GB2584485A

GB2584485A - An insulation assembly for a pipework and a method of monitoring a pipework

Info

Publication number: GB2584485A
Application number: GB1908118.1A
Authority: GB
Inventors: Clark Daniel; Howdle Paul
Original assignee: Rolls Royce PLC
Current assignee: Rolls Royce PLC
Priority date: 2019-06-07
Filing date: 2019-06-07
Publication date: 2020-12-09
Also published as: GB201908118D0

Abstract

An insulation assembly 2 for a pipework 4, comprising a plurality of insulation modules 10, 12, 14 each having a predefined shape, a first portion of which corresponds to a respective portion of an external shape of a pipework 4, wherein each of the plurality of insulation modules are removably attachable to the pipework 4 and to at least one of the other of the plurality of insulation modules and wherein at least one of the plurality of insulation modules comprises an embedded sensor (22, 22’, 22’’) for measuring a parameter of the pipework. Aspects include: the predefined shape of each of the plurality of insulation modules interlocks with the further portion of the predefined shape of another of the plurality of insulation modules; wherein one or more of the insulation modules comprises a base station 16 for wirelessly transmitting sensor data to an external device; creating a digital twin of the pipework and updating one or more parameters of the digital twin based on the sensor data. Further aspects include the sensor data relates to one or more of the: temperature; vibration; strain; torque; position; orientation of the pipework.

Description

AN INSULATION ASSEMBLY FOR A PIPEWORK AND A METHOD OF MONITORING A PIPEWORK

The present disclosure relates to an insulation assembly for a pipework and a method of monitoring a pipework.

Industrial plant pipework such as pipework for small modular reactors (SMRs) is frequently lagged for thermal insulation. This often involves wrapping a compliant mineral wool insulating material around the pipework and securing it in place using tape or sheet metal covers. It is often desirable to measure parameters relating to the pipework such as temperature and vibration. Accordingly, sensors for sensing parameters of the pipework may be inserted through the lagging in order to contact the pipework at regions of interest. Heavy protected cables leading from the sensors are fed out through the insulating material so as to allow data produced by the sensors to be externally analysed. The installation of such insulation assemblies is difficult, time-consuming and presents health and safety challenges. Further, accurate placement of the sensors is difficult to achieve and the cabling may become damaged and prevent access to the lagging and pipework.

It is therefore desirable to provide an improved insulation assembly and method of monitoring a pipework that overcomes these issues.

According to a first aspect there is provided an insulation assembly for a pipework, the insulation assembly comprising a plurality of insulation modules each having a predefined shape, a first portion of which corresponds to a respective portion of an external shape of the pipework, wherein each of the plurality of insulation modules are removably attachable to the pipework and to at least one of the other of the plurality of insulation modules, and wherein at least one of the plurality of insulation modules comprises an embedded sensor for measuring a parameter of the pipework.

A second portion of the predefined shape of each of the plurality of insulation modules may correspond to a further portion of the predefined shape of another of the plurality of insulation modules.

The second portion of the predefined shape of each of the plurality of insulation modules may interlock with the further portion of the predefined shape of the another of the plurality of insulation modules.

Each of the plurality of insulation modules may comprise an embedded sensor for measuring a parameter of the pipework.

Each of the plurality of insulation modules may comprise an electrical connector for electrically connecting each of the plurality of insulation modules to at least one of the other of the plurality of insulation modules.

One or more of the insulation modules may comprise a base station for wirelessly transmitting sensor data generated by the one or more sensors to an external device.

Each of the plurality of insulation modules may comprise one or more wires embedded within the insulation modules for transmitting sensor data generated by the one or more sensors to the base station and/or for transmitting power to the one or more sensors.

A body of each of the plurality of insulation modules may be formed of a rigid material such that the body of each of the insulation modules is rigid.

The first portion of each of the plurality of insulation modules may be defined by a layer formed of a flexible material, the flexible material being less rigid than the rigid material.

Two or more of the plurality of insulation modules may each comprise one or more transponders for determining the relative positions and/or orientations of the two or more insulation modules.

