Abstract: An apparatus for building an axially symmetrical workpiece of desired geometry by deposit welding which uses a welding head 18 for depositing molten weld material 14 and a rotatable, reusable preform 10 which translates with the welding head 18. The reusable preform 10 is provided with means for varying its shape 22 to minimize the weight of the preform 10. The rotatable, reusable preform 10 forms, supports and cools the deposited molten weld material puddle 14 while the weld material is solidifying thereby eliminating the need for a conventional consumable preform.

Abstract: A fiber optic microbend sensor with a braided arrangement of multiple optical fibers (or fibers and fillers) 16 such that the length dependent microbending losses result from the interaction of the fibers 10 themselves (or the fibers and fillers) without the need for additional external structures such as corrugated plates 12, 14. A plurality of fibers with at least one of the fibers being an optical fiber 10 are braided together into an interwoven strand 16 to produce the fiber optic microbend sensor. The spatial bend frequency of the braid 16 corresponds to the optimum microbend frequency for the fiber 10.

Abstract: An apparatus and method for separating unevaporated droplets from a hot gas stream such as a flue gas. The apparatus referred to as a droplet impingement device is designed to enable a modified electrostatic precipitator to efficiently remove sulfur dioxide and particulates. The droplet impingement device removes the unevaporated alkaline droplets and provides the first stage of flow correction necessary in reducing velocity mal-distribution.

Abstract: A method and apparatus for controlling superheater outlet temperature of a steam generator utilizes a feed-forward control signal to control a spray attemperator. The feed-forward control signal is developed as a difference between a selected flow rate for steam required by a turbine operated by the steam generator, and a measured flow rate of steam from a steam drum above the steam generator.

Abstract: A method and system are provided for validating monitoring instruments whereby the validating solution contains other analytes normally present in an industrial liquid. The solution is checked for water purity prior to addition of other analytes and is checked for homogeneity after mixing with analytes.

Abstract: An automatic system for sequentially controlling and monitoring for detecting at least two discrete devices used by a batch process. To accomplish this a plurality of device driver blocks are connected on a one to one basis with a plurality of discrete devices. Each driver block receives signals from the discrete device as to its status and sends a control signal to the device to indicate the operation of same. The device driver blocks are monitored by a monitoring function block which establishes status signals to a sequence controller which in turns controls the individual device driver blocks according to the requirements of the batch process.

Abstract: An overcurrent protection system for AC motor control systems which provides a separate overcurrent shut down mechanism for each phase of the AC power used in an AC motor. These separate phase shutdown mechanisms provide protection for minor overcurrent conditions without shutting down the entire motor control system. The overcurrent protection system also provides a mechanical feedback apparatus for totally shutting down the motor control system only in a severe overcurrent condition.

Abstract: Jaws of microbend sensor have corrugations and hold an optical fiber therebetween. One jaw is movable with respect to the other for squeezing and bending the optical fiber between the corrugations. The amount of bending modulates light passing through the fiber which can be a measurement of the relative movement between the jaws. The relative movement can be a mechanical input of a microbend sensor for sensing a process variable, for example a flow rate in a vortex shedding flowmeter. According to the invention, the corrugations of each jaw comprise flat areas lying in a common plane for each jaw extending perpendicularly to the displacement direction of the jaws, and projections extending parallel to the displacement direction of the jaws and positioned between the flat areas. The projections of each jaw are positioned to face the flat area of the other jaw with the optical fiber being held between the projections.

Abstract: A method and apparatus for controlling emissions of a coal fired boiler includes a hot catalytic baghouse for receiving flue gases along with injected ammonia and alkali. The alkali and ammonia react with SO.sub.x and NO.sub.x in the flue gas while particulates in the flue gas are trapped in the baghouse. The still hot but clean flue gases are supplied from the baghouse to a heat pipe air heater which also receives combustion air to be preheated before it is supplied to the boiler for combustion with coal to produce the flue gases.

Abstract: An automatic system for the control and fault detection of discrete devices used by a batch process which eliminates extensive function block configurations and system loading in process control systems by providing an assembly to monitor the discrete devices and means to match the monitoring assembly to the discrete devices and controlling the monitoring assembly.

Abstract: A surge control system (16) is provided for a compressor (14) which anticipates the actual surge condition and initiates anti-surge protection in proportion to the magnitude of the anticipated surge condition. This is done by providing a feed foward signal (20) to a summing station (48) along with a normally generated surge control line point (44) to offset this point (44) by an amount determined by the feed forward signal (20). This offset point (50) is used as an input to a controller for controlling the bypass valve (28) in a bypass loop (30) around the compressor (14).

Abstract: An accelerometer comprises a base and cover together defining a chamber which receives an inertial mass. A diaphragm carries the inertial mass and is bolted between the base and the cover. The inertial mass and the base have facing corrugated surfaces with offset teeth in each of the corrugated surfaces. An optical fiber is clamped between the teeth and extends between the corrugated surfaces. The intensity of light passing through the fiber changes with movement of the inertial mass with respect to the base. The inertial mass moves through the resiliency of the diaphragm, when the base is subjected to accelerations, such as those caused by vibrations. A reference optical fiber may also extend through the chamber above the inertial mass. The same light is supplied to both fibers and the intensity of light from both fibers is subtracted to leave the variation in intensity due to bending of the sensing optical fiber.

