Description Automatic Sampling Manifold
Technical Field This apparatus relates to the collection, transportation and analysis of gas samples which may be required in various scientific, environmental and resource contexts. As an example, in oil and natural gas exploration, drilling, recovery and storage, periodic sampling of recovered gases and fluid are required for subsequent analysis. In the oil industry, "mud" is a colloquial term for a thick chemical composition that is pumped into drills as they penetrate the substrate. This "mud" is returned to the surface and contains gases that are released from the rock as the drill penetrates. Significant data is acquired from the analysis of these gases. As a further example, in the context of natural gas storage, large underground storage deposits are often chemically tagged for later identification. This apparatus facilitates the recovery of samples from these storage deposits for testing and identification of the chemical tag. A need has been seen for automation of the sampling process and for being able to serial harvest samples by placing them is pressurized and non pressurized containers.
Background Art
United States Patent 5,116,330 to Spencer provided for a sample extraction system with a sampling container and valves. Such a sampling system requires the interruption of the fluid flow as sampling containers are exchanged. Further, extraction of the sample from the sampling container was accomplished by "bleeding" the container, a technique which relies on gravity and is suitable for fluids in a liquid rather than a gaseous state.
Disclosure of the Invention The present invention provides a gas sampling apparatus in which continuous or periodic gas samples may be isolated in gas sampling containers. The gas sampling container associated with this apparatus contains self-sealing valves on either end which open when the sample container is positioned in the apparatus and automatically closes
when the sampling container is removed from the apparatus. In one configuration, the apparatus has a plurality of sampling containers in a loader and the gas flow which is to be sampled is directed into and out of one gas sampling container by means of an automatically activated manifold. Upon filling the manifold releases the container and the indexer then delivers the container into a storage hopper for later retrieval. In this way, continuous sampling of a gas flow may be achieved.
Brief Description of the Drawings
Fig. 1 is a perspective view of the entire apparatus viewed from the right.
Fig. 2 is a perspective view of the rear of the apparatus illustrating the indexer.
Fig. 3 is a perspective view of the entire apparatus viewed from the left.
Fig. 4 is a cross section view of the manifold assembly with the manifold in the fill position.
Fig. 5 is a cross section view of the fixed chuck midway between fill and bypass positions.
Fig. 6 is a cross section view of manifold with the manifold in the bypass position.
Fig. 7 is a cross section view of the mechanical chuck operation mechanism.
Fig. 8 is a perspective view of a manual embodiment of the apparatus.
Fig. 9 is a perspective view of the sensor array.
Best Mode for Carrying Out the Invention The apparatus is, in both manual and automatic embodiments, designed to fill sample containers with a gas or fluid for later sample analysis. The automatic embodiment will feed sample containers seriatim, from a loader into a fill mechanism, then release the sample containers into a collection container or hopper. In the manual embodiment, the sample container will be manually loaded into the apparatus, the fill mechanism manually clamped and fluidly connected and sealed with the sample container. The sample container is substantially similar to the subject of PCT/US01/08652 and PCT/US04/038636, although a sampling container of sufficient length or modifiable to sufficient length with depression activated, self-sealing valves on opposing ends may be utilized in this device. Turning to Fig. 1, it is seen that the loader 24 consists of a frame 1. The frame supports a first guide rail 2 and a second guide rail 3
through means of a first lower guide rail support 4, a second lower guide rail support 5 (better shown in Fig. 3), a first upper guide rail support 6, a second upper guide rail support 7 (also better shown in Fig. 3). By further examining the first guide rail support 4, it can be seen that this, as in all guide rail supports, consists of a first lower guide rail support shaft 8 and a first lower guide rail support u-bracket 9. The first lower guide rail support u-bracket 9, as in all guide rail supports, consists of a segment proximal to the support shaft 8, a segment distal to support shaft 8 and a transverse section connecting the two. These segments are termed the u-bracket proximal segment 10, u-bracket distal segment 11 and u-bracket transverse