METHOD AND APPARATUS FOR DEACTIVATING A HYDRAULIC DEVICE THAT IS LEAKING HYDRAULIC OIL

Abstract

A method of deactivating an underwater hydraulic device provides a hydraulic device that is capable of being operated under water, the device having a hydraulic cylinder with a pushrod and a piston. The device is lowered below a water surface with a hose reel that is located at the water surface area such as on a marine vessel. The hose reel includes first and second hydraulic hoses that connect to the cylinder on opposing sides of the piston. Fluid flow in the first and second hydraulic hoses is continuously monitored. The ratio of the volume of fluid flowing into the cylinder from one side of the piston to the volume of fluid flowing into the cylinder from the other side of the piston is continuously calculated with a computer or controller. The hydraulic device is deactivated if the ratio varies from a preset value. One embodiment includes a plurality of flow meters for measuring fluid flow to and from one or more hydraulically powered apparatuses. In one embodiment outputs of the flow meters are analyzed to determine if the hydraulic system has a leak, and if a leak is detected, a warning is issued and/or one or more of the connected hydraulically powered apparatuses are shut down, and/or the hydraulic power supply is shut down. In one embodiment, the flow lines are jointed flow lines comprised of hose joints connected end to end. Some or all of the hoses have check valves. In one embodiment, the check valves stop flow in either direction if the flow pressure drops below a selected pressure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Priority of U.S. Provisional Patent Application Ser. No. 61/812,618, filed 16 Apr. 2013, which is hereby incorporated herein by reference, is hereby claimed.

Incorporated herein by reference are U.S. patent application Ser. No. 13/741,074, filed 14 Jan. 2013, International Patent Application No. PCT/US2013/021457, filed 14 Jan. 2013, U.S. Provisional Patent Application Ser. No. 61/586,530, filed 13 Jan. 2012, and U.S. Provisional Patent Application Ser. No. 61/727,324, filed 16 Nov. 2012.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

REFERENCE TO A “MICROFICHE APPENDIX”

Not applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to devices for controlling a flow line that has ruptured or that is leaking. More particularly, the present invention relates to a method and apparatus for deactivating a hydraulic system that uses jointed flow lines equipped with a specially configured check valve in each joint of the jointed flow line.

2. General Background of the Invention

In the offshore oil and gas industry, there are certain hydraulic devices that are needed in order to complete jobs in an underwater environment. A hydraulic shear is employed to conduct salvage operations. Such a hydraulic shear is lowered to a seabed area, for example several hundred feet (meters) deep. In this offshore environment, leakage of hydraulic oil has a profoundly disastrous effect on the environment.

Therefore, there exists a need for a simple and straightforward yet workable solution to the problem of leakage of hydraulic fluid from devices that are used in a marine environment.

It is not only important that a leak of hydraulic fluid be detected. It is further important that the hydraulic device be immediately disabled so that leakage is limited to a very minimal quantity.

Patents have issued that relate generally to the detection of leakage. One example is the Brandt patent (U.S. Pat. No. 5,748,077). The Brandt patent (U.S. Pat. No. 5,748,077) shuts down the hydraulic system if the leak is detected and notifies individuals in the area that a leak has occurred. The leak detection system has sensors for measuring hydraulic system parameters and a computer for detecting abnormalities in the system based on values returned by the sensors. Sensors used include an rpm pickup, a pressure transducer, a flow meter and a hydraulic fluid level and temperature switch. Outputs of the sensors are analyzed by the computer to determine if the hydraulic system has a leak. If a leak is detected, the computer sends response signals to a device for engaging or disengaging the prime mover from the hydraulic pump and to another device for actuating a valve to stop hydraulic fluid flow from the reservoir. The computer may also send indicator signals to a display console for activating a warning light, a buzzer or a display.

The Cass patent (U.S. Pat. No. 4,471,797) provides a hydraulic circuit breaker reset device. The system includes a pump, reservoir and an actuator system. The hydraulic circuit breaker is arranged to compare fluid flow to and from the actuator system and to shut off this flow in the event the flow to the actuator system is greater than the flow returning from the actuator system by more than a predetermined differential, thereby indicating a leakage condition. A hydraulic circuit breaker reset device is hydraulically connected to the actuator system and to the circuit breaker. When the circuit breaker is in a shut off condition, the reset device continuously pressure tests the actuator system. If the pressure in the actuator system increases to indicate the absence of fluid leakage, the reset device responds to the pressure increase in the actuator system to provide a reset signal to the circuit breaker. After the circuit breaker is reset to its normal operating position, a timing piston returns the reset device to its normal operating condition.

BRIEF SUMMARY OF THE INVENTION

In one embodiment, the present invention can employ a plurality of hose sections (e.g. 50 ft. (15.24 m) sections) with less than 2.5 gallons (9.46 liters) of total contents within each section. The primary design is to have a check type valve that holds the contents of the hose when there is a breach within any part of the hose, upon hydraulic power unit or “HPU” shutdown.

