Title: Apparatus and methods for remote monitoring of flow conduits
Abstract: A system for monitoring at least one parameter of interest relating to a flow conduit having a through passage and a fluid flow therein comprises at least one measurement station coupled to the flow conduit for taking a measurement relating to the parameter of interest. An interrogation device is adapted to move proximate the measurement station and to transmit a first signal to the measurement station, and to receive a second signal from the measurement station relating to the parameter of interest. The measurement station receives power from the first signal.
Patent Number: 6,891,477 Issued on 05/10/2005 to Aronstam
| Inventors:
|
Aronstam; Peter (Houston, TX)
|
| Assignee:
|
Baker Hughes Incorporated (Houston, TX)
|
| Appl. No.:
|
421475 |
| Filed:
|
April 23, 2003 |
| Current U.S. Class: |
340/606; 73/152.18; 340/854.6 |
| Intern'l Class: |
G08B 021/00 |
| Field of Search: |
340/606,854.3,854.6,870.01,870.02,870.16,870.18
73/196,152.18,116,135,190.4,861.05
|
References Cited [Referenced By]
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| 4119948 | Oct., 1978 | Ward et al.
| |
| 5149387 | Sep., 1992 | Moore, Sr.
| |
| 5289722 | Mar., 1994 | Walker et al.
| |
| 5390964 | Feb., 1995 | Gray, Jr.
| |
| 5404948 | Apr., 1995 | Fletcher.
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| 5489126 | Feb., 1996 | Gray, Jr.
| |
| 5505093 | Apr., 1996 | Giedd et al.
| |
| 5553504 | Sep., 1996 | Lyons et al.
| |
| 5720342 | Feb., 1998 | Owens et al.
| |
| 6068394 | May., 2000 | Dublin, Jr.
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| 6377203 | Apr., 2002 | Doany.
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| 6462672 | Oct., 2002 | Besson.
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| 6538576 | Mar., 2003 | Schultz et al.
| |
| 2001/0029989 | Oct., 2001 | Paz.
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| 2002/0043369 | Apr., 2002 | Vinegar et al.
| |
| 2003/0038734 | Feb., 2003 | Hirsch et al.
| |
| 2003/0098799 | May., 2003 | Zimmerman.
| |
| Foreign Patent Documents |
| S55-44929 | Mar., 1980 | JP.
| |
Other References
Cantrell, "Silicon Update: The Dust Flies", http://www.circuitcellar.com/online,
(Mar. 2002), 4 pages.
Horton et al., "MICA: The Commercialization of Microsensor Motes", Sensor Technolongy
and Design, http://www.sensorsmag.com, (Apr. 2002), [retrieved Mar. 20, 2003],
8 pages.
Fitzgerald, "Not Content to Gather Dust in the Lab, Pioneer Brings Moses to Market",
News About MEMS, Nanotechnology and Microsystems, http://www.smalltimes.com, (Feb.
26, 2003), [retrieved Mar. 20, 2003], 3 pages.
|
Primary Examiner: Hofsass; Jeffery
Assistant Examiner: Stone; Jennifer A.
Attorney, Agent or Firm: Madan, Mossman & Sriram, P.C.
Goverment Interests
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to remote monitoring of flow conduits, such as pipelines
and wellbores, and more particularly to a system of self-contained measurement
stations for measuring parameters of interest of the flow conduit and transmitting
the measurements to a mobile interrogation device.
2. Description of the Related Art
Fluid conduits such as pipelines and aqueducts extend for tens, hundreds, or
thousands of kilometers and may be used to transport liquids, gases, slurries or
combinations thereof. Such conduits may have multiple sections that run above or
below ground. Sections may be run underground to avoid natural obstacles such as
rivers or simply as a safety precaution. Other sections may be run above ground
depending on the topography and underlying strata. Sensing stations are commonly
located at major features, such as pumping station that may be separated by tens
or hundreds of kilometers. Sensors are used to determine any of a number of parameters
of interest related to the operation and safety of the conduit and/or related to
the fluid transported therein. However, due to the relatively large separation
of these stations, conditions that may be indicative of potential problems or failures
may go undetected until they become so great as to cause a catastrophic event,
such as for example a substantial leak that may be a serious environmental problem.
