WO2007021984A2 - Vibration monitoring - Google Patents
Vibration monitoring Download PDFInfo
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- WO2007021984A2 WO2007021984A2 PCT/US2006/031459 US2006031459W WO2007021984A2 WO 2007021984 A2 WO2007021984 A2 WO 2007021984A2 US 2006031459 W US2006031459 W US 2006031459W WO 2007021984 A2 WO2007021984 A2 WO 2007021984A2
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- WIPO (PCT)
- Prior art keywords
- coke
- drum
- data
- cutting
- signal
- Prior art date
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Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
- G01H1/00—Measuring characteristics of vibrations in solids by using direct conduction to the detector
- G01H1/12—Measuring characteristics of vibrations in solids by using direct conduction to the detector of longitudinal or not specified vibrations
- G01H1/14—Frequency
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B41/00—Safety devices, e.g. signalling or controlling devices for use in the discharge of coke
- C10B41/02—Safety devices, e.g. signalling or controlling devices for use in the discharge of coke for discharging coke
- C10B41/04—Safety devices, e.g. signalling or controlling devices for use in the discharge of coke for discharging coke by electrical means
Definitions
- the present invention relates to vibration monitoring devices and methods for using the same. Specifically, the present invention relates to determining the level of coke or coke byproducts inside a coker drum and to noninvasive signature recognition systems using accelerometers and mathematical algorithms for signature detection.
- Residual oil when processed in a delayed coker, is heated in a furnace to a temperature sufficient to cause destructive distillation in which a substantial portion of the residual oil is converted, or "cracked" to usable hydrocarbon products and the remainder yields petroleum coke, a material composed mostly of carbon.
- the delayed coking process involves heating the heavy hydrocarbon feed from a fractionation unit, then pumping the heated heavy feed into a large steel vessel commonly known as a coke drum.
- the unvaporized portion of the heated heavy feed settles out in the coke drum, where the combined effect of retention time and temperature causes the formation of coke.
- Vapors from the top of the coke vessel are returned to the base of the fractionation unit for further processing into desired light hydrocarbon products.
- Normal operating pressures in coke drums typically range from twenty-five to fifty p.s.i, and the feed input temperature may vary between 800°F and 1000°F.
- Coke drums are generally large, upright, cylindrical, metal vessels ninety to one-hundred feet in height, and twenty to thirty feet in diameter. Coke drums have a top head and a bottom portion fitted with a bottom head. Coke drums are usually present in pairs so that they can be operated alternately. Coke settles out and accumulates in a vessel until it is filled, at which time the heated feed is switched to the alternate empty coke drum. While one coke drum is being filled with heated residual oil, the other vessel is being cooled and purged of coke.
- Coke removal also known as decoking
- a quench step in which steam and then water are introduced into the coke filled vessel to complete the' recovery of volatile, light hydrocarbons and to cool the mass of coke.
- quench water is drained from the drum through piping to allow for safe unheading of the drum.
- the drum is then vented to atmospheric pressure when the bottom opening is unheaded, to permit removing coke. Once the unheading is complete, the coke in the drum is cut out of the drum by high pressure water jets.
- Decoking is accomplished at most plants using a hydraulic system comprised of a drill stem and drill bit that direct high pressure water into the coke bed.
- a rotating combination drill bit referred to as the cutting tool, is typically about twenty-two inches in diameter with several nozzles, and is mounted on the lower end of a long hollow drill stem about seven inches in diameter.
- the drill bit is lowered into the vessel, on the drill stem, through a flanged opening at the top of the vessel.
- a "bore hole” is drilled through the coke using the nozzles, which eject high pressure water at an angle between approximately zero and twenty-three degrees up from vertical. This creates a pilot bore hole, about two to three feet in diameter, for the coke to fall through.
- the drill bit is then mechanically switched to at least two horizontal nozzles in preparation for cutting the "cut" hole, which extends to the full drum diameter.
- the nozzles shoot jets of water horizontally outwards, rotating slowly with the drill rod, and those jets cut the coke into pieces, which fall out the open bottom of the vessel, into a chute that directs the coke to a receiving area.