A specially configured connector joins each hose joint to another hose joint with a threaded connection. The connector contains a specially configured check valve arrangement. The connector is preferably about equal in size to the current connection not to cause any change in function externally due to the fact it has to be spooled up on a hose reel.

The valve of the present invention employs springs that work against each other on a shaft with a plunger or piston in the middle. The springs can be calibrated to a selected pressure flow value. When the flow pushes the plunger or piston in one direction, a circular disk part of the plunger or piston moves to one side of an annular sealing surface and compresses a first spring allowing the flow to pass by the central disk.

When the flow changes direction, the plunger accommodates by moving to the other side of the valve bode compressing the opposing or second spring and allows flow in the other direction, when the flow stops the valve centers due to the equal amount of spring tension and shuts on a sealing area for the plunger.

There is a slight increase of system pressure when using these specially configured check valves of the present invention. For example, if a hydraulic system has two runs of 475 foot (145 m) hose that are one inch (2.54 cm) diameter hose with nine joints of hose, there would be an about 200 psi (1379 kPa) increase in operating pressure.

This method can be used with or without a separate spill mitigation system. The reaction time of a particular human operator can directly affect the amount of hydraulic fluid that is spilled. A computer controlled spill mitigation system can be more consistent and reliable than a human operator.

The present invention includes a method of deactivating an underwater hydraulic device. The method provides a hydraulic device that is capable of being operated under water, the device can have a hydraulic cylinder with a pushrod and a piston. The device can be lowered below a water surface with a hose reel that is located at the water surface area. The hose reel can include first and second hydraulic hoses that connect to the cylinder on opposing sides of the piston. The method includes intermittently monitoring fluid flow in the first and second hydraulic hoses. The method further includes calculating the ratio of the volume of fluid flowing into the cylinder from one side of the piston to the volume of fluid flowing into the cylinder from the other side of the piston. The method of the present invention further includes deactivating the hydraulic device if the ratio varies from a preset ratio or preset value. The hoses can be a plurality of joints, wherein a plurality of said joints house a check valve.

Preferably, the device can be a hydraulic shear.

Preferably, the flow can be measured with first and second flow meters, one flow meter monitoring fluid flow in the first hydraulic hose, the other flow meter monitoring flow in the second hydraulic hose.

Preferably, the hydraulic device can receive hydraulic fluid under pressure from a prime mover and hydraulic pump assembly and the prime mover and pump assembly can be deactivated.

Preferably, the prime mover can be deactivated.

Preferably, the prime mover can include an engine and the engine can be shut off.

Preferably, a controller can continuously monitor flow in the flow meters and continuously calculates the ratio.

Preferably, the present invention further comprises providing a selector switch having multiple selectable switch positions and wherein the ratio can be varied by selecting a different position of the selector switch.

Preferably, the computer can use a different ratio depending upon which switch position is selected and the dimensions of the cylinder and pushrod of the selected device.

Preferably, the volumes can be automatically calculated.

The present invention includes a method of deactivating a hydraulic device. The method provides a hydraulic device having a cylinder with a pushrod and a piston, the device receiving flow from a jointed flow line. The flow line can include first and second hydraulic jointed hoses that connect to the cylinder on opposing sides of the piston. The method further includes intermittently monitoring fluid flow in the first and second hydraulic hoses. The method further includes continuously comparing the volume of fluid that enters a pushrod retraction chamber section of the cylinder with a pushrod extension section of the cylinder. The method further includes deactivating the hydraulic device if the ratio varies from a preset value. The hoses can be a plurality of hose joints, wherein a plurality of said hose joints are connected together end to end with connectors that each house a check valve.

Preferably, the flow can be measured with first and second flow meters, one flow meter monitoring fluid flow in the first hydraulic hose, the other flow meter monitoring flow in the second hydraulic hose.

Preferably, the hydraulic device receives hydraulic fluid under pressure from a prime mover and hydraulic pump assembly and the prime mover and pump assembly is deactivated.

Preferably, the prime mover can be an engine and the engine can be shut off.

Preferably, a controller can continuously monitor flow in the flow meters and continuously calculates the ratio.

Preferably, the present invention further comprises providing a selector switch having multiple selectable switch positions and wherein the ratio can be varied by selecting a different position of the selector switch.

The present invention includes a hydraulic leak detection apparatus. The apparatus of the present invention can include a hydraulic device that can be operated with a prime mover, pump, and hydraulic cylinder having a cylinder, a pushrod, and a piston. The cylinder can have a first chamber that is receptive of hydraulic fluid when extending the pushrod and a second chamber that is receptive of hydraulic fluid when retracting the pushrod. A first hydraulic flow line can supply hydraulic fluid to the first chamber. A second hydraulic flow line can supply hydraulic fluid to the second chamber. At least one of said flow lines can be comprised of separate lengths of hose connected end to end. A computer can continuously monitor the ratio of the volume of fluid entering the first chamber to the volume of fluid entering the second chamber. The computer can operatively connect to the prime mover so that the computer can deactivate the prime mover when the ratio varies from a preset acceptable value of said ratio. At least one of the hydraulic flow lines can be comprised of a plurality of hose joints that are joined together with connectors that each contain a check valve.