An insulation module as described in any preceding statement may be provided.

According to a second aspect there is provided a method of monitoring a pipework using an insulation assembly as described in any preceding statement. The method comprises: creating a digital twin of the pipework; the one or more sensors generating sensor data relating to one or more parameters of the pipework; and updating one or more parameters of the digital twin based on the sensor data.

The sensor data may relate to one or more of the temperature of the pipework, the vibration of the pipework, the strain of the pipework, the torque of the pipework, the position of the pipework and the orientation of the pipework.

The method may further comprise determining the condition and/or performance of the pipework using the digital twin of the pipework.

The method may further comprise de-rating the pipework based on the condition and/or performance of the pipework.

The method may further comprise updating a maintenance diary based on the condition and/or performance of the pipework.

Embodiments will now be described by way of example only, with reference to the accompanying Figures, in which: Figure 1 is a perspective view of an insulation assembly for a pipework; Figure 2 is an exploded schematic view of the insulation assembly and the pipework; and Figure 3 shows a method of monitoring the pipework.

Figure 1 shows a perspective view of an insulation assembly 2 for a pipework 4. The pipework 4 may be pipework of a power plant or high value process plant such a petrochemical refinery, a high value waste processing plant or a mineral extraction plant, for example. In the example shown, the pipework 4 comprises a vertical pipe 6 leading to a horizontal pipe 8. However, the pipework 4 can have any shape and configuration. The insulation assembly 2 comprises a first insulation module 10, a second insulation module 12 and a third insulation module 14. The first, second and third insulation modules 10, 12, 14 are discrete units.

Each insulation module 10, 12, 14 has a predefined shape. That is, each module 10, 12, 14 has a known and substantially fixed shape prior to assembly onto the pipework 4. Although in some arrangements the insulation modules 10, 12, 14 may be somewhat flexible and partially deformable under stress, they return to their predefined shape upon removal of the stress (i.e. they are elastic). In other arrangements, the insulation modules 10, 12, 14 may be made of a relatively stiff material and thus exhibit very little or no deformation under stress. In the example arrangement shown, each insulation module 10, 12, 14 is 3D printed. Accordingly, the geometry of each insulation module 10, 12, 14 can be customised.

Figure 2 shows an exploded schematic view of the insulation assembly 4 shown in Figure 1. The size and shape of the components in Figure 2 are not to scale. A first portion 50 of the predefined shape of the insulation module 10 corresponds to a respective portion 100 of an external shape of the pipework 4. Likewise, a first portion 50' of the predefined shape of the insulation module 12 corresponds to a respective portion 100' of an external shape of the pipework 4. In addition, a first portion 50" of the predefined shape of the insulation module 14 corresponds to a respective portion 100" of an external shape of the pipework 4. In this manner, the first, second and third insulation modules 10, 12, 14 are profiled such that, when assembled, they conform to the exterior surface of the pipework 4.

A second portion of the predefined shape of each of the plurality of insulation modules 10, 12, 14 corresponds to a further portion of the predefined shape of another of the plurality of insulation modules 10, 12, 14. The second and further portions of the predefined shapes may form side surfaces of the insulation modules 10, 12, 14 extending from the first portions, which form lower surfaces of the insulation modules 10, 12, 14. The second portions and corresponding further portions of the predefined shapes of the first, second and third insulation modules 10, 12, 14 interlock (e.g. tessellate) with each other.

The plurality of insulation modules 10, 12, 14 are removably attachable to the pipework 4 and to each other. Once assembled together, the first, second and third insulation modules 10, 12, 14 are self-supporting. Such an arrangement simplifies and reduces the time taken to carry out the lagging process, thus reducing human exposure to the pipework 4 and plant shutdown time. Further, it ensures that the insulation modules 10, 12, 14 are accurately positioned at a desired location of the pipework 4 in a repeatable manner. In order to ensure that the first, second and third insulation modules 10, 12, 14 stay in place on the pipework 4 and do not separate from each other, the first, second and third insulation modules 10, 12, 14 may be pinned or strapped together. A base station 16 is attached to the upper surface of the third insulation module 14.

