Fluid analyzer manifold and techniques

A fluid analyzer manifold for facilitating flow of a fluid through at least one surface mounted component for analysis by a fluid analyzer. The exemplary fluid analyzer manifold can include an analysis chamber for connection with the fluid analyzer, a first flow channel having a first surface opening and a second flow channel having a second surface opening on the fluid analyzer manifold, and a mounting area on the fluid analyzer manifold. The mounting area can include the first and second surface openings of the first and second flow channels, and facilitates surface mounting the at least one surface mounted component to the fluid analyzer manifold.

BACKGROUND

The subject matter disclosed herein relates to fluid analyzers, such as gas analyzers. Fluid analyzers may be used to measure various properties of different types of fluids, such as liquids, gases, or mixed-phase fluids. As one example, a fluid analyzer may be used to determine the concentration of various chemical compounds in a fluid. This analysis may be used to determine whether or not the fluid meets certain acceptable process parameters, such as tolerances required during a refining or transport process.

For certain applications, continuous monitoring of a fluid is typically conducted in order to ensure that the fluid continuously conforms to required specifications. Such requirements are typically present in oil or gas pipelines or refineries, in which fluids are continually monitored to ensure proper functioning of the infrastructure. Continuous monitoring of a fluid from a pipeline may require valves and pressure regulators for allowing a specific pressure and flow rate of the fluid through the fluid analyzer. In addition, provisions may be required for so-called service gases to be sent through the analyzer for calibration or other purposes, and other components such as filters may be required or desired for a given application.

Deployment of fluid analyzers may be required in harsh conditions, for example, at temperatures as low as −40° C. in certain oil or gas pipeline applications. Further, the fluid analyzers may need to be deployed in relatively small spaces, and may need to be operable for long durations in remote areas. Typically, fluid analyzer systems are quite complex, with numerous flow components, valves, pressure regulators, and the like, required in a given deployment. Further, the system may include a fluid analyzer sensor that has a laser system and an analysis chamber. Conventionally, the fluid analyzer sensor and other components are assembled together using multiple discrete pipes, connectors, fittings, etc. Disadvantageously, a fluid analyzer system may include dozens of pipes and fittings to be connected and tested, a process which may take dozens of hours over the course of several days. In addition, each component or part of a fluid analyzer system may be prone to failure, leading to great expense and difficulty in achieving successful deployment in typical operating conditions. Therefore, enhancements to fluid analyzers and related systems to increase serviceability, reliability, ease of deployment, and decreased cost and footprint are desirable.

SUMMARY

Advantages can be provided by one or more of the embodiments disclosed herein through the provision, in one aspect, of a fluid analyzer manifold for facilitating flow of a fluid through at least one surface mounted component for analysis by a fluid analyzer. The exemplary fluid analyzer manifold can include an analysis chamber for connection with the fluid analyzer, a first flow channel having a first surface opening and a second flow channel having a second surface opening on the fluid analyzer manifold, and a mounting area on the fluid analyzer manifold. The mounting area includes the first and second surface openings of the first and second flow channels, and facilitates surface mounting the at least one surface mounted component to the fluid analyzer manifold. Advantages that may be realized in the practice of some disclosed embodiments of the fluid analyzers include increased reliability, reduced footprint, and reduced costs.

In another aspect, a fluid analyzer manifold for facilitating flow of a fluid through surface mounted components for analysis by a fluid analyzer is presented. The fluid analyzer manifold includes, for instance, an analysis chamber for connection with the fluid analyzer, and an inlet channel having an inlet opening and an outlet channel having an outlet opening on the fluid analyzer manifold, the inlet and outlet channels each being in fluid communication with the analysis chamber. In addition, the fluid analyzer may include a first flow channel comprising a first flow input opening and a first flow output opening on the fluid analyzer manifold, and a second flow channel comprising a second flow input opening and a second flow output opening on the fluid analyzer manifold. Further, the fluid analyzer may include a bypass channel comprising a bypass input opening and a bypass output opening on the fluid analyzer manifold, and a mounting area and a bypass mounting area on the fluid analyzer manifold, the mounting area including the first surface flow output opening, the second surface flow input opening, and the bypass input opening, and the bypass mounting area including the bypass output opening. The mounting area may facilitate surface mounting a first component of the surface mounted components to the fluid analyzer manifold and the bypass mounting area facilitates mounting a second component of the surface mounted components to the fluid analyzer manifold.

