INSULATION JACKET AND INSULATION JACKET SYSTEM

Abstract

A thermal insulation jacket system. The thermal insulation jacket system includes a thermal insulation jacket configured to surround a valve, a plurality of detection devices and a computing device. Each detection device is configured to detect a different temperature associated with the valve. The computing device is coupled to the thermal insulation jacket and is communicably connected to the plurality of detection devices. The computing device is configured to calculate real-time energy savings attributable to the thermal insulation jacket and perform at least one diagnostic analysis associated with the valve.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. §120 of the earlier filing date of U.S. Nonprovisional patent application Ser. No. 12/907,371 filed on Oct. 19, 2010, titled INSULATION JACKET AND INSULATION JACKET SYSTEM, which claims the benefit under 35 U.S.C. §119(e) of the earlier filing date of U.S. Provisional Patent Application No. 61/252,911 filed on Oct. 19, 2009, titled INSULATION JACKET AND INSULATION JACKET SYSTEM, the contents of which are hereby incorporated by reference in their entireties.

TECHNICAL FIELD

This invention relates generally to an insulation jacket used on valves and pipes, and more particularly to a “smart” insulation jacket system used on pipes and valves that can measure, monitor, communicate, and archive the energy savings realized by using the insulation jacket.

BACKGROUND

Currently, end users are able to employ a host of on-line energy savings calculators to estimate the average savings in fuel costs on a per pipe or valve basis. These calculators compute average energy savings by taking the following as input parameters:

1) Pipe or Valve Temperature

2) Ambient Air Temperature

3) Pipe or Valve Size information

4) Type and Thickness of Insulation

Inputs regarding valve geometry and jacket insulation can usually be obtained from standard vendor specifications. However, pipe and ambient air temperature measurements must be obtained manually (by hand) from the pipe. Usually, this process is done very infrequently since it is difficult to perform and good enough estimates can be derived from historical numbers to prove the economic benefit of purchasing a particular insulation product. Since there are no industry standard tools to measure the performance of an installed insulation product over time, specific performance analysis of insulation products is not done outside of the laboratory due to the difficulty in obtaining the required input parameters.

It is well known in the industrial piping market that insulating high temperature pipes and valves from the ambient temperature can save a significant amount of energy. Historically, insulators put in place permanent insulation that required removal and replacement during maintenance operations. More recently, removable valve jackets and pipe insulations were innovated to remove the need to replace insulating materials during maintenance. Reusable insulation represents a significant advance for the owner/operators; however, there is no direct means of measuring the energy savings from a program of insulation, be it removable or permanent.

Thus there is a need for a system and device that can obtain the above desired energy savings data and on a regular basis, archive the data, and communicate the data to a device such as a computer, or hand held monitoring apparatus.

SUMMARY OF THE INVENTION

The disclosed invention relates to a thermal insulation jacket system. In one embodiment the thermal insulation jacket system includes a thermal insulation jacket configured to surround a valve, a plurality of detection devices and a computing device. Each detection device is configured to detect a different temperature associated with the valve. The computing device is coupled to the thermal insulation jacket and is communicably connected to the plurality of detection devices. The computing device is configured to calculate real-time energy savings attributable to the thermal insulation jacket and perform at least one diagnostic analysis associated with the valve.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will be better understood by those skilled in the pertinent art by referencing the accompanying drawings, where like elements are numbered alike in the several figures, in which:

FIG. 1 is a top view of the thermal insulation jacket;

FIG. 2 is a side view of the skirt of the thermal insulation jacket in flattened condition;

FIG. 3 is a perspective view of the cap of the thermal insulation jacket;

FIG. 4 is a side view of the insulation jacket, partially cut away, when used in conjunction with a valve casing;

FIG. 5 is an end view of the insulation jacket in the assembled position;

FIG. 6 is a schematic diagram of the insulation jacket system;

FIG. 7 is a conceptual illustration of the ad-hoc network; and

FIG. 8 is a semi-exploded view of the advanced diagnostics embodiment of the invention.