Preferably, the hydraulic device can be a power tong.

Preferably, each of said first and second flow lines can have a flow meter interfaced with said computer so that the flow meters continuously transmit flow data to the computer.

Preferably, the present invention further comprises a selector switch that enables the computer to compare the said ratio with a selected one of a plurality of ratios, each ratio of the plurality of ratios corresponding to different hydraulic cylinder configurations.

Preferably, the present invention further comprises a selector switch that enables the computer to compare the said ratio with a selected one of a plurality of ratios, each ratio of the plurality of ratios corresponding to different hydraulic cylinder dimensions.

Preferably, the computer can be programmable to designate any ratio as the acceptable value.

Preferably, the acceptable value can be a range.

Preferably, further comprises a hose reel that enables the device to be lowered to a sea bed area.

Preferably, multiple hydraulic flow lines can be part of the hose reel.

Preferably, each of said first and second hydraulic hoses can have a flow meter interfaced with a computer or controller so that the flow meters continuously transmit flow data to the computer.

Preferably, each flow meter can be in a said hydraulic hose in between the hose reel and the device.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

FIG. 1 is a partial elevation view of a preferred embodiment of the momentum controller;

FIG. 2 is a sectional view taken along lines 2-2 of FIG. 1;

FIG. 3 is a partial sectional view of a preferred embodiment of the apparatus of the present invention;

FIG. 4 is a partial sectional view of a preferred embodiment of the apparatus of the present invention;

FIG. 5 is a sectional view taken along lines 5-5 of FIG. 2;

FIGS. 5A and 5B are fragmentary views of a preferred embodiment of the apparatus of the present invention;

FIG. 6 is a sectional view taken along lines 6-6 of FIG. 2;

FIG. 7 is a side, partially cut away view of a preferred embodiment of the apparatus of the present invention;

FIG. 8 is a side, partially cut away view of a preferred embodiment of the apparatus of the present invention;

FIGS. 9A and 9B provide a schematic diagram of a preferred embodiment of the apparatus of the present invention wherein lines A-A of FIGS. 9A and 9B are match lines; and

FIG. 10 is a schematic diagram of an alternate embodiment of the present invention, wherein lines A-A of FIGS. 10 and 9B are match lines.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 9A and 9B show a preferred embodiment of the apparatus of the present invention, designated generally by the numeral 10. In FIG. 9A, hydraulic power is provided with a hydraulic power unit or HPU which is designated generally by the numeral 17. Hydraulic power unit 17 includes a prime mover 20 which can be for example a diesel engine (20) or electric motor 44 (as seen in FIG. 10). The prime mover 20 powers a pump 21 which can be a compensating pump. Such compensating pumps are commercially available (e.g. from Linde Hydraulics (www.lindeamerica.com)). The pump 21 receives hydraulic fluid from reservoir 22 and flow line 27. A case drain line or recycle line 24 is provided for bypassing the hose reel 40 which is a condition that can occur with such a compensating pump 21 in some situations. Fuel is provided for the hydraulic power unit 17, for example tank 23 which can be a diesel fuel tank for supplying diesel fuel via flow line 65 with valve 64 to prime mover/diesel engine 20. Pump 21 has a discharge flow line 25 which is a pressure line that communicates with hydraulic control valve 54. Hydraulic control valve 54 has a lever or operator handle 69 that is used to operate an implement 11 (e.g., cutter 11) such as to either open or close the jaw 30 of implement or shear 11. In FIG. 9B, the lever or handle 69 is in a position that transmits fluid to lines 31, 32 so that jaw 30 is opened. The lever or handle 69 can be moved to a position (see dotted lines in FIG. 9B) that transmits fluid to lines 31, 32 so that jaw 30 is closed. Valve 54 is commercially available such as from Hawe North America, Inc. of Charlotte, N.C.

From control station 29, the line 31 exits to supply pressurized hydraulic fluid to hose reel 40. A first flow meter 45 is placed in flow line 31 or at the junction of flow lines 25, 31 as shown in FIGS. 9A-9B.

Line 32 also receives flow from control station 29 to communicate with hose reel 40. The flow line 32 carries a second flow meter 46. Return flow is able to travel from the hose reel 40 to the flow line 32 through the flow meter 46 and then to the control station 29. From the control station 29, the flow in line 32 communicates with the return line 26 for returning fluid to hydraulic tank or reservoir 22. Flow meters 45, 46 can be commercially available CT Series flow meters from Webster Instruments of Milwaukee, Wis.

The hose reel 40 provides flow lines 41, 42 which enable a hydraulic cylinder on implement 11 to either open jaw 30 or close jaw 30 by either extending a pushrod or retracting the pushrod. This is accomplished by connecting one flow line 41 to hydraulic cylinder on one side of a piston (that is on implement 11 and that operates jaw 30) and by connecting the other flow line 42 to the hydraulic cylinder on the other side of the piston.