- the drill rod is then withdrawn out the flanged opening at the top of the vessel. Finally, the top and bottom of the vessel are closed by replacing the head units, flanges or other closure devices employed on the vessel unit. The vessel is then clean and ready for the next filling cycle with the heavy hydrocarbon feed.
- the drill stem In some coke-cutting systems, after the boring hole is made, the drill stem must be removed from the coke drum and reset to the cutting mode. This takes time, is inconvenient and is potentially hazardous. In other systems the modes are automatically switched.
- the present invention relates to systems for remotely monitoring the status of a cutting tool during delayed decoker unit operation, and systems for remotely monitoring the level of coke or foam in a drum during the coking process.
- the former systems relate to systems for allowing operators involved in removing solid carbonaceous residue, referred to as "coke,” from large cylindrical vessels called coke drums to determine the status of the decoking operation from a remote location.
- the latter systems relate to systems for allowing operators involved in monitoring coke and/or foam levels in the drum during coking to more accurately and efficiently prevent foamovers and disastrous results resulting from coke levels from rising too high.
- the monitoring systems may be utilized to measure bearing wear. In a preferred embodiment, bearing deterioration can be detected before failure occurs on critical rotating machinery. In some embodiments, the monitoring systems may be used for detecting coke clogging the furnace pipes that are heating the petroleum before going into the coke drum. In some embodiments, the monitoring systems may be used to monitor/detect the movement of fluids/gas in pipes.
- Preferred embodiments relate to systems which utilize vibration monitoring systems to receive useful information regarding the decoking or coking operation. Some embodiments relate to systems that use acoustical monitoring systems, temperature monitoring systems, and/or pressure monitoring systems to receive such useful information.
- Preferred embodiments of the invention relate to a system that allows an operator to remotely detect the status of a cutting tool while cutting coke within a coke drum, and to remotely detect when the tool has switched between the "boring" and the “cutting” modes, while cutting coke within a coke drum reliably, and without raising the drill bit out of the coke drum for mechanical alteration or inspection.
- Preferred embodiments of the invention also relate to a system that allows an operator to remotely measure coke or foam levels within a coke drum via use of vertically positioned accelerometers.
- Preferred embodiments provide a visual display which indicates the status of the decoking or coking operation.
- a visual display allows the operator to determine what mode the cutting tool is presently in.
- a visual display includes display of a signal run through an FFT algorithm.
- vibrational data is utilized to provide information regarding the mechanical status of the cutting tool of a delayed decoker unit; in some embodiments, the data is utilized to provide information regarding the coke and/or foam levels with respect to the top of the drum.
- Preferred embodiments utilize a vibration monitoring device comprising an accelerometer.
- the vibration monitoring device may be attached to one or more locations in the delayed decoker unit.
- some of these measurements are relayed by a wireless device to a network access point and/or to a repeater which relays the signal from the wireless device to network access points.
- the data generated by the vibration monitoring devices is transmitted via a wired connection to a computer system without the use of a wireless device.
- the data received at the network access point is relayed to a computer system where the vibration data may be monitored and utilized.
- the data received from the vibration monitoring device is converted by software applications to a useable form.
- data is run through a fast Fourier transform (“FFT"), which converts the data into an FFT fingerprint that may be utilized as a signature associated with the different modes of operation during a decoking operation.
- FFT fast Fourier transform
- Some embodiments comprise a vibration monitoring device comprising: an accelerometer, wherein the accelerometer provides an output signal; at least one network access point which receives the output from the vibration monitoring device; software for converting the raw data from the output signal into a useable wave form; and a display apparatus which either informs an operator of the status of the cutting tool in a coke drum, or informs an operator of the levels of coke and/or foam in the drum during coking.
- Figure IA shows a representative computer-based system in accordance with some embodiments of the present invention
- Figure IB illustrates a basic refinery flow diagram
- Figures 2 A and 2B illustrate alternative embodiments of an operational layout utilized to assess the status of the cutting tool during decoking operation
- Figure 3 illustrates an embodiment of a coke drum with a partially lowered drill stem
- Figure 4 illustrates an embodiment of a coke drum with a fully raised drill stem
- Figure 5 illustrates an embodiment showing two accelerometers placed on a stationary pipe that supplies water to a drill
- a representative system for implementing the invention may include computer device 100, which may be a general-purpose or special-purpose computer.