segment 12. Support shaft 8 is connected to the u- bracket proximal segment 10, which exhibits u-bracket proximal segment first end 13 u- bracket proximal segment second end 14. The u-bracket proximal segment first end 13 is connected to support shaft 8 and the first guide rail 2, near the first guide rail discharge end 15. The u-bracket proximal segment second end 14 is connected to the u-bracket transverse segment first end 19. U-bracket transverse segment second end 20 is in turn connected to u-bracket distal segment second end 18. U-bracket distal segment first end 17 is attached near second guide rail discharge end 21. This configuration supports the guide rail but yet allows the sample container stem valve to pass through the support u- bracket segment of the guide rail support. The first guide rail 2 and second guide rail 3 are configured in two parallel rising "S" shapes or parallel and vertical serpentine shapes such that the sample container stem valve 23 is slidably confined between the two. A similar "S" configuration and attachment to frame 1 is seen with third guide rail 25 and fourth guide rail 26. The third guide rail 25 and fourth guide rail 26 pair are mounted opposite the first guide rail 2 and second guide rail 3 pair. Thus, a sampling container with stem valves on both ends may be loaded seriatim within the "S" shaped loading mechanism. Gravity will act on the queue of sampling containers A driving them downward. Turning now to Fig. 2, the indexer 27 is illustrated. The indexer 27 is a spool shaped device consisting of an indexer tube 28 having an indexer tube first end 29 and an indexer tube second end 30. Mounted to indexer tube first end 29 is a first indexer disk 31. Mounted to indexer tube second end 30 is second indexer disk 32. The indexer tube 28 is slid over the manifold return tube 33 illustrated in Fig. 4 and is rotatably mounted
thereon. Returning to Fig. 2, it can be seen that a first spacer 34, also a tube, is slid over the manifold return tube 33 and rest between the manifold 35 and first indexer disk 31. A second spacer 36 is located between the fixed chuck 37 and the second indexer disk 32. Each indexer disk has a plurality of stem valve slots, in the outer edge of the disks. In this illustration four are shown, 90 degrees from one another being first stem valve slot 38, second stem valve slot 39, third stem valve slot 40, fourth stem valve slot 41, all located on first indexer disk 31 are similarly configured. Fifth stem valve slot 42, sixth stem valve slot 43, seventh stem valve slot 44 and eighth stem valve slot 45 are located on second indexer disk 32. The first stem valve slot 38 is opposite the fifth stem valve . slot 42. The second stem valve slot 39 is opposite the sixth stem valve slot 43. The third stem valve slot 40 is opposite the seventh stem valve slot 44 and the fourth stem valve slot 41 is opposite the eighth stem valve slot 45. A sample container having stem valves at each end can be carried by the indexer when its stem valves rest within opposite stem valve slots. Turning now to Fig. 2 A, it is seen that the longitudinal axis of the stem valve slot is not in line with the a diameter line of the disc but is instead rotated away from the diameter line toward the edge of the disc. Each stem valve slot is rotated away from the diameter line in the same direction and through the same angle. This allows the sampling container to remain cradled in the indexer so that the sampling container may be properly positioned to engage with the fixed and moveable chuck 75. Turning now to Fig. 3, the indexer is rotated by the indexer stepper motor 46, by means of a gear set 47 with gears driveably connected from the indexer stepper motor 46 to the second indexer disk 32 or belt drive mechanism 48 where a belt extends around and from a pulley on the indexer stepper motor to around and to a pulley on the second indexer disk 32. Turning now to Fig. 4, the manifold assembly 49 is illustrated. The manifold assembly 49 exhibits a manifold 35 which is connected to the manifold return tube first end 51. The manifold return tube second end 52 is connected to a fixed chuck assembly 53. Thus the manifold return tube become part of the flow path circuit. Fixed chuck assembly 53 is composed of fixed chuck body 54. Fixed chuck body 54 exhibits fixed chuck body return tube seat 55 into which manifold return tube second end 52 sealably seats. Fixed chuck body return tube seat 55 is connected to fixed chuck bore first end 57 of fixed chuck bore 56 which provides a path through fixed chuck body 54. Fixed chuck