It would be highly desirable to be able to determine various parameters relating
to the physical condition of the conduit including, but not limited to, mechanical
strain and stress, crack initiation and propagation, temperature, acceleration
and vibration, seismic events, corrosion, pressure integrity, and flowing fluid
properties, such as chemical species, radiation, and chemical contamination. The
very nature of the length and location of such conduits, however, make the distribution
of power and signal lines to multiple measurement stations substantially impractical
and cost prohibitive.
There is a demonstrated need for a system for providing more measurements along
fluid conduits without the need for additional power and signal lines.
SUMMARY OF THE INVENTION
The present invention contemplates a system for monitoring a flow conduit using
remotely interrogated measurement stations disposed along the conduit.
In one preferred embodiment, a system for monitoring at least one parameter of
interest relating to a flow conduit having a through passage and a fluid flow therein
comprises at least one measurement station coupled to the flow conduit for taking
a measurement relating to the parameter of interest. An interrogation device is
adapted to move proximate the measurement station and to transmit a first signal
to the measurement station, and to receive a second signal from the measurement
station relating to the parameter of interest.
In one aspect, a method for monitoring at least one parameter of interest relating
to a flow conduit having a fluid flow therein, comprises coupling at least one
measurement station to the flow conduit at a predetermined location. The measurement
station is adapted to measure the at least one parameter of interest. An interrogation
device is passed proximate the at least one measurement station. A first signal
is transmitted from the interrogation device to the measurement station, and the
measurement station measures the at least one parameter of interest in response
thereto. A second signal related to the parameter of interest and transmitted by
the measurement station is received at the interrogation device.
In another aspect, a system for determining at least one parameter of interest
relating to a flow conduit having a fluid flowing therein, comprises making the
flow conduit from a composite material. At least one electrical conductor is embedded
along the flow conduit in the composite material, and is adapted to transmit and
receive radio frequency signals. A plurality of measurement stations are disposed,
spaced apart, along the flow conduit at predetermined locations. Each of the plurality
of measurement stations is adapted to receive a first signal transmitted from the
at least one electrical conductor and to transmit a second signal in response thereto
related to a measurement of the at least one parameter of interest.
Claims
1. A system for monitoring at least one parameter of interest relating to a flow
conduit having a through passage and a fluid flow therein comprising:
a) at least one measurement station coupled to said flow conduit for taking a
measurement relating to the parameter of interest; and
b) an interrogation device adapted to move proximate said measurement station,
said interrogation device further adapted to transmit a first signal to said measurement
station and to receive a second signal from the measurement station relating to
the parameter of interest.
2. The system of claim 1 wherein said measurement station includes a sensor for
making a measurement and a device for storing data relating thereto.
3. The system of claim 2 wherein the measurement station includes a power device
for supplying power to the measurement station.
4. The system of claim 1 wherein the measurement station is adapted to transmit
data relating to the parameter of interest upon receipt of a command signal.
5. The system of claim 1 wherein:
i. the interrogation device sends a command signal to the measurement station;
and
ii. the measurement station transmits data upon receipt of the command signal.
6. The system of claim 1 wherein the at least one measurement station includes
a plurality of measurement stations disposed spaced apart along a length of the
flow conduit.
7. The system of claim 6 wherein the plurality of measurement stations includes
sensors that provide measurements of at least two different parameters of interest.
8. The system of claim 1 wherein the parameter of interest is selected from a
group consisting of (i) corrosion, (ii) pressure, (iii) temperature, (iv) fluid
flow state, (v) vibration, (vi) chemical composition, (vii) mechanical strain,
(viii) chemical contamination, (ix) radioactive contamination, (x) biological contamination,
and (xi) seismic events.
9. The system according to claim 2, wherein the measurement station receives
power from said interrogation device through radio frequency transmission.