- computer device 100 may be a personal computer, a notebook computer, a personal digital assistant ("PDA") or other hand-held electronic device, a workstation, a minicomputer, a mainframe, a supercomputer, a multi-processor system, a network computer, a processor-based electronic device, etc.
- PDA personal digital assistant
- the term "computer device” herein is used generally and may refer either to a single computer device or to multiple computer devices, whether stand-alone or networked.
- Computer device 100 may include a system bus 120, which may be configured to connect various components of the computer device 100 and may enable data to be exchanged between the components.
- System bus 120 may include one of a variety of bus structures including a memory bus or memory controller, a peripheral bus, or a local bus that uses any of a variety of bus architectures.
- Typical components connected by system bus 120 may include a processing system 140 and memory 160.
- Other components may include one or more mass storage device interfaces 180, input interfaces 200, output interfaces 220, and/or network interfaces 240.
- Processing system 140 may include one or more processors, such as a central processor and optionally one or more other processors designed to perform a particular function or task. It is typically processing system 140 that executes computer-readable instructions found in memory 160, which in turn may be embodied in computer-readable media such as RAM or ROM media, magnetic hard disks, removable magnetic disks, magnetic cassettes, optical disks, etc.
- Memory 160 may be embodied in one or more computer-readable media that may be configured to include thereon data or instructions for manipulating data, and may be accessed by processing system 140 through system bus 120.
- Memory 160 may include, for example, ROM 280, used to permanently store information, and/or RAM 300, used to temporarily store information.
- ROM 280 may include a basic input/output system ("BIOS") having one or more routines that are used to establish communication, such as during start-up of computer device 100.
- BIOS basic input/output system
- RAM 300 may include one or more program modules, such as one or more operating systems, software applications, and/or program data.
- One or more mass storage device interfaces 180 may be used to connect one or more mass storage devices 260 to system bus 120.
- the mass storage devices 260 may be incorporated into or may be peripheral to computer device 100 and allow computer device 100 to retain large amounts of data.
- one or more of the mass storage devices 260 may be removable from computer device 100. Examples of mass storage devices include hard disk drives, magnetic disk drives, tape drives, and optical disk drives.
- a mass storage device 260 may read from and/or write to a magnetic hard disk, a removable magnetic disk, a magnetic cassette, an optical disk, or other computer-readable medium.
- Mass storage devices 260 and their corresponding computer-readable media may provide nonvolatile storage of data and/or executable instructions that may include one or more program modules such as an operating system, one or more software applications, program modules, program data, etc. Such executable instructions are examples of means for implementing steps or methods disclosed herein.
- One or more input interfaces 200 may be employed to enable a user to enter data and/or instructions to computer device 100 through one or more corresponding input devices 320. Examples of such input devices include but are not limited to: a keyboard, a mouse, a trackball, a touch screen, a light pen, a stylus or other pointing device, a microphone, a joystick, a game pad, a satellite dish, a scanner, a camcorder, a digital camera, etc. Examples of input interfaces 200 that may be used to connect the input devices 320 to the system bus 120 include a serial port, a parallel port, a game port, a universal serial bus (“USB”) port, a firewire (IEEE 1394), etc
- One or more output interfaces 220 may be employed to connect one or more corresponding output devices 340 to system bus 120.
- Examples of output devices 340 include a monitor or display screen, a speaker, a printer, etc.
- a particular output device 340 may be integrated with or be peripheral to computer device 100.
- Examples of output interfaces 220 include a video adapter, an audio adapter, a parallel port, etc.
- One or more network interfaces 240 may enable computer device 100 to exchange information with one or more other local or remote computer devices, illustrated generally at 360, via a network 380 that may include wired and/or wireless connections.
- network interfaces 240 include a network adapter for connection to a local area network ("LAN") or a modem, wireless link, or other adapter for connection to a wide area network (“WAN”), such as the Internet.
- the network interface 240 may be incorporated with or peripheral to computer device 100.
- accessible program modules or portions thereof may be stored in a remote memory storage device.
- computer device 100 may participate in a distributed computing environment, where functions or tasks are performed by a plurality of networked computer devices.