The prime mover can be either an engine 20 or an electric motor 44 (see FIG. 10). The engine 20 (e.g., diesel) is provided with a battery 71 for starting the engine 20. The battery 71 also provides positive and negative leads 72, 73 that communicate with control station or controller 29 as shown in FIGS. 9A-9B. The control station 29 can include a commercially available computer or controller 33 such as a Model Plus 1 from Sauer Danfoss such as Model No. MC024-010 or MC024-012.

The computer or controller 33 is part of the control station 29. The control station 29 can provide a key switch for enabling the control station 29 to be activated or deactivated. A rotary cam switch 74 can be provided to pre-program controller 33 for a number of different configurations (e.g., dimensional changes) of cylinder, pushrod and chamber sections of hydraulic cylinder of implement 11. The cam switch 74 enables an operator to dial in or select a particular hydraulic cylinder by selecting a pre-programmed cam switch position. Such a rotary cam switch is commercially available from Control Switches International, Inc.

A start button 75 can be provided for enabling use of control station 29. Lamps 76, 77 can be provided to indicate whether or not the control station 29 has been activated or is deactivated. For the diesel engine 20, a valve (e.g., solenoid operated valve) 64 is provided in flow line 65 which supplies diesel fuel from tank 23 to engine 20. This solenoid operated valve 64 is closed in a situation where a leak is detected (e.g., see leakage/damage at 70 in FIG. 8). In alternate embodiment 10A seen in FIG. 10, for an electric motor 44 (as prime mover), a solenoid operated switch 78 is provided. The switch 78 deactivates the electric motor 44 if a leak situation is detected. For each of the diesel engine 20 (or electric motor 44), a cooler 67 can be provided in the flow line 24 as shown.

In one embodiment, the method and apparatus can be provided with a display which may include a leak detection visual and/or audible alarm. A display console can be provided for controller 33 which can include a selector or cam switch 74, on-off button 75, indicator lamps 76 and 77, along with default program button. Controller 33 can be operatively connected to a computer (e.g., a notebook computer) for programming operating values into controller 33 regarding its operations.

FIGS. 9A and 9B provide schematic block diagrams of leak detection system 10 connected to two hydraulic systems—(a) hydraulic shears 11 and (b) the reel drive motor 38 for hose reel 40. Leak detection system 10 can detect undesirable conditions in one or both of these two connected hydraulic systems.

A plurality of flow meters 45 and 46 can be used to measure flow to and from the monitored hydraulic systems (e.g., shears 11 and reel drive motor 38). The flow meter 45 sends a signal to controller 33 which is proportional to the rate of fluid flow in flow line 31. The flow meter 46 sends a signal to controller 33 which is proportional to the rate of fluid flow in flow line 32.

Pre-Leak Detection Testing

Leak detection 10 system can go through various pre-leak detection monitoring checks which are designed to ensure that the connected hydraulic systems (e.g., shears 11 and reel drive motor 38) are operating correctly. In one embodiment leak detection system 10 will shut off hydraulic power to the hydraulic pump 21 if one or more pre-monitoring exceptions are found.

Pre-monitoring exceptions can include, but are not limited to:

• • (a) powering hydraulic pump 21 not operating such as not rotating between a predefined rotational range;
  • (b) the level of hydraulic fluid in reservoir tank 22 not being above a predefined reservoir tank level;
  • (c) the pressure in flow line 31 not being above a predefined pressure for such flow line;
  • (d) the pressure in flow line 32 not being above a predefined pressure for such flow line;
  • (e) the pressure in flow line 41 not being above a predefined pressure for such flow line; and
  • (f) the pressure in flow line 42 not being above a predefined pressure for such flow line.
    If one or more of the above pre-monitoring exceptions are found, leak detection system 10 can turn off power to pump 21, and issue a warning signal indicating the identification of a pre-monitoring exception. The pressure exerted by the hydraulic fluid can be monitored by pressure transducers in flow lines 31, 32, 41, and 42.

If an exception condition is found, including satisfaction of the time periods for existence of such exception, the leak detection system 10 shuts down the identified leaking hydraulic system (e.g., shears 11 and/or reel drive motor 38). Shutting down a hydraulic system can include shutting off the flow of hydraulic fluid from the reservoir tank 22 to pump 21 and shutting off power to pump 21. The hydraulic fluid flow can be shut off at reservoir tank 22 by turning a valve in line 27 to a closed position.

If a leaking exception condition satisfying leaking parameters has been found, the leaking hydraulic system (e.g., shears 11 or reel drive motor 38) causing the leaking event to be identified may be shut down and the indicator or display signals are sent to console to warn that a leaking event has been identified. Leak detected light 76 or 77 can be provided and turned on and optionally an auditory alarm can also be issued.

Leak Detection Monitoring

In one embodiment, following the completion of the various pre-leak detection monitoring checks, leak detection system 10 can monitor one or both connected hydraulic systems (shears 11 and/or reel drive motor 38) by monitoring flow though flow meters 45 and 46 and comparing such monitored flow to certain predefined flow amounts for the particular hydraulic system being monitored.