The insulation modules 10, 12, 14 can be retrofit onto existing pipework 4. A 3D scanner may be used to gather point cloud data relating to the geometry of the existing pipework 4, which may then be used to determine suitable geometry for the insulation modules 10, 12, 14. The first, second and third insulation modules 10, 12, 14 may be colour-coded for ease of assembly.

Each of the insulation modules 10, 12, 14 comprises a body 18, 18', 18" and an inner layer 20, 20', 20". The bodies 18, 18', 18" of the insulation modules 10, 12, 14 are formed of a rigid material such that the bodies 18, 18', 18" and the insulation modules 10, 12, 14 as a whole are rigid. In the example shown, the bodies 18, 18', 18" are ceramic. The inner layers 20, 20', 20" are formed of a flexible material that is less rigid (i.e. more flexible) that the rigid material of the bodies 18, 18', 18". The relatively soft inner layers 20, 20', 20" form the first portion of the predefined shapes of the insulation modules 10, 12, 14. Since the inner layers 20, 20', 20" are relatively flexible, the first portions of the predefined shapes of the insulation modules 10, 12, 14 conform closely to the exterior surface of the pipework 4. The inner layers 20, 20', 20" may be formed of a polymer and be sprayed or laminated onto their respective ceramic bodies 18, 18', 18".

Each insulation module 10, 12, 14 comprises a sensor 22, 22', 22". The sensors 22, 22', 22" may be used to sense parameters of the pipework 4 such as the temperature of the pipework 4, the vibration of the pipework 4, the strain of the pipework 4, the torque of the pipework 4, the position of the pipework 4 and/or the orientation of the pipework 4. The sensors 22, 22', 22" are located in shielded ports disposed on the lower surfaces of the insulation modules 10, 12, 14. The sensors 22, 22', 22" are embedded in the insulation modules 10, 12, 14 such that their position is fixed relative the remainder of the insulation modules 10, 12, 14. The sensors 22, 22', 22" are positioned such that when the insulation modules 10, 12, 14 are assembled on the pipework 4 and connected together, the sensors 22, 22', 22" are located at positions of interest (e.g. at safety-critical locations, at locations with high stress concentrations and/or high flow rates, etc.).

A first electrical connector 26 is disposed on the side wall of the insulation module 10, a second electrical connector 28 is disposed on the side wall of the insulation module 12 and third and fourth electrical connectors 30, 32 are disposed on the side wall of the insulation module 14. The sensor 22 of the insulation module 10 is electrically connected to the first electrical connector 26 by a first wire or cable 34. The sensor 22' of the insulation module 12 is electrically connected to the second electrical connector 28 by a second wire or cable 36. The sensor 22", the third electrical connector 30 and the fourth electrical connector 32 of the insulation module 14 are electrically connected to the base station 16 by a third wire or cable 38, a fourth wire or cable 40 and a fifth wire or cable 42, respectively. The electrical connectors 26, 28, 30, 32 may be spring-loaded electrical contacts.

In use, the sensor 22 produces data indicative of a measured parameter of the pipework 4 at its position and sends it to the base station 16 via the first wire 34, the first electrical connector 26, the third electrical connector 30 and the fourth wire 40. The sensor 22' produces data indicative of a measured parameter of the pipework 4 at its position and sends it to the base station 16 via the second wire 36, the second electrical connector 28, the fourth electrical connector 32 and the fifth wire 42. The sensor 22" produces data indicative of a measured parameter of the pipework 4 at its position and sends it to the base station 16 via the third wire 38. Power may be supplied to the sensors 22, 22', 22" from the base station 16 via the same wires and electrical connectors.

The sensor data is wirelessly transmitted from the base station 16 to an external device, which, in the arrangement shown, is a drone 44. The drone 44 may move within the plant so as to gather data from multiple base stations 16 within the plant.