- Figure IB illustrates an embodiment of a refinery operation 2.
- high boiling petroleum residues are fed to one or more coke drums 5 where they are thermally cracked into light products and a solid residue—petroleum coke.
- the coke drums 5 are typically large cylindrical vessels having a top head and a conical bottom portion fitted with a bottom head.
- the fundamental goal of coking is the thermal cracking of very high boiling point petroleum residues into lighter fuel fractions.
- Coke is a byproduct of the process. Delayed coking is an endothermic reaction with a furnace 7 supplying the necessary heat to complete the coking reaction in a drum 5.
- the process is extremely temperature-sensitive with the varying temperatures producing varying types of coke. For example, if the temperature is too low, the coking reaction does not proceed far enough and pitch or soft coke formation occurs. If the temperature is too high, the coke formed generally is very hard and difficult to remove from the drum with hydraulic decoking equipment. Higher temperatures also increase the risk of coking in the furnace tubes or the transfer line. As stated, delayed coking is a thermal cracking process used in petroleum refineries to upgrade and convert petroleum residuum into liquid and gas product streams leaving behind a solid concentrated carbon material, or coke. Furnace 7 is used in the process to reach thermal cracking temperatures, which range upwards of 1,000° F.
- coking of the feed material is thereby "delayed” until it reaches large coking drums 5 downstream of the heater.
- on-line drum 6 or to an off-line drum 4
- reference herein to one or more coke drums in general shall be indicated by the number 5.
- coke In a typical petroleum refinery process, several different physical structures of petroleum coke may be produced. These are, namely, shot coke, sponge coke, and/or needle coke (hereinafter collectively referred to as "coke"), and are each distinguished by their physical structures and chemical properties. These physical structures and chemical properties also serve to determine the end use of the material.
- coke shot coke, sponge coke, and/or needle coke
- coke Several uses are available for manufactured coke, some of which include use as fuel for burning, use as calcined coke in the aluminum, chemical, or steel industries, or use as gasified coke that is able to produce steam, electricity, or gas feedstock for the petrochemicals industry.
- a delayed coker feed originates from a supply of crude oil 9, travels through a series of process members, and finally empties into one of the coke drums 5 used to manufacture coke.
- the delayed coking process typically comprises a batch- continuous process, which means that the process is ongoing or continuous as the feed stream coming from the furnace 7 alternates filling between the two or more coke drums 5.
- the process is ongoing or continuous as the feed stream coming from the furnace 7 alternates filling between the two or more coke drums 5.
- the other is being stripped, cooled, decoked, and prepared to receive another batch.
- this has proven to be an extremely time and labor intensive process, with each batch in the batch-continuous process taking approximately 12 to 20 hours to complete.
- hot oil or "resid” as it is commonly referred to, from the tube furnace 7 is fed into one of the coke drums 5 in the system.
- the oil is extremely hot and produces hot vapors that condense on the colder walls of the coke drum 5.
- a large amount of liquid runs down the sides of the drum 5 into a boiling turbulent pool at the bottom.
- the hot resid and the condensing vapors cause the coke drum walls to heat. This naturally, in turn, causes the resid to produce less and less of the condensing vapors, which ultimately causes the liquid at the bottom of the coke drum 5 to start to heat up to coking temperatures.
- the bottom flange (typically a 7-foot- diameter flange) is unbolted and removed. This process is commonly known as "de- heading" because it removes or breaks free the head of coke that accumulates at the surface of the flange.
- the coke is removed from the drum 5 by drilling a pilot hole from top to bottom of the coke bed using high pressure water jets. Following this, the main body of coke left in the coke drum 5 is cut into fragments which fall out the bottom and into a collection bin, such as a bin on a rail cart, etc. The coke is then dewatered, crushed and sent to coke storage or a loading facility.
- the present invention is intended to cover the use of vibration monitoring systems throughout a delayed coker unit system, and the devices of the present invention may be utilized to monitor vibration at any point in the delayed coker unit operation, one ordinarily skilled in the art will recognize that the invention as explained and described herein may also be designed and used in other environments where monitoring vibration may provide useful data regarding mechanical operations.