In one embodiment leak detection system 10 provides a predefined startup period of time from activation of a hydraulic system to beginning of monitoring operations of flow meters 45 and 46. Such predefined start up period of time allows the monitored hydraulic system time to stabilize before leak detection system 10 begins looking for leaking exceptions in monitoring conditions. In one embodiment such predefined start up period of time can be at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, and/or 50 seconds. In various embodiments such predefined period of time can be a range between any two of the specified time periods.

Exceptions for leak detection can be identified by leak detection system 10 where a measured parameter falls outside of the predefined allowed ranged for such measured parameter. Additionally, preferably leak detection system 10 requires that the exception be present for a predetermined period of time before considering that an identified leaking exception is considered a leaking event and acting accordingly, such as by shutting down pump 21 and/or the hydraulic system (e.g., shears 11 or reel drive motor 38) causing the identified leaking exception to be present.

Frequency of Sampling Flow Meter Readings

In one embodiment leak detection system 10 can be user programmed regarding the frequency of sampling of which the system accepts signals from the plurality of flow meters 45 and 46. Although “continuous” is used in this specification it is anticipated that, in any given time period, only a finite number sampling of measurements can be taken by leak detection system 10.

In various embodiments embodiment sampling rates can be at least 1, 5, 10, 50, 100, 120, 150, 200, 300, 500, 1000, 2000, or 3000 Hertz. In various embodiments sampling rates can be a range between any two of the specified sampling rates.

Time Period for Existence of Leaking Exception

In one embodiment leak detection system 10 responds or reacts rapidly to an identified leaking event, such as by shutting off power to pump 21 along with shutting off fluid flow from reservoir 22 to pump 21. With the occurrence of such an event, leak detection system 10 can also issue a warning signal such as be lighting lamp 76 or lamp 77, along with possibly issuing a audible warning signal such as a siren.

In one embodiment, after a leaking event is determined, leak detection system 10 will shut down the flagged hydraulic system (shears 11 or reel drive motor 38). This can occur after determining a leaking exception exists for a predetermined time. In one embodiment such predefined period of time that the leaking exception must exist before a leaking event can be identified, can be at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, 50, and/or 60 seconds. In various embodiments such predefined period of time can be a range between any two of the specified time periods. In various embodiments the user can program this predefined period of time and/or range into leak detection system 10.

Programming Based on Actual Operating Conditions of Hydraulic Systems in a Non-Leaking Condition

In one embodiment benchmark conditions in known non-leaking conditions to be expected when taking sampling measurements can be automatically programmed into the method and apparatus. In one embodiment predefined exception conditions can be programmed into leak detection system 10 based on actual operating conditions of the hydraulic system being monitored (e.g., shears 11 and/or reel drive motor 38). In one embodiment, the default predefined button can be provided in leak detection system 10, and a method of programming predefined conditions for flow meters 45 and 46 can be as follows:

(1) Shear System

With hydraulic shear system 11, hydraulic power can be supplied by pump 21 though lines 31 and 32 which respectively flow through lines 41 and 42. The ratio of flow measured by flow meter 45 to compared to flow meter 46 (or vice versa) can be calculated by controller 33 and such ratio be set in the method and apparatus as the ideal predefined ratio in a non-leaking condition.

For any particular movement of the piston inside of the hydraulic cylinder of implement 11, the amount of hydraulic fluid entering/leaving one chamber is less than the amount of hydraulic fluid entering/leaving the other chamber. The difference is a result of the pushrod taking up part of the volume of one chamber section. Although not expected to be a 1:1 ratio, because the pushrod has a substantially uniform cross sectional area the ratio of the amount of fluid exchange between the two chamber sections is expected to be constant regardless of the position of piston in the cylinder. In a preferred embodiment the ratio can be 1:2.28 and measured variations from this ratio can be used by leak detection system 10 to identify leaking exceptions for shear 11 and, if such identified leaking exception persists, a leaking event for shear 11.

(2) Driving Motor for Hose Reel

For reel drive motor 38 hydraulic power can be supplied by pump 21 though lines 31 and 32 which power reel drive motor 38 to outlay or take up lines 41 and 42. The ratio of flow measured by flow meter 45 to 46 can be calculated by controller 33 and such ratio be set as a predefined ratio in a non-leaking condition. However, this ratio in a non-leaking situation is expected to be 1:1 and this step can be omitted for programming the leak detection parameters for reel drive motor 38.

Unlike shears 11, reel drive motor 38 operably connected to hose reel 40 (and rotating reel 40 to outlet and take up of flow lines 41 and 42) will have input and output lines which, in a non-leaking condition, are expected to have a 1:1 ratio of hydraulic fluid entering and exiting driving motor 38.