Abstract: Steel tubulars are deposited into an insulated container shortly after the steel tubulars are formed in a seamless hot rolling machine. The tubulars are covered by an insulating blanket and allowed to cool at a selected rate to form desired microstructure in the steel of the tubulars. No external energy supply or controls are necessary to achieve the desired microstructure. The side walls of the container taper outwardly and are made of a sandwiched structure, having spaced apart sheet metal members with a layer of insulation there between. The end walls are similarly constructed. The bottom of the container is lined with granular insulating material to cushion the shock of the tubulars being dropped into the container and to insulate the bottom of the container. Stainless steel mesh is used as a sling and embraces the tubulars to facilitate removing the tubulars from the container after the desired amount of cooling.

Abstract: A method and apparatus for locating a leak which produces a continuous acoustic emission having background noise and spikes, comprises continuously monitoring the acoustic emissions using spaced apart detectors which produce signals having background noise and spikes corresponding to those of the continuous acoustic emissions. The spikes of one signal are offset in time with respect to the spikes of the other signal, which corresponds to the difference in travel time of the acoustic signals to each of the detectors. By measuring the offset between the spikes, the relative position of the acoustic emission, and thus the relative position of the leak, can be determined with respect to the position of the detectors. To facilitate separating the spikes from the background noise, a floating detection threshold value is applied to the signals for eliminating the background noise.

Abstract: A method for inspecting the surface of a workpiece for the presence of flaws using a ferrofluid as a penetrant which is applied to the surface of the workpiece and then scanning the surface of the workpiece with electrical detection means placed adjacent to the surface for providing responses indicative of the presence of flaws in the surface of the workpiece. If desired, a magnetic field can be used to induce the flow of the ferrofluid into any flaws prior to inspection, and for post-inspection cleanup as well. By the use of a ferrofluid, the sensitivity of the electrical detection means, advantageously of the eddy current type, is enhanced in typical applications, and also allows the use of an eddy current probe to inspect workpieces made of nonconductive and/or nonferromagnetic materials.

Abstract: An apparatus and method for sampling a gas containing a reactive particulate solid phase flowing through a duct and for communicating a representative sample to a gas analyzer. A sample probe sheath 32 with an angular opening 34 extends vertically into a sample gas duct 30. The angular opening 34 is opposite the gas flow. A gas sampling probe 36 concentrically located within sheath 32 along with calibration probe 40 partly extend in the sheath 32. Calibration probe 40 extends further in the sheath 32 than gas sampling probe 36 for purging the probe sheath area with a calibration gas during calibration.

Abstract: A design and analysis system uses an engineering data base in which Finite Element Models of structural components, such as offshore structures are stored. The data base is controlled by a network type database management system to provide input of "finite element" model data into the database from an external design engineering source and output of model data to non-design engineering sources with all sources having concurrent access to the database.

Abstract: A method and apparatus for automatically cooling a workpiece being manufactured by shape melting whereby a gas/liquid coolant mixture is pumped onto the external surface of the part to be cooled. Temperature and pressure data is fed to a computer control system which regulates the flow of the gas and liquid coolant mixtures. A suction device which enshrouds the spray head extracts the heated and vaporized fluid from the vicinity of the surface. The apparatus may be provided with multiple spray heads which comprise the cooling head and have the ability to control the total rate at which coolant flows through the device by individually controlling coolant and gas flow through each of the multiple spray heads. If more cooling is desired, the computer control system activates more nozzles for flow, or it increases flow rate through already activated nozzles.

Abstract: Formation of continuous grooves on the internal surface of a tube shell, in a single continuous cold drawing step, in which the tube shell is first sunk in a die over a reduced diameter cylindrical mandrel portion so that the diameter of the inner surface of the tube shell is reduced to a dimension below the base of the grooves of a grooved plug portion of the mandrel thereby retarding longitudinal movement of a portion of the reduced internal surface of the sunk tube shell at a plurality of circumferentially spaced intervals to effect formation of longitudinally continuous shallow grooves. The mandrel is allowed to rotate if it is desirable to facilitate the formation of spiral grooves on the tube inner surface.

Abstract: An automatic calibration and control system for a combined oxygen and combustibles analyzer comprises a process control computer which automatically calibrates a combined oxygen and combustibles analyzer. The computer initiates a calibration sequence through a mechanical unit which introduces calibration gases to the analyzer. The computer calculates a drift adjustment for both oxygen and combustibles and applies it to the incoming oxygen and combustibles signal from the analyzer to arrive at calibrated oxygen and combustibles signals. The system allows both oxygen and combustibles signals to be calibrated automatically and concurrently with minimal operator interface.