- Some embodiments relate to systems that use acoustical monitoring systems to receive useful information regarding the decoking operation. Some embodiments relate to systems that use temperature monitoring systems to receive useful information regarding the decoking operation. Some embodiments relate to systems that use pressure monitoring systems to receive useful information regarding the decoking operation. While the majority of this discussion focuses primarily on the use of vibration monitoring systems as an exemplary embodiment of the present invention, the following description is equally germane to the use of acoustical, temperature, and/or pressure monitoring systems. It is contemplated that the use of acoustical, temperature, and/or pressure monitoring systems could be used to replace the vibration monitoring systems as described herein, or be used in combination with the vibration monitoring systems as described herein. Accordingly, the following discussion is not limited to vibration monitoring systems.
- vibration monitoring systems are a non-limiting example of preferred embodiments of the present invention.
- the discussion herein relates specifically to these manufacturing areas. It is foreseeable, however, that the present invention may be adapted for use in other manufacturing processes that produce various elements or byproducts other than coke. Such other processes should thus be considered within the scope of the invention.
- a vibration monitoring system is shown for monitoring during the delayed coker unit operation.
- a decoking system is depicted, the decoking system including a drill stem 8 and a cutting head 14 for cutting coke inside a drum 5.
- Cutting head 14 further comprises nozzles for boring 12 and nozzles for cutting 10. Nozzles for boring 12 are generally downward-facing, and nozzles for cutting 10 are generally horizontally oriented.
- the vibration monitoring system comprises a sensor or transducer (preferably a vibration sensor such as an accelerometer) 16 coupled to at least one position within the delayed coker unit system and operatively coupled to a computer system 21.
- a sensor or transducer preferably a vibration sensor such as an accelerometer
- One or more accelerometers 16 may be placed on a component of the coker unit system to measure vibrations of the respective component;
- Figure 2 A shows two accelerometers placed thereon.
- accelerometers 16 may be placed at any position or location on the coker unit system.
- Figure 2 A shows one accelerometer 16 placed on the outside of the drum 5, and one accelerometer 16 placed on the drill stem 8 (note that the accelerometers 16 may be placed on any location on the drum 5 or the drill stem 8 and are not limited to the specific locations shown).
- Figure 2B shows accelerometers 16 placed on a first fluid line 16, a water or fluid pump 50, and a second fluid line 16 wherein the coker unit system shown includes a fluid reservoir 52 (again, accelerometer 16 placement is
- the accelerometers 16 may also be placed in any orientation within the coker unit system.
- Figure 2A shows the accelerometer 16 on the drill stem 8 being placed in a vertical orientation, and the accelerometer 16 on the outside of the coke drum 5 in a horizontal orientation.
- the accelerometers 16 of the present invention may be attached to the drill stem 8, for example, so as to coincide with the drill stem's radial axis, rotational axis, longitudinal axis, horizontal axis, and/or vertical axis. Accordingly, the type of data acquired ⁇ from an accelerometer 16 will depend upon the placement and the orientation of the accelerometer 16.
- the sensors or accelerometers 16 preferably collect vibration data from one or more points in the coker unit system, and the data is transmitted to the computer system 21.
- the accelerometer 16 may be used to measure vibration in one or more axes.
- the accelerometer 16 measures vibration in one axis such as a horizontal or vertical axis.
- multiple accelerometers 16 may be used at a single location to measure vibration in multiple axes.
- the accelerometer 16 measures vibration in two or more axes.
- one accelerometer 16 may be used to measure vibration in a horizontal axis
- another accelerometer 16 may be used to measure vibration in a vertical axis.
- computer system 21 may include one or more of the following: an active repeater 18, a network access point 20, a local computer device, a remote computer device 24, and/or another computer device or other component 23. It is contemplated that connections between components within the computer system 21, or to and from the computer system 21, may comprise wired or wireless connections, regardless of what the Figures illustrate in the depicted embodiments.
- the accelerometer 16 measures vibration associated with the operational status of the cutting tool 14 (for example, whether the cutting tool is in cutting, boring, or ramping modes—ramping being the process of switching from boring to cutting or vice versa) in a given coke drum 5.