Use of Physical Dimensional Parameters to Calculate Predefined Ratios

For any particular movement of the piston inside of the hydraulic cylinder, the amount of hydraulic fluid entering/leaving one chamber section is less than the amount of hydraulic fluid entering/leaving the chamber section. The difference is a result of the pushrod taking up part of the volume of chamber section. Although not expected to be a 1:1 ratio, because the pushrod has a substantially uniform cross sectional area the ratio of the amount of fluid exchange between the two chamber sections is expected to be constant regardless of the position of the piston in the cylinder. In a preferred embodiment the ratio can be 1:2.28 and measured variations from this ratio can be used by leak detection system 10 to identify leaking exceptions for shear 11 and, if such identified leaking exception persists, a leaking event for shear 11.

In one embodiment, where the push rod has a diameter D_r and the piston has a diameter D_P the ratio between the two flow rates will be the same as the ratio of the cross sectional areas on either side of the piston, and can be calculated by the formula:

$\frac{\left[D_p^2-D_r^2\right]}{D_p^2}$

In this embodiment a user can enter the diameter of the rod “D_r” and the diameter of the piston “D_P” and the method and apparatus can calculate the ideal predefined ratio in a non-leaking condition from which allowable variations can be looked for by the method and apparatus.
Customizing Allowable Variations from Predefined Non-Leaking Ratios

In various embodiments a user can custom program leak detection system 10 to allow a variation of a selected amount from the predefined ratio in a non-leaking condition for either the hydraulic shear system 11 and/or reel drive motor 38. In various embodiments such can be a symmetrical variation from the initial predefined ratio and can be an allowable percentage variation from the initial predefined ratio. In various embodiments this allowable percentage can be at least about 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 18, 20, 25, 30, 35, 40, and/or 50 percent. In various embodiments such exception variations can differ from variations above compared to variations below the user selected value in a non-leaking condition (e.g., the initial predefined ratio).

In various embodiments the lower limit can be one of the specified allowable variations, and the upper limit can be a different one of the specified allowable variations.

In various embodiments such user selected predefined parameters may be changed from time to time as the user desires.

At different points in time the user can use the default program button to calculate another predefined ratio for either hydraulic system (shear 11 or drive motor 38) as either hydraulic system's non-leaking characteristics may change over time. In one embodiment such predefined variations can be numerically entered into controller 33 by a computer.

As disclosed herein it is anticipated that leak detection system 10 can have programmed multiple sets of ratios for flow in flow meters 45 and 46 based on the different hydraulic systems which flow meters 45 and 46 are measuring flow in relation to. For example, when reel drive motor 38 is operating to lay out or take up hoses 41 and 42 (respectively lowering or raising shears 11), hydraulic shears 11 will not be operating. Accordingly, the values programmed for reel drive motor 38 are used by leak detection system 10.

Catastrophic Leak Detection Testing

During operations, leak detection system 10 system can go through various checks for catastrophic leaking events which are designed to ensure that the connected hydraulic systems (e.g., shears 11 and reel drive motor 38) do not suffer a catastrophic leaking event. In one embodiment leak detection system 10 will shut off hydraulic power to the hydraulic pump 21 and/or hydraulic systems if one or more pre-monitoring exceptions are found.

Catastrophic monitoring exceptions can include, but are not limited to:

• • (a) no flow read by flow meter 45 while flow is read by flow meter 46;
  • (b) no flow read by flow meter 46 while flow is read by flow meter 45;
  • (c) the pressure in flow line 31 not being above a predefined pressure for such flow line;
  • (d) the pressure in flow line 32 not being above a predefined pressure for such flow line;
  • (e) the pressure in flow line 41 not being above a predefined pressure for such flow line; and
  • (f) the pressure in flow line 42 not being above a predefined pressure for such flow line.

If one or more of the above catastrophic leak detection monitoring exceptions are found, leak detection system 10 can turn off power to pump 21, shut down the hydraulic systems, and issue a warning signal indicating the identification of a catastrophic leak detection event. The pressure exerted by the hydraulic fluid can be monitored by pressure transducers in flow lines 31, 32, 41, and 42.

FIGS. 1-8 show a specially configured valve to be employed with a preferred embodiment of the apparatus of the present invention. Leak detection system 10 employs a specially configured valve assembly or valve 12 which also can function as a connector to connect one joint of hose 13 to another joint of hose 14 as seen in FIGS. 7 and 8. The valve 12 can have male connector ends 57, 58 that each connect to a female connector end on a joint of hose 13 or 14. Once so configured, the joints of hose 13, 14 can be connected end to end to make up a long hose run of for example 300-500 feet (91-152 m) or more. Connector ends 57, 58 could be both male as shown, both female, or one male and one female, for example.

In FIGS. 1-8, valve 12 includes an annular or generally cylindrically shaped or tubular valve body 16 having a central longitudinal flow bore 56. Valve body 16 can be in three sections 59, 60, 61 (see FIGS. 1-4). The section 60 is central section. The sections 59, 61 are end sections that connect to the central section with a threaded connection. In FIGS. 2-4, section 59 connects to section 60 with threaded connection 62. In FIG. 2, section 61 connects to section 60 with threaded connection 62.

