Fee Related
- 1997-06-26 WO PCT/US1997/011489 patent/WO1998000640A1/en not_active Application Discontinuation
- 1997-06-26 CN CN97195930A patent/CN1114040C/en not_active Expired - Fee Related
- 1997-06-26 CA CA002259282A patent/CA2259282A1/en not_active Abandoned
- 1997-06-26 AU AU35893/97A patent/AU702633B2/en not_active Ceased
- 1997-06-26 EP EP97932432A patent/EP0907828A1/en not_active Withdrawn
- 1997-06-26 US US09/214,021 patent/US6247352B1/en not_active Expired - Lifetime
- 1997-06-26 JP JP50442298A patent/JP3223511B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| AU702633B2 (en) | 1999-02-25 |
| CN1224485A (en) | 1999-07-28 |
| EP0907828A1 (en) | 1999-04-14 |
| US6247352B1 (en) | 2001-06-19 |
| CN1114040C (en) | 2003-07-09 |
| WO1998000640A1 (en) | 1998-01-08 |
| AU3589397A (en) | 1998-01-21 |
| JPH11514066A (en) | 1999-11-30 |
| JP3223511B2 (en) | 2001-10-29 |
| EP0907828A4 (en) | 1999-05-06 |
| US5883299A (en) | 1999-03-16 |
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