- the accelerometer 16 will measure vibrations that are produced as a result of the boring process.
- the data received by the accelerometer 16 during the boring process may be transmitted wirelessly to active repeaters 18, directly to a network access point 20, or to another computer device 23 in the computer system 21.
- Wireless repeaters 18 preferably relay data to network access points 20, but may relay data to any computer device 23 in the computer system 21.
- the data produced by the accelerometer 16 is transmitted to a component in the computer system 21 and may be stored in a database.
- the data may be amplified, exported to a Fast Fourier Transform ("FFT"), calibrated, and/or transformed.
- FFT Fast Fourier Transform
- the resulting wave form may then be used to create a FFT fingerprint. Accordingly, as the drill stem 8 is in a boring mode, data created by the vibrational nature of boring is translated into a FFT fingerprint that represents and thereby identifies the boring process for a given coke drum. The same process can take place with respect to the cutting and ramping modes. It is contemplated by the present invention that each individual coke drum may have a unique fingerprint.
- the present invention contemplates using a software which is capable of identifying the unique fingerprint of a given coke drum 5, and which is capable of producing and/or interpreting modified data (for example, an FFT fingerprint) that would allow an operator to readily ascertain that the cutting tool was presently boring, cutting, or ramping.
- modified data for example, an FFT fingerprint
- the run mode signature of a cutting tool 14 in a cutting mode would produce a run mode signature that, when compared with the birth certificate, would allow an operator at a remote location to reliably and repeatedly identify that the cutting tool 14 was in a cutting mode.
- the computer system 21 collects and assembles data, allowing the computer system 21 and/or operator to recognize by the data being received from one or more accelerometers 16, whether a delayed coker unit is cutting, boring and/or ramping.
- the accelerometer 16 receives data relating to the vibration associated with a particular cutting tool 14 which is in the cutting mode, the amplitude and frequency of the vibration is measured by the accelerometer 16 in one or more axes, and such data is transmitted through the computer system 21 to a central processing unit where the data is converted by the FFT into an FFT fingerprint that correlates with the cutting mode of a particular cutting tool 14.
- averaging and correlating fundamental signatures are also used. Accordingly, for any delayed coker unit operation, the software of the present invention will receive data from an accelerometer 16 associated with boring, cutting or ramping and will identify FFT fingerprints which correspond to the boring, cutting and/or ramping modes of a particular drill.
- the accelerometer 16 may be coupled to a portion of the delayed coker unit operation by magnetic coupling. In other embodiments, the accelerometer 16 may be bolted to the apparatus to be measured. In other embodiments, the accelerometer 16 may be placed in a "saddle" and strapped to the apparatus for which vibration is to be measured. In a non- limiting example, an accelerometer 16 may be placed in a "saddle” and strapped with stainless steel straps to the top of the drill stem 8, securing the accelerometer 16 to the drill stem 8 in a desired orientation and in a fashion that preserves the integrity of the data acquiring process by ensuring consistent positioning and contact with the drill stem 8.
- Figure 3 illustrates an on-line coke drum 6 and an off-line coke drum 4, wherein the off-line coke drum 4 has a drill stem 8 in a partially lowered position.
- the cutting tool 14 of Figure 3 is depicted as ejecting fluid in a horizontal direction from the drill head. Accordingly, the drill head depicted in Figure 3 is in a cutting mode.
- Figure 3 additionally depicts the bore hole 13 which has already been cut through the coke which allows debris to fall through to a chute below the coke drum 5.
- Figure 3 illustrates additional possible placements for accelerometers 16 in the coker unit system. The invention contemplates attaching one or more accelerometers 16 to other positions in the delayed coker unit operation to measure the vibrational output of the cutting and boring modes of the drill.
- accelerometers 16 are redundantly placed and utilized in more than one position on a drill stem.
- multiple accelerometers 16 may be attached to one drill stem to redundantly feed data to the computer operating systems 21 of the present invention for analysis.
- multiple accelerometers 16 may be attached to the first pipe
- the accelerometer 16 may further comprise an electric sensor, a temperature sensor, a digital signal processor, data memory, a wireless transceiver, internal battery, and/or an internal antenna.