Plunger or piston 63 is mounted within body 16, attached to a pair of spaced apart flow through disks 19, 28 (see FIGS. 5A, 5B). Each disk 19, 28 has a central opening 79 and a plurality of circumferentially extending arcuate openings 80, 81, 82 as seen in FIGS. 5, 5A, 5B. Piston or plunger 63 has a rod or shaft 87 that extends through the opening 79 of disks 19 and also through the opening 79 of disk 28 as seen in FIGS. 2-4. Disk 66 is mounted on rod 87. Springs 83, 84 normally center disk 66 upon annular or cylindrically shaped sealing surface 49. Beveled annular surfaces or inclined sections 47, 48 can be provided on opposing sides of sealing surface 49 as seen in FIG. 2. Spring 83 is positioned in between disk 66 of plunger/piston 63 and disk 19 which is anchored to valve body 16 between sections 59 and 60 (see FIGS. 3-4). Spring 84 is positioned in between disk 66 of plunger/piston 63 and disk 28 which is anchored to valve body 16 between sections 60 and 61 (see FIGS. 3-4).

Disk 66 of piston/plunger 63 has an annular groove 68 fitted with an o-ring 85. When o-ring 85 registers upon annular surface/sealing surface 49, flow through valve body 16 bore 56 is halted. Springs 83, 84 are calibrated so that if a selected flow pressure value is overcome, the piston or plunger 63 moves toward a disk 19 or 28 and the plunger/piston leaves sealing surface 49 to open the flow. Thus, if a leak occurs in any length or joint of hose (e.g., 13 or 14 or 41 or 42) the pressure will drop below the preselected pressure value and wherein the springs 83, 84 center disk 66 on sealing surface 49 to close flow and stop any further leakage.

The hydraulic control system of the present invention provides a valve arrangement that works in two directions. Flow from either direction of hose joint 13 or 14 will open the valve bore 56 as long as sufficient pressure is available to overcome spring pressure. Conversely, in the event of leakage a pressure drop below a preset minimum pressure value will enable springs 83, 84 to center disk 66 on sealing surface 49 to halt flow. FIG. 7 shows position of piston 63 if no damage has occurred. In FIG. 3, arrows 55 show normal flow that overcomes and compresses spring 84. In FIG. 4, arrows 86 show normal flow that overcomes spring 83. FIG. 8 shows damage and leakage 70 in line 13. Pressure in hose bore 15 drops as a result of the leak at 70. Springs 83, 84 center piston 63 is seen in FIG. 8.

Incorporated herein by reference are U.S. patent application Ser. No. 13/741,074, filed 14 Jan. 2013, and International Patent Application No. PCT/US 13/21457, filed 14 Jan. 2013. The present invention is preferably used with the inventions disclosed therein.

The following is a list of parts and materials suitable for use in the present invention:

PARTS LIST:
PART NUMBER DESCRIPTION
10          hydraulic spill control apparatus
10A         hydraulic spill control apparatus
11          implement/shear
12          valve assembly/valve
13          hose joint with damage and leakage
14          hose joint
15          hose bore
16          valve body
17          hydraulic power unit
19          flow through disk
20          prime mover/engine
21          pump
22          reservoir/hydraulic fluid
23          fuel tank
24          flow line
25          flow line
26          flow line
27          flow line
28          flow through disk
29          control station
30          jaw
31          flow line
32          flow line
33          controller/computer
38          hose reel motor
40          hose reel
41          flow line
42          flow line
43          flow line
44          electric motor
45          flow meter
46          flow meter
47          inclined section
48          inclined section
49          annular surface/sealing surface
54          control valve
55          arrow
56          flow bore
57          connector end
58          connector end
59          section
60          section
61          section
62          threaded connection
63          plunger/piston
64          solenoid operated valve/valve
65          flow line
66          disk
67          cooler
68          annular groove
69          lever/handle
70          leaking/damaged section
71          battery
72          positive lead
73          negative lead
74          rotary cam switch
75          start button
76          lamp
77          lamp
78          switch
79          central opening
80          arcuate opening
81          arcuate opening
82          arcuate opening
83          spring
84          spring
85          O-ring
86          arrows
87          rod/shaft

All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.

The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.

Claims

1. A method of deactivating an underwater hydraulic device, comprising the steps of:

a) providing a hydraulic device that is capable of being operated under water, the device having a hydraulic cylinder with a pushrod and a piston;

b) lowering the device below a water surface with a hose reel that is located at the water surface area;

c) wherein the hose reel of step “b” includes first and second hydraulic hoses that connect to the cylinder on opposing sides of the piston;

d) intermittently monitoring fluid flow in the first and second hydraulic hoses;

e) calculating the ratio of the volume of fluid flowing into the cylinder from one side of the piston to the volume of fluid flowing into the cylinder from the other side of the piston;

f) deactivating the hydraulic device if the ratio varies from a preset ratio or preset value; and

g) wherein the hoses are a plurality of joints, wherein a plurality of said joints house a check valve.