10. The system of claim 1 wherein the first signal and the second signal are
radio frequency signals.
11. The system of claim 1 wherein the measurement station includes interface
circuitry and a processor acting according to programmed instructions.
12. The system of claim 10 wherein the measurement station receives electrical
power from said first signal.
13. The system of claim 1 wherein the measurement station includes a real-time
clock for time stamping a measurement event.
14. The system of claim 13 wherein said measurement event includes a measurement
matching a predetermined criterion.
15. The system of claim 1 wherein the at least one measurement station is coupled
to at least one of (i) an outer surface of said flow conduit and (ii) an inner
surface of said flow conduit.
16. The system of claim 1 wherein the flow conduit is at least one of (i) a fluid
pipeline (ii) a wellbore tubular, and (iii) an aqueduct.
17. The system of claim 16 wherein the wellbore tubular is at least one of (i)
a casing and (ii) a production tubing.
18. The system of claim 1 wherein the interrogation device moves in said through
passage in said flow conduit.
19. The system of claim 1 wherein the interrogation device moves external to
said flow conduit.
20. The system of claim 19 wherein said external interrogation device is as least
one of (i) an automotive device and (ii) an aircraft device.
21. The system of claim 1 wherein the flow conduit is made from at least one
of (i) a metallic material, (ii) a composite material and (iii) a cementitious material.
22. The system of claim 21, wherein the at least one measurement station is embedded
in the flow conduit made of a composite material.
23. The system of claim 22, wherein the flow conduit made of a composite material
includes at least one electrical conductor embedded along the length of said flow
conduit, said electrical conductor adapted to act as an RF antenna for transmitting
and receiving RF signals.
24. The system of claim 1, wherein the measurement station receives power from
a power source chosen from the group consisting of (i) a commercially packaged
battery, (ii) a thick film battery integrally attached to the measurement station,
(iii) a piezoelectric power source deriving power from shock and vibration in the
proximity of the measurement station, (iv) a solar cell integrated into an external
surface of the measurement station, and (v) a thermoelectric generator integrated
into the measurement station.
25. A method for monitoring at least one parameter of interest relating to a
flow conduit having a fluid flow therein, comprising;
a) coupling at least one measurement station to said flow conduit at a predetermined
location, said measurement station adapted to measure said at least one parameter
of interest;
b) passing an interrogation device proximate said at least one measurement station;
c) transmitting a first signal from said interrogation device to said measurement
station, said measurement station measuring said at least one parameter of interest
in response thereto; and
d) receiving a second signal related to said parameter of interest at said interrogation
device transmitted by said measurement station.
26. The method of claim 24 wherein the first signal and the second signal are
radio frequency signals.
27. The method of claim 26, wherein the at least one measurement station receives
power from said first signal.
28. The method of claim 25 wherein measuring at least one parameter of interest
includes measuring at least one parameter selected from a group consisting of (i)
corrosion, (ii) pressure, (iii) temperature, (iv) fluid flow state, (v) vibration,
(vi) chemical composition, (vii) mechanical strain, (viii) chemical contamination,
(ix) radioactive contamination, (x) biological contamination, and (xi) seismic events.
29. The method of claim 25 wherein the interrogation device is at least one of
(i) an inspection pig, (ii) an automotive device, and (iii) an aircraft device.