In a further aspect, a technique for fabricating a unibody fluid analyzer manifold from a solid bar of material is presented. For instance, an analysis chamber for connection with the fluid analyzer may be formed in the solid bar of material. In addition, the solid bar of material may be machined to form an inlet channel having an inlet opening and an outlet channel having an outlet opening on the fluid analyzer manifold. The inlet and outlet channels may each be in fluid communication with the analysis chamber. Further, the solid bar of material may be machined to form a first flow channel having a first flow input opening and a first flow output opening on the fluid analyzer manifold, a second flow channel comprising a second flow input opening and a second flow output opening on the fluid analyzer manifold, and a bypass channel having a bypass input opening and a bypass output opening on the fluid analyzer manifold. Further, the solid bar of material may be machined to form a mounting area and a bypass mounting area on the fluid analyzer manifold. The mounting area may include the first surface flow output opening, the second surface flow input opening, and the bypass input opening. The bypass mounting area may include the bypass output opening. The mounting area may facilitate surface mounting a first component of the surface mounted components to the fluid analyzer manifold and the bypass mounting area may facilitate mounting a second component of the surface mounted components to the fluid analyzer manifold.

The above embodiments are exemplary only. Other embodiments are within the scope of the disclosed subject matter.

DETAILED DESCRIPTION

Embodiments of the disclosed subject matter provide techniques for fluid analysis, and more particularly for fluid analyzer manifolds and fabrication techniques. The present disclosure provides, in part, fluid analyzer manifolds for use in applications such continuous monitoring of fluids, as well as techniques for fabricating fluid analyzer manifolds. Advantageously, these fluid analyzer manifolds combine an analysis chamber for a fluid analyzer with facilities for connecting the fluid analyzer with a fluid source and a variety of modular surface mounted components to perform various fluidic functions such as pressure regulation, flow control, bypass, calibration, filtration, etc. As such, the fluid analyzer manifolds reduce the size and footprint required for a fluid analyzer system because the fluid analyzer manifolds include internal chambers and channels that eliminate or reduce the need for various separate parts such as tubes, pipes, fittings, etc. As a further advantage, the fluid analyzer manifolds facilitate increased reliability and ease of deployment due, in part, to the unibody designs and integrated channels and chambers provided therein. In addition, the reduction in the number of pipes, fittings, connections, etc., reduces the time required for field installation and eliminates numerous potential points of failure in the system. Other embodiments are within the scope of the disclosed subject matter.

FIG. 1depicts an exemplary fluid analyzer system100, in accordance with aspects set forth herein. In the embodiment ofFIG. 1, fluid analyzer system100includes a fluid analyzer manifold101, a fluid analyzer102, and an analysis device103. Fluid analyzer102may be connected to an analysis chamber125of the fluid analyzer manifold. In one specific example, the fluid analyzer may include tunable diode laser absorption spectroscopy (TDLAS) to measure the moisture content of a gas, such as natural gas. Fluid analyzer system100may further include multiple modular components110, which may be surface mounted on fluid analyzer manifold101. Modular components110may be used to provide various fluid related functions, including fluid inlets, fluid outlets, pressure regulators, filters, etc. For example, modular components110may include regulators or sensors, selection valves, filters, temperature sensors, rotameters, bypass valves, etc. Example supported valve types include: diaphragm, needle, toggle, pneumatic, metering, check and shut-off valves. Example supported regulator types include: back-pressure, pressure-reducing, and application options for phase changes, low pressure, or high pressure flow. Example supported filters include: filters: coalescing (membrane), high purity, and particulate. Other example components include: fittings, adapters and ports. Example sensors include: flow sensor (rotameter), pressure gauge, pressure transducer, thermometer, thermowell, and variable area flowmeter.

In one embodiment, fluid analyzer manifold101may be fabricated from a solid bar of metal (e.g., bar stock or billet) from which material has been removed to form various internal channels and chambers, as well as various surface mount areas. The channels, chambers, and surface mount areas of fluid analyzer manifold101allow connection of modular components110and fluid analyzer102. The internal channels and chambers of fluid analyzer manifold101may allow a fluid to pass through fluid analyzer system100in a regulated manner to facilitate accurate fluid analysis. Advantageously, the unibody construction of fluid analyzer manifold101may allow for the elimination of numerous tubes, pipes, fittings, seals, connectors, etc., thus reducing the number of components which may potentially fail in fluid analyzer system100, therefore increasing reliability. As another advantage, overall system size and installation complexity may be reduced, allowing more flexible field deployment options. As a further advantage, a unibody construction in which a solid bar of metal has been machined to form the various channels and surface mount areas may allow for greater fluid pressure to be handled by the system.