DETAILED DESCRIPTION

The disclosed invention integrates advanced electronics, sensing, and software directly into traditional removable insulation products.

A wide variety of thermal insulation jackets may be used with the disclosed invention. The thermal insulation jacket itself may be made of a wide variety of materials and in a wide variety of thicknesses and dimensions. In one embodiment, the thermal insulation jacket itself comprises a fiberglass cloth fabric coated with a silicone rubber coating so as to render the fabric resistant to water and ambient conditions. One fabric may be 100% fiberglass lagging cloth. By selecting the proper outer facing for the insulation jacket the jacket may be easily removed and readily re-used thus reducing cost while providing effective insulation efficiency.

The insulation jacket may be stuffed with a lightweight flexible mat which preferably comprises type-E glass fibers although other types of packing may obviously be used depending upon the particular specifications. The thickness of the jacket may commonly be between 1 and 2 inches although other thicknesses are within the scope of the invention depending upon specific conditions.

The jacket may be provided with a pair of inboard and outboard straps on each of the lateral sections of the jacket which make it possible to tightly secure the jacket around a valve casing such that the jacket extends beyond the flange formed between the casing and the line and may thus be tightened around the pipe insulation provided on the line to completely and thermally insulate the valve casing from the atmosphere.

The straps may be held in place by means of lateral fasteners which hold the straps in place while permitting longitudinal sliding movement. When properly fitted, the jacket may extend beyond the flange and the inboard and outboard straps are properly adjusted so as to provide an effective seal in conjunction with insulation provided along the connecting line.

FIG. 1 illustrates one embodiment of a thermal insulation jacket 10 which comprises lateral sections 18 and 24 with end flap sections 20, 22 and 26, 28 separated by means of slightly differing U-shaped cutouts 14 and 16 respectively. Each of the lateral sections 18 and 24 is separated by means of a central section 12. The central section comprises weep holes 15 which permit fluid which has leaked from the line to visibly drain out of the jacket. Outboard straps or belts 30 and 34 as well as inboard straps or belts 32 and 36 are respectively located on each of lateral sections 24 and 18. Each of the straps is provided with a buckle at one end thereof adapted to receive the other end of the strap such that the strap may be tightened around the valve casing when the jacket is wound around the casing. Although the straps are each illustrated as having a buckle 38 and a free end, the straps may be provided with a wide variety of fastening means to be used in conjunction with each of the straps.

Each of the straps is generally maintained in place by means of lateral securing strips 31 which, although holding the straps onto the jacket, nevertheless permit the straps to slide longitudinally.

As shown, the flaps 20 and 26 comprise unpadded insulation while flaps 22 and 28 are padded in a fashion similar to the central portion of the jacket. Flaps 20 and 26 are adapted to overlap flaps 22 and 28 when the jacket is used. To facilitate assembly of the jacket grommets 11 may be provided which permit the user to secure flaps 22 and 28 around the upstanding portion of the valve by means of wires or the like which secure one end of the jacket to the valve casing thus freeing both of the user's hands to wrap and strap the jacket.

FIG. 2 illustrates an insulation skirt which may be used in conjunction with the jacket of the invention so as to thermally insulate the upstanding portion of a valve casing against thermal losses. As shown, the skirt 40 is provided with parabolic shaped sections which, when the skirt is wrapped around an upstanding section of a valve casing, correspond to the U-shaped cutouts of the insulation jacket. The skirt 40 is additionally provided with fastening means 46 and 48 which make it possible to securely fasten the skirt. The fastening means may comprise a series of hooks adapted to be used in conjunction with twist wires or the like for securing the skirts. Additionally, the skirt may be provided with a series of straps such as those disclosed in FIG. 1 or may be fastened in any other desired fashion.

FIG. 3 illustrates an insulation cap 50 provided with an upper wall and a slit 56 adapted to accommodate the control wheel of a valve mounted on a valve stem such that the cap may be slipped over the control wheel and lowered to surround the skirt by means of a lateral wall 58. The lateral wall is provided with a strap 52 and buckle 54 for securing the cap over the skirt and around the valve casing.