- the accelerometer 16 may be preferably powered with an internal lithium battery wherein the solid state accelerometer 16- collects and transmits vibration data securely by a wireless link.
- the data collection parameters may be configured from a network Windows® computer.
- the accelerometer 16 is completely wireless. In other embodiments, the accelerometer 16 is wired to a computer system 21.
- the accelerometer 16 is vibration and/or temperature sensing. In some embodiments of the invention, the accelerometer 16 measures or has a 0.5 Hz to 10 kHz frequency response with 1 Hz to 40 kHz sampling speed. In other embodiments of the invention, the accelerometer 16 measures or has a frequency response below 0.5 Hz 1. In other embodiments, the accelerometer 16 measures or has a frequency response above 10 kHz. In a non-limiting example, the accelerometer 16 has a frequency response at .01, 0.1, 0.2, 0.3, 0.4, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, H 5 12, 13, 14, 15, 20, 30, 50, 60, 70, 80, 90 and/or 100 kHz.
- the accelerometer may transmit data to 300 ft, 400 ft, 500 ft, 600 ft, 700 ft, 800 ft, 900 ft, 1000 ft, 2000 ft, 3000 ft, 4000 ft, 5000 ft, 10000 ft and/or more than 10000 ft.
- the accelerometer 16 has an easily replaceable battery with a life span that lasts for more than two (2) years.
- FIG. 5 depicts two accelerometers 16 positioned on a water or fluid pipe 54 that may represent either pipe 54 or pipe 56 shown in the previous Figures.
- more than one accelerometer 16 may be utilized to measure vibrational data at any given point in the operation.
- the accelerometers 16 are coupled to a mount 17 and connected to wires 15 that connect them to a computer operating system 21 so that the accelerometers 16 can transmit data to a computer for analysis.
- various accelerometers 16 may be oriented in different axes to acquire multiple data sets in order to confirm the operational status of a cutting tool 14 in a delayed coker operation.
- one accelerometer 16 may be placed to measure vibration in a horizontal axis while another accelerometer 16 may be placed to measure vibration in a vertical axis. Accelerometers 16 as depicted in Figure 5 may be positioned likewise throughout the delayed coker unit operation.
- Figure 6 depicts a display screen 70 that may be displayed on a computer monitor and utilized by an operator, technician or engineer to monitor and/or analyze whether a cutting tool 14 is cutting, drilling, or ramping during delayed coker unit operation.
- the display 70 may indicate what mode—ramping, cutting, or drilling ⁇ the drill is in at a current time and may indicate the orientation axes from which the data is being received.
- the orientation axes here being measured is vertical 58.
- data related to the real time frequency in Hertz for a particular accelerometer 16 may be displayed 60.
- the real time frequency may be utilized to analyze the frequency associated with drilling, cutting, ramping, or other processes in delayed coker unit operations, including the vibration associated with the water pump 50.
- the drill mode history 62 may be displayed allowing an operator or other person to analyze the history of drilling, ramping, or cutting that has occurred over a period or minutes, hours, days, weeks, years or longer.
- the present invention contemplates allowing users to access and productively use and modify other data sets. As depicted in
- a display 70 may also contain a simple indicator light 64 which would allow an operator to determine a current drill mode, including whether the drill is cutting, ramping, or drilling.
- a vibration monitoring system for monitoring the vibration at any point in the delayed coker unit operation.
- some embodiments relate to continuous monitoring and detection of reduced material thickness in elbows and pipes that are carrying high temperature and/or high pressure fluids or gases.
- the monitoring system may be used for detecting coke clogging the furnace pipes that are heating the petroleum before going into the coke drum. In some embodiments, the monitoring system may be used to monitor/detect the movement of fluids and/or gas in pipes.
- other characteristics such as heat, pressure, sound, and/or some other quantifiable characteristic may be monitored instead of or as well as vibration characteristics.
- the embodiments have been discussed in terms of using sensors or accelerometers 16 to determine the mode of the cutting tool 14.
- Some embodiments of the present invention also contemplate similarly using sensors or accelerometers 16 to detect vibrations in the coker unit system during the coking process so as to determine coke and foam levels inside the drum 5 so as to prevent undesirable drum outage and promote more efficient operation of the coking unit.