bore 56 also exhibits fixed chuck tube second end 58 which is fluidly connected to fixed chuck head 59. Now turning to Fig. 5, fixed chuck head 59 is illustrated. Fixed chuck 59 is composed of an annular body 60 with externally threaded end 61. A first central bore section 63 is seen followed by larger diameter second central bore section 64. First central bore section 63 is fluidly connected with fixed chuck bore 56. Within first central bore section 63 rests plunger depressor 65. Plunger depressor 65 has three components, a finger member 66, transverse member 67 and a stem 68. The first transverse member is that portion of the plunger depressor 67, which communicates with the flexible washer 69 which itself is disposed at the top of annular body 60. Flexible washer 69 is disposed over the finger member 66 such that finger member 66 protrudes above flexible washer 69. Transverse member 67 is kept in contact with flexible washer 69 by pressure exerted by spring 70 resting at the bottom of first central bore section 63. Flexible washer 69 is held in place by internally threaded cap 71 threaded over the externally threaded end 61 of annular body 60. The valve stem 73 of stem valve 72 is depressed when it comes in contact with finger member 66 allowing fluid flow from the sampling container. However, valve stem 73 depresses to a maximum depth and stops. The sampling container continues in travel within the fixed chuck head 59 and the valve stem 73 still in contact with finger member 66, depresses the transverse member 67 down and away from flexible washer 69 allowing fluid flow passed the transverse member 67 into second central bore section 64 then first central bore section 63 then into fixed chuck bore 56. Returning to Fig. 4, it is seen that the movable chuck head 74 is substantially similar in configuration to fixed chuck head 59. The movable chuck 75 is composed of movable chuck head 74, mounted to movable chuck shaft 76 which is mounted to spool 77. Moveable chuck shaft 76 exhibts chuck shaft central bore 87. Moveable chuck shaft 76 and spool 77, cylindrical in shape, slidably and sealably communicate with the walls of manifold race 78 within manifold 50. Spool 77 has three annular grooves. First annular groove 79 provides a seat for first spool o-ring 80. Second annular goove 81 provides a seat for second spool o-ring 82. The third annular groove 83 provides a fluid pathway around spool 77. Turning now to Fig. 6, manifold 50 exhibits flow input aperture 84 and flow output aperture 85 fluidly connected with manifold race 78. Flow
input aperture 84 and flow output aperture 85 are in close enough proximity for both to be contained with in third annular groove 83 when movable chuck 75 and accompanying spool 77 are in an appropriate position term the "bypass position." This allows a fluid connection with fluid coming into flow input aperture 84, through third annular groove 83 and out flow output aperture 85. Fluid moves into manifold 50 and directly out bypassing the sampling container A. While in the bypass position the movable chuck 75 rests against or near the rear wall of the manifold race 78. Returning again to Fig. 4, it can be seen the moveable chuck 75 is in the "fill position." Manifold 50 exhibits flow from return tube 33 through bore 86 and into manifold race 78. When in fill position, moveable chuck 75 is in a forward position, away from the rear wall of the manifold race 78 and is in fluid connection with a stem valve of the sampling container. In this configuration, fluid passes into manifold race 78 through flow input aperture 84, passes down chuck shaft central bore 87 through moveable chuck head 74 into stem valve 72 and into and through sampling container A. The fluid continues to flow through the opposite stem valve 72, into the fixed chuck head 59, on into fixed chuck bore 56, then into manifold return tube 33 into flow through bore 86 of manifold 50 and then into manifold race 78, but is captured by third annular groove 83. In the "fill position" the third annular groove 83 fluidly communicates with both the flow through bore 86 and flow output aperture 85. This allows sampling container A to be filled with the fluid with the flow returned to the fluid flow path. Two methods of actuation of the moveable chuck 75 within the manifold race 78 are seen and are termed mechanical and manual. The mechanical chuck operation mechanism 88 is seen in Fig. 7. It consists of the chuck stepper motor, 89 which is connected to and drives the lead screw 90 in both a clockwise and counterclockwise direction. The lead screw 90 exhibits a lead screw first end 91 attached to the chuck stepper motor 89 and a lead screw second end 92 which is externally threaded. Collar 93 exhibits internally threaded collar aperture 94. Lead screw second end 92 is threaded within collar aperture 94. Collar 93 is fixed to moveable chuck 75. When chuck stepper motor 89 rotates lead screw 90 the threaded connection of the collar 93 and lead screw 90 causes the collar to move on and off lead screw 90 causing, in turn, the moveable chuck 75 to move forward and backward within manifold race 78. Fig. 8 exhibits the manual