30. A system for determining at least one parameter of interest relating to a
flow conduit having a fluid flowing therein, comprising:
a) the flow conduit made from a composite material;
b) at least one electrical conductor embedded along said flow conduit in said
composite material, said at least one electrical conductor adapted to transmit
and receive radio frequency signals; and
c) a plurality of measurement stations disposed spaced apart along said flow
conduit at predetermined locations, each of said plurality of measurement stations
adapted to receive a first signal transmitted from said at least one electrical
conductor and to transmit a second signal in response thereto related to a measurement
of the at least one parameter of interest.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
BRIEF DESCRIPTION OF THE DRAWINGS
For detailed understanding of the present invention, references should be made
to the following detailed description of the preferred embodiment, taken in conjunction
with the accompanying drawings, in which like elements have been given like numerals, wherein:
FIG. 1 is a schematic drawing of a fluid conduit traversing an uneven terrain;
FIG. 2 is a schematic drawing of a self contained measurement and information
station according to one embodiment of the present invention;
FIG. 3 is a schematic drawing of a measurement module of a self contained measurement
and information station according to one embodiment of the present invention;
FIG. 4 is a schematic drawing of an articulated conduit inspection pig for use
as a mobile interrogation device according to one embodiment of the present invention;
FIG. 5 is a schematic drawing showing an automotive device and an aircraft device
for use as mobile interrogation devices according to one embodiment of the present invention;
FIG. 6 is a schematic drawing of a composite conduit with embedded conductors
for transmitting command signals and/or power to multiple measurement stations
according to one embodiment of the present invention;
FIG. 7 is a schematic drawing of a coiled composite tubing having embedded conductors
and a plurality of self contained measurement and information stations disposed
along the tubing according to one embodiment of the present invention; and
FIG. 8 is a schematic drawing of a casing with a plurality of self contained
measurement and information stations disposed along the tubing and an interrogation
device deployed on a tubular member according to one embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
In one preferred embodiment, see FIG. 1, a fluid conduit
1 extends across
terrain
10. Note that the term fluid conduit as used herein, means a closed
conduit, such as a pipeline or other substantially tubular member, and an open
conduit such as an aqueduct for transporting liquids such as water. Such conduits
may extend for tens, hundreds, or thousands of kilometers and may be used to transport
liquids, gases, slurries or other fluids. The conduit
1, for example may
be a pipeline having multiple sections
5,
6,
7 that run above
or below ground. Sections may be run underground to avoid natural obstacles such
as river
8 or simply as a safety precaution. Other sections may be run above
ground depending on the topography and underlying strata. Self contained measurement
and information stations
20, called measurement stations for simplicity,
are disposed along conduit
1 at predetermined locations, to determine any
of a number of parameters of interest related to the operation and safety of the
conduit and/or related to the fluid transported therein. The greater the number
of measurement stations
20, the better will be the confidence that the conduit
is operating properly. Various parameters may be measured relating to various physical
conditions including, but not limited to, mechanical strain and stress, crack initiation
and propagation, temperature, acceleration and vibration, seismic events, corrosion,
pressure integrity, and flowing fluid properties, such as flow rate and chemical
species, radiation, and chemical contamination. For an open channel, such as an
aqueduct, measurement stations
20 may be mounted to determine parameters
related to the flow channel such as, for example, seismic events, and/or for determining
parameters related to the flowing fluid. Such fluid related parameters, for a water
supply flow for example, may relate to chemical analysis and water purity or to
contamination by chemical and/or biological agents. The very nature of the length
and location of such conduits make the distribution of power and signal lines to
multiple measurement stations
20 physically impractical and cost prohibitive.
FIG. 2 shows one preferred embodiment of measurement station
20 having
measurement module
30, radio frequency (RF) transmitting and receiving antenna
22, and flexible adhesive base
21 for attaching measurement module
30 to flow conduit
1. In one embodiment, see FIG. 3, measurement
module
30 includes at least one sensor
27 for detecting the parameter
of interest. Alternatively, sensor
27 may be external to measurement module
30 and suitably electrically connected using techniques known in the art.
Interface module
24 conditions the output signal from sensor
27,
if necessary, and transfers the signal to data memory in controller module
23.
Controller module
23 has a processor with sufficient memory for storing
program instructions and for storing acquired sensor measurement data. The controller
module may contain a unique identification, such as a digital identifier, for uniquely
identifying each measurement station
20 that may be used for correlating
the measurements with location on the conduit
1. Also included is RF transceiver
26 for receiving command and power signals and for transmitting data signals
in response to the received command signals.