The drone 44 is able to reach difficult to access areas of the pipework 4 in non-line-of-sight locations. Once the drone 44 has collected the data, it can move to a local hub 46 and send the data to the local hub 46. The local hub 46 may be located on the other side of a bulkhead 48 from the drone 44. Accordingly, the drone 44 may communicate with and send data to the local hub 46 using lasers through glass in the bulkhead 48, thereby minimising bulkhead 48 penetrations. The use of this type of data transmission prevents direct data capture by third parties. The local hub 46 can then send the data to an external monitoring and control system 56 for analysis so as to determine the performance of the system. The following methods and processes can be carried out by one or more processors located in the external monitoring and control system 56. This process can be repeated at intervals during operation of the plant.

In some arrangements, the insulation modules 10, 12, 14 may comprise transponders (not shown) that communicate with each other. The transponders may be RFID transponders. The transponders may be embedded within the insulation modules 10, 12, 14. A processor may determine the relative positions and/or orientations of the insulation modules 10, 12, 14 based on the signals received from the transponders. The processor may compare the actual positions and orientations of the insulation modules 10, 12, 14 to nominal positions and orientations of the insulation modules 10, 12, 14 in order to determine whether they have been installed correctly. Alternatively or additionally, a processor may determine the positions and orientations of the insulation modules 10, 12, 14 relative to the features of the plant. This information can be used to determine where to position the drone 44 when collecting data or carrying out servicing tasks.

The wires 34, 36, 38, 40, 42 and the electrical connectors 26, 28, 30, 32 are embedded within the insulation assemblies 10, 12, 14. Accordingly, the amount of external wiring is minimised. Only the third module 14 has external wiring in order to provide power to the base station 16. Accordingly, there are no loose or exposed wires proud of the insulation assembly 2 except at specific, pre-defined locations. Since the geometry of each insulation module 10, 12, 14 and the location of the sensors 22, 22', 22" within each of the insulation modules 10, 12, 14 are customised according to the geometry and areas of interest of the pipework 4, the sensors 22, 22', 22" can be positioned accurately and in a repeatable manner. This is useful for plant monitoring, where the positioning of the sensors 22, 22', 22" can significantly impact their readings. Further, the insulation modules can be assembled and disassembled quickly, ergonomically and without damage or loss of sensor position data.

The insulation assembly 2 described above can be used to assist in product lifecycle management (PLM). For example, as shown in Figure 3, in a first step S2 of a method 52, a digital twin of the pipework 4 may be created. The digital twin is a virtual representation of the actual pipework 4. The digital twin has a number of parameters associated with it, such as temperature, vibration, strain, torque, position, orientation, geometry and material that are intended to mirror the parameters of the actual pipework 4. In a second step S4 of the method, the sensors 22, 22', 22" generate sensor data relating to one or more parameters of the pipework 4. The parameters of the pipework 4 may be the temperature of the pipework 4, the vibration of the pipework 4, the strain of the pipework 4, the torque of the pipework 4, the position of the pipework 4 and/or the orientation of the pipework 4. In a third step S6 of the method, the processor updates one or more parameters of the digital twin based on the sensor data. Steps S4 and S6 can be repeated such that the digital twin is updated continuously and in real time.

The digital twin of a component can be monitored so as to determine S8 or estimate the performance and/or condition of its physical counterpart. The estimated performance or condition of the component can be monitored and compared to that of existing components operating in identical plants with different service lives. The estimated performance or condition of the component can be used to determine whether to repair or replace the component. The estimated performance of the component may alternatively be used to estimate how long the component can be used under a set of conditions before it requires repair or replacement. The pipework can be de-rated S10 (i.e. operated at less than its maximum rated capacity) based on the condition and/or performance of the pipework as determined from the digital twin. For example, based on the estimated remaining life of a component based on previous or existing operation conditions, a component may be de-rated so as to increase the remaining life of the component and of the plant as a whole. In an example, it may be apparent from the digital twin of a pipe section that a portion of the pipe wall is relatively thin in comparison to other portions of the pipe wall. This geometric information about the pipe section as well as information about the pipe section gathered from the sensors (e.g. thermal or vibration information) may allow a processor to more accurately estimate whether the plant is currently operating safely, and, if so, for how much longer it would be considered to be operating safely.