mechanism of actuating the moveable chuck 75. It consists of a lever 95. Lever 95 is rotatably connected to manifold 50. Lever link 96 is mutually connected to both lever 95 and collar 93 such that when lever 96 is depressed downward, moveable chuck 75 moves forward in manifold race 78, then engages stem valve 72 and the mechanism is now in "fill position." When lever 95 is raised, the mechanism is returned to the "bypass position." Returning to Fig. 8, input pressure gauge 98 is seen. Fluid, under pressure is received by input pressure gauge 98 and a pressure reading is obtainable. Input pressure gauge 98 is fluidly connected to flow meter 99 which determines rate of fluid flow, flow meter 99 is fluidly connected to flow input aperture 84 of manifold 35. Also seen in Fig. 8 is output pressure gauge 100 which is fluidly connected to the flow output aperture 85. Pressure readings of output flow may be obtained. Output pressure gauge 100 is then fluidly connected to an exhaust means or connected to the fluid flow path. Part of the manual embodiment is the spring loaded chuck stop 50. When a sampling container is removed from the manifold assembly 49 spring loaded chuck stop 50 rotates away from the manifold assembly blocking the path of moveable chuck 75 preventing moveable chuck 50 form moving out of bypass mode. When sampling container A is inserted the container body then moves spring loaded chuck stop to a position proximate to the manifold assembly 49 allowing movable chuck to lower and come into contact with sampling container. Returning to Fig. 1, it is seen that first pressure transducer 101 takes the place of input pressure gauge 98 in the manual embodiment, receiving fluid from input flow B. Pressure transducer 101 is fluidly connected with flow sensor 102 which, in turn, is fluidly connected with flow input aperture 84. Second pressure transducer 103 is fluidly connected with flow output aperture 85. Fluid passes from flow output aperture 85 through second pressure transducer 103 and into output flow C which represents an exhaust or return to the fluid source. Also seen in Fig. 1 is control housing 104. Control housing 104 houses a microcontroller 105. Turning now to Fig. 9, microcontroller 105 reads the state of sampling container ready sensor 106 to determine if the sampling container is the ready position. Sampling container ready sensor is a photointerrupter type. If there are no
sampling containers detected in the ready position, the microcontroller activates an alarm that alerts the user that the loader 24 is empty. Once the user loads sampling containers A into loader 24, the first sampling container drops directly into ready position and microcontroller 105 reads the state change of the sensor and deactivates the alarm. Microcontroller 105 next reads the state of the chuck position sensor 107. If the moveable chuck 75 is in the bypass position, a sampling container is then ready to be moved by the indexer 27 into the sample position. Microcontroller 105 signals the index motor driver to apply power to indexer stepper motor 46 through index stepper motor line 111 to apply power to the rotate indexer 27. Microcontroller 105 monitors the indexer position sensor 108. When microcontroller 105 reads a change in the state of the indexer position sensor 108 that indicates that the indexer has rotated the sampling container from the ready to the sample position, Microcontroller 105 signals the index motor driver to apply power to indexer stepper motor 46 to stop rotating indexer 27. Microcontroller 105 reads the state of the sampling position sensor 109 that detects if a sampling container is in the sample position. If so, the microcontroller signals the chuck stepper motor driver to apply power to chuck stepper motor 89 to rotate lead screw 90 and move moveable chuck 75 such that a fluid connection with sampling container is obtained. Microcontroller 105 monitors the chuck position sensor 107. When microcontroller 105 reads a change in the state of the chuck position sensor 107 that indicates that the chuck has moved the chuck from the bypass to the sample position, the microcontroller signals the chuck stepper motor driver to apply power to chuck stepper motor to stop rotating lead screw 90. Microcontroller 105 reads the state of the chuck position sensor 107. If moveable chuck 75 is in the sample position, microcontroller 105 signals the chuck stepper motor driver to apply power to chuck stepper motor 89 to rotate the lead screw 90 and move the chuck to the bypass position. Microcontroller 105 monitors the chuck position sensor. When the microcontroller reads a change in the state of the chuck position sensor 107 that indicates that the movable chuck 75 has moved from the sample to the bypass position, the microcontroller 105 signals chuck stepper motor driver to apply power to the chuck stepper motor to stop applying rotational force to lead screw 90.