2. The method of claim 1 wherein the device is a hydraulic shear.

3. The method of claim 1 wherein the flow is measured with first and second flow meters in step “d”, one flow meter monitoring fluid flow in the first hydraulic hose, the other flow meter monitoring flow in the second hydraulic hose.

4. The method of claim 1 wherein the hydraulic device receives hydraulic fluid under pressure from a prime mover and hydraulic pump assembly and in step “f”, the prime mover and pump assembly is deactivated.

5. The method of claim 4 wherein the prime mover is deactivated.

6. The method of claim 5 wherein the prime mover includes an engine and in step “f” the engine is shut off.

7. The method of claim 3 wherein a controller continuously monitors flow in the flow meters and continuously calculates the ratio of step “e”.

8. The method of claim 7 further comprising providing a selector switch having multiple selectable switch positions and wherein the ratio of step “e” can be varied by selecting a different position of the selector switch.

9. The method of claim 8 wherein the computer uses a different ratio depending upon which switch position is selected and the dimensions of the cylinder and pushrod of the selected device.

10. The method of claim 1 wherein the volumes of step “e” are automatically calculated after step “d”.

11. A method of deactivating a hydraulic device, comprising the steps of:

a) providing a hydraulic device having a cylinder with a pushrod and a piston, the device receiving flow from a jointed flow line;

b) wherein the flow line of step “a” includes first and second hydraulic jointed hoses that connect to the cylinder on opposing sides of the piston;

c) intermittently monitoring fluid flow in the first and second hydraulic hoses;

d) continuously comparing the volume of fluid that enters a pushrod retraction chamber section of the cylinder with a pushrod extension section of the cylinder;

e) deactivating the hydraulic device if the ratio varies from a preset value; and

f) wherein the hoses are a plurality of hose joints, wherein a plurality of said hose joints are connected together end to end with connectors that each house a check valve.

12. The method of claim 11 wherein the flow is measured with first and second flow meters in step “c”, one flow meter monitoring fluid flow in the first hydraulic hose, the other flow meter monitoring flow in the second hydraulic hose.

13. The method of claim 11 wherein the hydraulic device receives hydraulic fluid under pressure from a prime mover and hydraulic pump assembly and in step “e”, the prime mover and pump assembly is deactivated.

14. The method of claim 13 wherein the prime mover is an engine and in step “e” the engine is shut off.

15. The method of claim 12 wherein a controller continuously monitors flow in the flow meters and continuously calculates the ratio of step “d”.

16. The method of claim 11 further comprising providing a selector switch having multiple selectable switch positions and wherein the ratio of step “e” can be varied by selecting a different position of the selector switch.

17. A hydraulic leak detection apparatus, comprising:

a) a hydraulic device that is operated with a prime mover, pump, and hydraulic cylinder having a cylinder, a pushrod, and a piston;

b) the cylinder having a first chamber that is receptive of hydraulic fluid when extending the pushrod and a second chamber that is receptive of hydraulic fluid when retracting the pushrod;

c) a first hydraulic flow line that supplies hydraulic fluid to the first chamber;

d) a second hydraulic flow line that supplies hydraulic fluid to the second chamber;

e) at least one of said flow lines being comprised of separate lengths of hose connected end to end;

f) a computer that continuously monitors the ratio of the volume of fluid entering the first chamber to the volume of fluid entering the second chamber;

g) the computer operatively connected to the prime mover so that the computer can deactivate the prime mover when the ratio varies from a preset acceptable value of said ratio; and

h) at least one of the hydraulic flow lines being comprised of a plurality of hose joints that are joined together with connectors that each contain a check valve.

18. The apparatus of claim 17 wherein the hydraulic device is a power tong.

19. The apparatus of claim 17 wherein each of said first and second flow lines has a flow meter interfaced with said computer so that the flow meters continuously transmit flow data to the computer.

20. The apparatus of claim 17 further comprising a selector switch that enables the computer to compare the said ratio with a selected one of a plurality of ratios, each ratio of the plurality of ratios corresponding to different hydraulic cylinder configurations.

21. The apparatus of claim 17 further comprising a selector switch that enables the computer to compare the said ratio with a selected one of a plurality of ratios, each ratio of the plurality of ratios corresponding to different hydraulic cylinder dimensions.

22. The apparatus of claim 17 wherein the computer is programmable to designate any ratio as the acceptable value.

23. The method of claim 17 wherein the acceptable value is a range.

24. The apparatus of claim 22 wherein the acceptable value is a range.

25. The apparatus of claim 17 further comprising a hose reel that enables the device to be lowered to a sea bed area.

26. The apparatus of claim 25 wherein multiple hydraulic flow lines are part of the hose reel.

27. The apparatus of claim 25 wherein each of said first and second hydraulic hoses has a flow meter interfaced with a computer or controller so that the flow meters continuously transmit flow data to the computer.

28. The apparatus of claim 27 wherein each flow meter is in a said hydraulic hose in between the hose reel and the device.