In one preferred embodiment, the measurement module
30 has no internal
power source, but receives power via the received RF signal. This power is converted
to usable power by power module
28. Sensor
27 is chosen as a low
power sensor such that the RF link transmits sufficient power to power measurement
module
30 including sensor
27 and to transmit the resulting data
signal using RF transceiver
26. The components of measurement module
30
are encapsulated in a suitable compound
29 to protect the components from
the environment.
The RF command signal and RF power are transmitted from, and the data signals
received by, a mobile interrogation device (see FIGS. 4 and 5) such as an internal
inspection pig
40, an automotive device
45, and an aircraft device
50. Inspection pigs are commonly self-powered for movement in the conduit
or, alternatively, may be pumped through flow conduit
1. Any type of inspection
pig is suitable for this invention The automotive device
45 may be any common
vehicle including, but not limited to an automobile, a truck, and an all-terrain
vehicle. The automotive device, is adapted to carry an RF transceiver (not shown)
and a controller (not shown) transmitting command signals and power to measurement
stations
20 and receiving and storing data signals from measurement stations
20. The aircraft device
50 may be an airplane, helicopter, or any
suitable aircraft and may be manned or a remotely controlled, unpiloted aircraft.
Remotely controlled aircraft device
50 may be preprogrammed to follow a
predetermined flight pattern along the known path of flow conduit
1, using,
for example, preprogrammed way points and GPS signals to guide aircraft device
50 along the predetermined flight pattern. Relatively small remotely controlled
vehicles are commercially available.
The placement of a particular measurement station
20 at a predetermined
location and the type of flow conduit
1 will be used to determine the type
of interrogation device used for that particular measurement station
20.
For example, the flow conduit
1 may be (i) a tubular conduit of metallic
material such as steel, (ii) a tubular conduit out of a non-metallic material such
as a composite material, or (iii) an open-channel conduit. For a metallic conduit,
the RF energy will not penetrate the conduit. Therefore, a measurement station
20 mounted inside the metallic conduit
1 (see FIG. 4) requires an
internal interrogation device such as a pipeline pig
40. A measurement station
20 mounted outside of a metallic conduit
1 (see FIG. 5) requires
an external interrogation device such as automotive device
45 and/or aircraft
device
50. For a composite material, the conduit
1 is substantially
transparent to RF energy and allows the measurement stations
20 to be mounted
internally, externally, and/or embedded within the conduit and be able to operate
with an internal and/or external interrogation device.
The sensors
27 used to detect the parameters of interest include, but
are not limited to, (i) mechanical strain gages, (ii) fiber optic strain gages,
(iii) ultrasonic detectors for detecting micro-crack initiation and propagation,
(iv) accelerometers, (v) temperature sensors, including distributed fiber optic
temperature sensors known in the art, (vi) pressure sensors, (vii) corrosion detectors,
(viii) radiation detectors, (ix) spectroscopic chemical detectors, and (x) ultrasonic
detectors for measuring the wall thickness of the flow conduit for detecting erosion
and/or corrosion of the conduit. The sensors
27 may detect characteristics
associated with the conduit and/or the fluid flowing therein. One skilled in the
art will recognize that many of the sensors, for example accelerometers and seismic
detectors, are currently achievable using Micro Electromechanical Systems (MEMS)
fabrication techniques for providing low power consumption devices. Other sensors
are available using piezoelectric crystal technology or resonant crystal technology
that require very low power consumption. Thermocouple temperature sensors, for
example, generate their own electrical signal and do not require external power
to operate.
In operation, the measurement stations
20 are disposed along the flow
conduit
1. The measurement stations
20 may be both above and below ground
along the length of flow conduit
1 depending on the path of conduit
1.
An interrogation device is caused to pass in relative proximity to the measurement
stations
20. The interrogation device has an RF transceiver for transmitting
command signals and power to the measurement stations
20 and for receiving
data signals from the measurement stations
20. The data collected is downloaded
from the interrogation device, using techniques known in the art, to a central
control station (not shown) for monitoring the various parameter data collected.