The cap may further be provided with mating Velcro sections 59a and 59b in cutaway section 58 to provide for further ease of assembly.

FIG. 4 illustrates the insulation jacket when used in conjunction with a valve casing 60 having an upstanding section 65 and a horizontal section 66. The horizontal section of the valve casing ends in a flange 72 which mates with a flange 74 provided at the edge of line pipe 68. Line pipe 68 is encased within conventional insulation 70 which forms a cylindrical casing around the pipe line. As shown, the insulation 70 extends up to flange 74. Insulation jacket 10 provided with inboard strap 30 and outboard strap 32 is wound around horizontal valve casing section 66 and is adapted to extend beyond flanges 72 and 74 such that it extends up to and over insulation jacket 70. Inboard strap 30 surrounds the mating point of the two flanges 72 and 74 to tightly seal the jacket around the horizontal section of the casing while outboard strap 32 located beyond flange 74 securely and effectively maintains the insulation jacket wrapped around insulation jacket 70 thus assuring an essentially complete seal.

As may be seen from FIG. 5, the insulation jacket may be used by winding it around the valve casing such that flaps 26 and 20 overlap flaps 22 and 28 and are strapped over line insulation 70 by means of outboard straps 30 and 36. The above disclosed thermal insulation jacket is but one embodiment of a thermal insulation jacket, other thermal insulation jacket designs may be used with this invention.

The disclosed invention may be referred to as “Smart Jacket” concept that builds upon the concepts disclosed in U.S. Pat. No. 4,207,918 and extends those concepts to produce a jacket capable of direct monitoring of the energy savings realized by the end user of the smart jacket. The smart jacket concept focuses on embedding a computer, power supply, pipe temperature sensors, ambient temperature sensors, jacket surface temperature sensors, human interface devices, solid state storage, and display into the jackets concepts indicated by FIG. 6 above. Thus, the smart jacket, using energy savings calculations, would be enabled to directly monitor, log, and communicate the realized energy savings directly or indirectly to the end user.

FIG. 6 shows a schematic of the disclosed system. The box 10 represents the thermal insulation jacket. The entire system 120 is the “smart jacket”. Located within the insulation jacket 10 is a microcontroller 80, which may be, but is not limited to, an Arduino Duemilanove microcontroller board. In signal communication with the microcontroller 80 is a memory device 84, which may be, but is not limited to an SD RAM. Also in signal communication with the microcontroller 80 may be an optional display device 88 such as, but not limited to an organic LED display. Also in signal communication with the microcontroller 80 is an optional communication device 92, such as, but not limited to a wireless radio, that can both transmit and receive wireless signals. In signal communication with the microcontroller 80 is network communication connection 96, which may be an Ethernet connection. In addition, the smart jacket may have a USB port 100 that is in signal communication with the microcontroller 80. An optional power supply 104 may be located within the smart jacket. An optional fan 108 may also be part of the smart jacket. There will be at least one temperature measuring means 112. The temperature measuring means may include, but are not limited to thermocouples, thermistors, and RTDs. The temperature measuring means 112 measures the temperature of the industrial or heating equipment that achieves a high temperature. The disclosed insulation jacket and insulation jacket system may be used on any industrial or heating equipment that achieves a high temperature, including but not limited to: pipes, valves, furnaces, tanks, vessels, boilers, pumps, turbomachinery, reciprocating machinery, and ball joints. The temperature measuring means 112 is in signal communication with the microcontroller 80. In addition, there is a temperature measuring means 116 that measures the ambient air temperature, and is also in signal communication with the microcontroller 80. The temperature measuring means 112 may be a high temperature thermocouple. It may be placed under the thermal insulation jacket 10 in order to measure the pipe temperature. The thermocouple 116 may be an ambient temperature thermocouple exposed to the environment to measure the ambient temperature. The microcontroller 80 may be configured to convert the signals from the temperature measuring means 112 and 116 into calibrated temperatures, and may configured to calculate the energy savings due to the prevention of excessive heat transfer due to the insulation properties of the insulated jacket. The memory 84 may be solid state memory such as SD RAM, and may be configured to store telemetry in a log that can be used for audit and invoicing purposes. The smart jacket 120 may also comprise a display (not shown) in communication with the microcontroller 80. The display may display the real-time energy savings provided by the invention. The radio 92 may be configured to web-enable the smart jacket system 120. The fan 108 (optional) may be configured to cool the smart jacket system 120, especially when operating in high temperature environments. The optional power supply 104 may be configured to allow the smart jacket system 120 to run on 120 V AC, 12 VDC, or internal LION power supply. In another embodiment, the smart jacket system 120 may include a bank of thermoelectric generators (TEGs) 212 that are capable of converting the heat energy radiated by the pipe directly into electrical energy. This is possible due to the “Seebeck” or thermoelectric effect. This effect makes it possible to directly convert heat energy into electrical electricity.