The pipework may comprise one or more pipes, couplings, fittings or valves. A digital twin may be created for each component of the pipework 4. The digital twins for each of the components may be updated using sensor data gathered from the sensors 22, 22', 22" of the insulation assembly 2. In this manner, a digital twin of the entire pipework 4 can be created. In alternative arrangements, a digital twin is only created and updated for high value or safety critical components. The digital twin of a component may be sectioned into multiple volumetric zones. The volumetric zones may be analysed separately so as to estimate the performance and condition of a corresponding volumetric zone of the physical component.

Certain zones of the digital twin, referred to as sentinel zones, may be monitored in order to determine whether the corresponding volumetric zone of the physical component requires manual inspection. Sentinel zones identified as requiring manual inspection may be flagged as such. A frequency filter may be used to determine whether a sentinel zone should be flagged. A maintenance diary may be updated S12 to include entries for inspecting flagged sentinel zones. Data relating to sentinel zones may be used to inform component and sensor placement and the use of components having concessions for operation.

Although it has been described that both data and power are transmitted between the insulation modules 10, 12, 14 via physical wires and connectors, in alternative arrangements only power is transmitted between the insulation modules 10, 12, 14 via physical wires and connectors. In such alternative arrangements, data may be transmitted wirelessly between the insulation modules 10, 12, 14.

Although it has been described that data is sent from the base station 16 to a drone 44, in alternative arrangements the drone 44 may be dispensed with and the sensor may be sent directly from the base station 16 to the local hub 46. In further alternative arrangements, the base station 16 may be dispensed with and the data may be to the local hub 46 via a wired connection.

Although it has been described that power is supplied to the sensors 22, 22', 22" from the base station 16, in alternative embodiments the sensors 22, 22', 22" may be self-powered. For example, each sensor 22, 22', 22" may be coupled to a separate thermoelectric generator located within its respective insulation module 10, 12, 14. The thermoelectric generators may convert temperature differences between the lower and upper surfaces of the insulation modules 10, 12, 14 into electrical energy, which is then supplied to the sensors 22, 22', 22". In yet further alternative arrangements, the sensors 22, 22', 22" may receive power from an interrogation signal and sense a parameter, produce sensor data and transmit the data using the received power.

Although it has been described that the insulation modules 10, 12, 14 are 3D printed, they may be manufactured using alternative manufacturing methods. For example, a mould may be 3D printed from which the insulation modules 10, 12, 14 are subsequently cast.

Although it has been described that the insulation assembly 2 comprises three insulation modules (i.e. a first insulation module 10, a second insulation module 12 and a third insulation module 10), in alternative arrangements the insulation assembly 2 may comprise any number of insulation modules. Further, although it has been described that each of the insulation modules 10, 12, 14 comprises a single sensor, in alternative arrangements the sensors of one or more of the insulation modules 10, 12, 14 may be dispensed with. In the same or further arrangements, each of one or more of the insulation modules 10, 12, 14 may comprise multiple sensors. Each of the multiple sensors may be located at positions of interest. Each sensor of the same or different modules 10, 12, 14 may be of the same type (i.e. a temperature sensor, a position sensor, etc.) or a different type of sensor.

Although it has been described that sensor data generated by the sensors 22, 22', 22" is transmitted to a single insulation module 10, 12, 14 and transmitted away from the insulation assembly 2 to the drone 44, this need not be the case. For example, in alternative arrangements, multiple or each insulation modules may be provided with a base station for transmitting data generated by its respective sensor to the drone 44. In this manner, the sensor data need not necessarily pass between the insulation modules.