- Figure 8 shows a display 90 of four different signatures, 92, 94, 96, and 98 corresponding, respectively, to 12" fill, 18" fill, 24" fill, and 26" fill (top).
- Embodiments of the present invention that involve the use of sensors or accelerometers 16 to determine the coke level in the drum 5 are implemented similarly to the embodiments of the present invention utilized to determine cutting tool 14 status, and the previous discussion of the various embodiments may be applied to embodiments used for coke or foam level measurement.
- Vibration monitoring systems for monitoring coke or foam levels preferably measure the levels with respect to the top of the drum 5 and include one or more sensors or accelerometers 16 coupled to a coking system and a computer system 21.
- the sensors 16 used to determine coke or foam level status may be placed in any position or location in the coking system, in any orientation, and corresponding to various axes.
- the sensors 16 in the coke or foam level measuring system are coupled to the outside of the drum 5.
- the sensors or accelerometers 16 are placed vertically on a drum 5. More particularly, some embodiments contemplate four accelerators 16 placed vertically in a line on a drum 5 in a manner similar to that shown in the simulation of Figure 7. What is claimed:
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002619524A CA2619524A1 (en) | 2005-08-12 | 2006-08-11 | Vibration monitoring |
CN200680037542.XA CN101611293B (en) | 2005-08-12 | 2006-08-11 | Vibration monitoring |
JP2008526247A JP2009505078A (en) | 2005-08-12 | 2006-08-11 | Vibration monitoring |
BRPI0614582-5A BRPI0614582A2 (en) | 2005-08-12 | 2006-08-11 | vibration monitoring |
EP06801308.5A EP1920225A4 (en) | 2005-08-12 | 2006-08-11 | Vibration monitoring |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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US70792905P | 2005-08-12 | 2005-08-12 | |
US60/707,929 | 2005-08-12 | ||
US11/502,342 US20070038393A1 (en) | 2005-08-12 | 2006-08-10 | Vibration monitoring |
US11/502,342 | 2006-08-10 |
Publications (2)
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WO2007021984A2 true WO2007021984A2 (en) | 2007-02-22 |
WO2007021984A3 WO2007021984A3 (en) | 2009-05-14 |
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Application Number | Title | Priority Date | Filing Date |
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PCT/US2006/031459 WO2007021984A2 (en) | 2005-08-12 | 2006-08-11 | Vibration monitoring |
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US (1) | US20070038393A1 (en) |
EP (1) | EP1920225A4 (en) |
JP (1) | JP2009505078A (en) |
CN (1) | CN101611293B (en) |
BR (1) | BRPI0614582A2 (en) |
CA (1) | CA2619524A1 (en) |
RU (1) | RU2416784C2 (en) |
WO (1) | WO2007021984A2 (en) |
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- 2006-08-11 JP JP2008526247A patent/JP2009505078A/en active Pending
- 2006-08-11 RU RU2008109210/28A patent/RU2416784C2/en not_active IP Right Cessation
- 2006-08-11 BR BRPI0614582-5A patent/BRPI0614582A2/en not_active IP Right Cessation
- 2006-08-11 CN CN200680037542.XA patent/CN101611293B/en not_active Expired - Fee Related
- 2006-08-11 WO PCT/US2006/031459 patent/WO2007021984A2/en active Application Filing
- 2006-08-11 EP EP06801308.5A patent/EP1920225A4/en not_active Withdrawn
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Cited By (1)
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US9244042B2 (en) | 2013-07-31 | 2016-01-26 | General Electric Company | Vibration condition monitoring system and methods |
Also Published As
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RU2416784C2 (en) | 2011-04-20 |
CN101611293A (en) | 2009-12-23 |
JP2009505078A (en) | 2009-02-05 |
EP1920225A2 (en) | 2008-05-14 |
US20070038393A1 (en) | 2007-02-15 |
CA2619524A1 (en) | 2007-02-22 |
CN101611293B (en) | 2014-02-19 |
BRPI0614582A2 (en) | 2011-04-05 |
EP1920225A4 (en) | 2014-04-02 |
RU2008109210A (en) | 2009-09-20 |
WO2007021984A3 (en) | 2009-05-14 |
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