In one embodiment, their may be a plurality of smart jackets in communication with one another to monitor the energy savings of an entire area and may communicate and may reason regarding efficiency.

The smart jacket may monitor its own energy savings and alert the owner to situations when the savings falls below a threshold. Examples of problems that would reduce efficiency are: the smart jacket has become physically damaged; the jacket has become dislodged; the jacket insulation efficiency has deteriorated, etc. In another embodiment of the invention, there may be an additional thermistor, RTD, or thermocouple on the surface of the jacket to measure the differential between the pipe temperature and the temperature of the jacket surface. This is a different measurement than the ambient air temperature referred to in FIG. 6.

Power Generation

In another embodiment of the invention, the smart jacket would have a power harvesting device that can convert heat energy from the valves and/or pipes into electrical energy to power smart jacket.

The smart jacket system 120, in an other embodiment, may include a bank of thermoelectric generators (TEGs) 212 (see FIG. 6) that are capable of converting the heat energy radiated by the pipe directly into electrical energy. This is possible due to the “Seebeck” or thermoelectric effect. This effect makes it possible to directly convert heat energy into electrical electricity.

Generated electrical energy can be used to directly power the smart jacket electronics or charge the onboard battery. Thermoelectric generators have typical efficiencies of around 5-10% (each device producing on the order of microvolts per degree Kelvin). As an example, copper-constantan produces 41 micro volts per degree Kelvin, requiring the use of several devices to produce a sufficient output voltage for direct or indirect power.

The smart jacket concept can be extended to include the idea of harvesting energy in the form of heat from the pipe and converting it to electrical energy to power smart jacket electronics, communications. This power harvesting capability will free the smart jacket from the need to have internal batteries or external power.

In addition, for smart jackets that are used outdoors they may be used in conjunction with solar cells, to provide direct power to the smart jacket electronics as well as indirect power through charging of the batteries.

Power management electronics make it possible to construct a smart jacket that includes any combination of power generation and energy storage devices, for example batteries, fuel cells, solar cells, thermoelectric generators, micro-steam turbines, etc. to provide a constant stream of power to the smart jacket components.

Smart Jacket Network

An integral part of the smart jacket assembly is the radio 92 that enables bi-directional flow of control signals and telemetry. As such, a facility instrumented with radio equipped smart jackets 120 can form explicit or ad-hoc networks (see FIG. 7) that can forward and relay information between smart jacket devices. Furthermore, smart jackets 120 can interface with external networks to provide remote displays of status and enable remote control. FIG. 7 is conceptual illustration of the radio equipped smart jacket system forming an ad-hoc network. A first smart jacket system 120 is shown, with a first zone of radio signal communication 122. The first zone of radio signal communication, as well as every other zone of radio signal communication, is that zone where the radio 92 in the respective smart jacket system is able to transmit and receive radio signals. A second smart jacket system 124 is shown, with a second zone of radio signal communication 126. A third smart jacket system 128 is shown, with a third zone of radio signal communication 130. A fourth smart jacket system 132 is shown, with a fourth zone of radio signal communication 134. A fifth smart jacket system 136 is shown, with a fifth zone of radio signal communication 138. A sixth smart jacket system 140 is shown, with a sixth zone of radio signal communication 142. A seventh smart jacket system 144 is shown, with a seventh zone of radio signal communication 146. An eighth smart jacket system 148 is shown, with an eighth zone of radio signal communication 150. Whenever two or more smart jacket systems are within a single zone of radio signal communication, those two or more smart jacket systems can communicate with each other via their respect radios 92.