In another preferred embodiment, measurement module
30 includes an internal
power source (not shown) for powering the electronic devices and sensors as required.
The internal power source may include, but is not limited to, (i) a commercially
packaged battery, (ii) a thick film battery integrally attached to the measurement
module, (iii) a piezoelectric power source deriving power from shock and vibration
in the proximity of the measurement module, (iv) a solar cell integrated into an
external surface of the measurement module, and (v) a thermoelectric generator
integrated into the measurement module. All of these power sources are known in
the art. Any combination of these sources may be used and their selection is application
specific, and may be determined without undue experimentation, by considering such
factors as (i) power required for the type of sensors, (ii) transmission strength
required of data signals, and (iii) location of measurement station and flow conduit
(for example, above ground or below ground).
In another preferred embodiment, the power sources described above are mounted
external to the measurement module
30 and connected to the measurement module
via connectors and/or cables using techniques known in the art.
In one preferred embodiment, measurement module
30 contains a real time
clock for time stamping measurements. A low power seismic detector, for example,
may be continuously measuring seismic activity, but the data is only stored and
time stamped if the sensed event exceeds a predetermined threshold or alarm criterion.
The data is retrieved by the interrogation device and may be used to indicate that
more extensive inspection is needed in the area where the seismic event was detected.
In one preferred embodiment, shown in FIG. 6, composite fluid conduit
60
has electrical conductors
61 embedded in the wall
63 of fluid conduit
60 during the manufacturing process for forming the conduit. Measurement
stations
20 are disposed along the conduit at at least one of (i) on an
internal walls of conduit
60, (ii) on an external wall of conduit
60,
and (iii) embedded in a wall
63 of conduit
60. The electrical conductors
61 may be disposed substantially longitudinally in the wall of conduit
60.
Alternatively, the electrical conductors
61 may be spirally wrapped in the
wall of conduit
60. Electrical conductors
60 are connected to RF
transceiver (not shown) in a controller
62. Power and command signals are
transmitted through the conductors which act as RF antennas. The signals are detected
by the measurement modules
30 along the conduit. The measurement stations
20 receive and convert the RF signals to power and command instructions
for taking data from sensors in the measurement modules
30. The data are
then transmitted via an RF signal that is received by the electrical conductors
61 and decoded by controller
62, according to programmed instructions.
The signals from measurement stations
20 are suitably encoded and identified,
using techniques known in the art, so as to be able to determine the measurement
stations
20 associated with each data signal.
In one preferred embodiment, see FIG. 7, a composite conduit, as described previously
having embedded electrical conductors and internal, external, and/or embedded measurement
stations
20, may be formed as a coiled tubing
71, contained on reel
70, for use in drilling and/or completing a wellbore
72. Measurements
from measurement modules
30, embedded in the coiled tubing
71, may
be used to determine parameters of interest regarding the condition of the tubing
string and/or parameters related to the drilling process. Such parameters of interest
include, but are not limited to, (i) directional parameters, (ii) drilling induce
vibration, including axial and torsional, (iii) weight on bit, (iv) downhole pressure,
(v) downhole temperature, and (vi) formation parameters including natural gamma
ray emission.
In one preferred embodiment, see FIG. 8, metallic casing
83 is fixed in
place in production wellbore
80. Measurement modules
30 are fixed
to an internal surface of casing
83 and measure parameters of interest including,
but not limited to, (i) fluid pressure, (ii) fluid temperature, (iii) fluid flow
rate, (iv) corrosion, and (v) casing stress. An interrogation device
82
is deployed on wireline
81 and is passed in proximity to measurement modules
30 and has an RF transceiver that transmits RF power and command signals
to measurement modules
30, which in turn, make measurements and transmit
that data via RF transmission to interrogation device
82. Interrogation
device
82 has internal memory for storing the received data and is downloaded
at the surface. Alternatively, wireline
81 has electrical conductors and
received data is transmitted directly to the surface. The interrogation device
82 may alternatively be deployed on a coiled tubing (not shown) using techniques
known in the art.
*