Claims

CLAIMS1. An insulation assembly (2) for a pipework (4), the insulation assembly (2) comprising a plurality of insulation modules (10, 12, 14) each having a predefined shape, a first portion (50, 50', 50") of which corresponds to a respective portion (100, 100', 100") of an external shape of the pipework (4), wherein each of the plurality of insulation modules (10, 12, 14) are removably attachable to the pipework (4) and to at least one of the other of the plurality of insulation modules (10, 12, 14), and wherein at least one of the plurality of insulation modules (10, 12, 14) comprises an embedded sensor (22, 22', 22") for measuring a parameter of the pipework (4).
2. An insulation assembly (2) as claimed in claim 1, wherein a second portion of the predefined shape of each of the plurality of insulation modules (10, 12, 14) corresponds to a further portion of the predefined shape of another of the plurality of insulation modules (10, 12, 14).
3. An insulation assembly (2) as claimed in claim 2, wherein the second portion of the predefined shape of each of the plurality of insulation modules (10, 12, 14) interlocks with the further portion of the predefined shape of another of the plurality of insulation modules (10, 12, 14).
4. An insulation assembly (2) as claimed in any preceding claim, wherein each of the plurality of insulation modules (10, 12, 14) comprises an embedded sensor (22, 22', 22") for measuring a parameter of the pipework (4).
5. An insulation assembly (2) as claimed in any preceding claim, wherein each of the plurality of insulation modules (10, 12, 14) comprises an electrical connector (26, 28, 30, 32) for electrically connecting each of the plurality of insulation modules (10, 12, 14) to at least one of the other of the plurality of insulation modules (10, 12, 14).
6. An insulation assembly (2) as claimed in any preceding claim, wherein one or more of the insulation modules (10, 12, 14) comprises a base station (16) for wirelessly transmitting sensor data generated by the one or more sensors (22, 22', 22") to an external device (44).
7. An insulation assembly (2) as claimed in claim 6, wherein each of the plurality of insulation modules (10, 12, 14) comprises one or more wires (34, 36, 38, 40, 42) embedded within the insulation modules (10, 12, 14) for transmitting sensor data generated by the one or more sensors (22, 22', 22") to the base station (16) and/or for transmitting power to the one or more sensors (22, 22', 22").
8. An insulation assembly (2) as claimed in any preceding claim, wherein a body (18, 18', 18") of each of the plurality of insulation modules (10, 12, 14) is formed of a rigid material such that the body (18, 18', 18") of each of the insulation modules (10, 12, 14) is rigid.
9. An insulation assembly (2) as claimed in claim 8, wherein the first portion (50, 50', 50") of each of the plurality of insulation modules (10, 12, 14) is defined by a layer (20, 20', 20") formed of a flexible material, the flexible material being less rigid than the rigid material.
10. An insulation assembly (2) as claimed in any preceding claim, wherein two or more of the plurality of insulation modules (10, 12, 14) each comprise one or more transponders for determining the relative positions and/or orientations of the two or more insulation modules (10, 12, 14).
11. An insulation module (10, 12, 14) as claimed in any preceding claim.
12. A method of monitoring a pipework (4) as described in any of claims 1 to 10 using an insulation assembly (2) as claimed in any of claims 1 to 10, the method comprising: creating (S2) a digital twin of the pipework (4); the one or more sensors (22, 22', 22") generating (S4) sensor data relating to one or more parameters of the pipework (4); and updating (S6) one or more parameters of the digital twin based on the sensor data.
13. A method as claimed in claim 12, wherein the sensor data relates to one or more of the temperature of the pipework (4), the vibration of the pipework (4), the strain of the pipework (4), the torque of the pipework (4), the position of the pipework (4) and the orientation of the pipework (4).
14. A method as claimed in claim 12 or 13, further comprising determining (S8) the condition and/or performance of the pipework (4) using the digital twin of the pipework (4).
15. A method as claimed in claim 14, further comprising de-rating (S10) the pipework (4) based on the condition and/or performance of the pipework (4).
16. A method as claimed in claim 14 or 15, further comprising updating (S12) a maintenance diary based on the condition and/or performance of the pipework (4).