A smart jacket network, thus formed, provides significant value to the facility owner/operator. The network serves as a monitoring and diagnostic device for the entire pipe network in the same way that a single jacket monitors the valve (or similar device) that it encloses. Furthermore, smart jackets can contain additional features unrelated to piping that enhance facility safety, security, and operations.

For example, a smart jacket equipped with motion detectors can publish activity through the network to the remote control station. This provides a significant ability to enhance facility security and simultaneously monitor pipeline performance.

Smart Jacket Sensors

The smart jackets sensors may include humidity, pressure, vibration, inertial, anti-tamper, visual and thermal cameras, point and line lasers to provide advanced diagnostics and auxiliary monitoring functionality.

For example, a networked smart jacket with visual or thermal cameras could monitor pipe performance and serve a facility security function as well.

Another example, a line laser could provide a safety function by having the microphone-equipped smart jacket issue a warning to approaching personal to watch out for “hot pipes” and low hanging structures that present risk for head injury. There are a million other examples.

The smart jacket can also support control and actuation in either individual or networked modes. Example uses of smart jacket actuation include facility access control, lighting control, temperature control, etc.

Smart jackets can be configured to with a variety of sensors and actuators to perform an essentially limitless number of facility monitoring and control functions. Furthermore, the control and monitoring of these functions can be transported to a remote monitoring facility by the smart jacket network.

For example, if a component fails the smart jacket could communicate the failed status of the device into the smart jacket network and affect an upstream bypass that would keep the steam supply moving through a parallel path and effectively take the failed component off line.

Advanced Smart Jacket Pipeline Diagnostics

Smart Jackets in individual or networked configurations can perform advanced pipeline diagnostics. For example, an individual smart jacket can be configured to monitor the inflow and outflow temperature of a valve (or other device) using, for example, a two-temperature measuring means arrangement, see FIG. 8. This configuration enables advanced diagnostics on performance and provides redundancy to the to energy savings calculation. FIG. 8 shows a semi-exploded view of a smart jacket system 120 comprising a device, in this example a stream trap 208, to be enclosed by the thermal insulation jacket 10 (not shown). The smart jacket system 120 will comprise a first temperature measuring means 200 to detect the inflow temperature of the stream, and a second temperature measuring means 204 detects the outflow temperature of the stream. The temperature measuring means will be in communication with the microcontroller 80 (not shown).

This arrangement in the preceding paragraph can be extended to multiples of sensors of the types described previously. This increasingly potent combinations device-level and network level functions are made possible using the smart-jacket-network. As previously described network level functions can include pipeline diagnostics, facility monitoring, security, and safety (as examples). The smart jacket system 120 may be configured such that the microcontroller 80 is in signal communication with a remote monitoring facility, such as a site control room.

It should be noted that the terms “first”, “second”, and “third”, and the like may be used herein to modify elements performing similar and/or analogous functions. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.

While the disclosure has been described with reference to several embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.

Claims

1. A thermal insulation jacket system, comprising:

a thermal insulation jacket configured to cover a steam trap;

a first sensing device configured to output a signal indicative of an external surface temperature of the steam trap;

a second sensing device configured to output a signal indicative of an ambient temperature proximate the steam trap;

a third sensing device configured to output a signal indicative of an inflow temperature of the steam trap;

a fourth sensing device configured to output a signal indicative of an outflow temperature of the steam trap; and

a processing device communicatively connected to the first, second, third and fourth sensing devices, wherein the processing device is configured to: determine real-time energy savings attributable to the thermal insulation jacket based on signals received from the first and second sensing devices; and diagnose an operating condition of the steam trap based on signals received from at least one of the third and fourth sensing devices.

2. The thermal insulation jacket system of claim 1, wherein the thermal insulation jacket comprises a removable and reusable thermal insulation jacket.

3. The thermal insulation jacket system of claim 1, wherein the first sensing device is positioned between the thermal insulation jacket and the steam trap.

4. The thermal insulation jacket system of claim 1, wherein the processing device is further configured to convert signals from the first, second, third and fourth sensing devices into calibrated temperatures.

5. The thermal insulation jacket system of claim 4, wherein the processing device is further configured to calculate the real-time energy savings based on the calibrated temperatures associated with the first and second sensing devices.

6. The thermal insulation jacket system of claim 4, wherein the processing device is further configured to determine the operating condition of the steam trap based on the calibrated temperatures associated with the at least one of the third and fourth sensing devices.

7. The thermal insulation jacket system of claim 1, wherein the operating condition of the steam trap comprises a working steam trap condition.

8. The thermal insulation jacket system of claim 1, wherein the operating condition of the steam trap comprises a failed steam trap condition.

9. The thermal insulation jacket system of claim 8, wherein the failed steam trap condition comprises a failed open steam trap condition.

10. The thermal insulation jacket system of claim 8, wherein the failed steam trap condition comprises a failed closed steam trap condition.

11. A thermal insulation jacket system, comprising:

a thermal insulation jacket configured to surround a steam trap, wherein the thermal insulation jacket comprises a removable and reusable thermal insulation jacket;

a controller proximate the thermal insulation jacket; and

a plurality of sensors communicably connected to the controller, wherein the controller is configured to: calculate real-time energy savings attributable to the thermal insulation jacket based on an external surface temperature of the steam trap and an ambient temperature proximate the steam trap; and diagnose a performance status of the steam trap based on at least one of the following: an inflow temperature of the steam trap; and an outflow temperature of the steam trap.

12. The thermal insulation jacket system of claim 11, wherein the plurality of sensors comprises:

a first sensor positioned between the thermal insulation jacket and an external surface of the steam trap;

a second sensor configured to sense the ambient temperature proximate the steam trap;

a third sensor configured to sense the inflow temperature of the steam trap; and

a fourth sensor configured to sense the outflow temperature of the steam trap.

13. The thermal insulation jacket system of claim 11, wherein the performance status of the steam trap comprises a failed status.

14. The thermal insulation jacket system of claim 13, wherein the failed status comprises a failed open status.

15. The thermal insulation jacket system of claim 13, wherein the failed status comprises a failed closed status.

16. A thermal insulation jacket system, comprising:

a thermal insulation jacket configured to surround a valve;

a plurality of detection devices, wherein each detection device is configured to detect a different temperature associated with the valve; and

a computing device coupled to the thermal insulation jacket and communicably connected to the plurality of detection devices, wherein the computing device is configured to: calculate real-time energy savings attributable to the thermal insulation jacket; and perform at least one diagnostic analysis associated with the valve.

17. The thermal insulation jacket of claim 16, wherein the valve comprises a steam trap.

18. The thermal insulation jacket of claim 16, wherein the plurality of detection devices comprise:

a first detection device configured to detect an external surface temperature of the valve;

a second detection device configured to detect an ambient temperature proximate the valve;

a third detection device configured to detect an inflow temperature of the valve; and

a fourth detection device configured to detect an outflow temperature of the valve.

19. The thermal insulation jacket system of claim 16, wherein the at least one diagnostic analysis comprises an operational state of the valve.

20. The thermal insulation jacket system of claim 16, further comprising a communication device communicably connected to the computing device, wherein the communication device is configured to communicate with at least one other thermal insulation jacket system.