The embodiment ofFIG. 1illustrates one exemplary flow path through fluid analyzer system100. For instance, first a fluid may be connected to a supply fluid valve component110a. Next, the fluid may flow within fluid analyzer manifold101to a membrane filter component110b, which may be designed to remove impurities to protect fluid analyzer102. For example, membrane filter component110bmay be used to remove small amounts of liquid present in a gas on a continuous basis. For example, filter component110bmay serve one or more purposes. One purpose may be to protect other modular components110, e.g., the rotameter, which are sensitive to impurities. Another purpose is to help filter the gas for users of the fluid analyzer system100. Advantageously, filtering in the continuous fluid analyzer may improves gas product quality without requiring a separate deployment. A further purpose may be to mitigate blockage in the system, due to impurities collecting in flow channels. In another embodiment, a wedge window may be provided to separate the fluid analyzer from the sampling region, so that the fluid analyzer components are not directly exposed to the gas.

Next, the fluid may travel within fluid analyzer manifold101to a pressure regulator component110c, which may be used to adjust the pressure of the fluid to ensure that an appropriate target fluid pressure continues within fluid analyzer system100for analysis by fluid analyzer102.

Continuing with the exemplary flow path, the fluid may flow within fluid analyzer manifold101from pressure regulator component110ctowards both a bypass valve component110dand a selection valve component110e. In such a case, some fluid may be allowed to exit fluid analyzer system100at bypass valve component110d, e.g., to reduce the amount of fluid in fluid analyzer system100to facilitate faster analysis. Then, the rest of the fluid may flow within fluid analyzer manifold101towards selection valve component110e.

Next, selection valve component110emay be connected to a service fluid valve component110fand a sample fluid valve component110g. Selection valve component110emay therefore select whether the fluid under test from pressure regulator component110c, or a service fluid from service fluid valve component110f, may flow to sample fluid valve component110g. For example, a service fluid may be used to calibrate the system. The selected fluid may flow within fluid analyzer manifold101from sample fluid valve component110gto analysis chamber125. Sample fluid valve component110gmay be used to fine-tune the pressure or amount of fluid entering analysis chamber125.

In addition, once the fluid enters analysis chamber125, the fluid may be analyzed by fluid analyzer102, and the results of the analysis may be sent to analysis device103. Analysis device103may also receive signals from any or all of components110. Next, the fluid may flow through fluid analyzer manifold101to a rotameter component110hwhich may calculate the fluid flow rate. The fluid may subsequently exit fluid analyzer system100, and enter the next phase of a customer process.

In various embodiments, the multiple components110, which may be surface mounted to fluid analyzer manifold101, may comprise any of the components noted above, e.g., supply fluid valve component110a, membrane filter component110b, pressure regulator component110c, bypass valve component110d, selection valve component110e, service fluid valve component110f, sample fluid valve component110g, rotameter component110h, and the like. Depending upon a specific application, different components110may be surface mounted in different orders or configurations to fluid analyzer manifold101. In the descriptions that follow, for ease of comprehension a similar nomenclature will be used, and a suffix letter will identify the location of an element in correspondence with the suffixes a-h, etc., as used above with respect to components110a-110h.

By way of overview of the operation of fluid analyzer system100, signals from fluid analyzer102may be sent to analysis device103via electronic connections. Advantageously, the integrated design of fluid analyzer system100allows for the elimination of a junction box, which would otherwise be mounted to fluid analyzer manifold101. Instead of using a junction box, the electronics and electrical connections may be housed directly within the analyzer through a back portion of fluid analyzer manifold101, allowing for elimination of a separate junction box, reducing bulk and further connection points that may fail. In addition, analysis device103may also capture signals from various sensors, such as sensors integrated within components110. These sensors may include pressure sensors, temperature sensors, etc. Analysis device103may combine the input from fluid analyzer102and other sensors, such as components110, in performing fluid analysis functions.

For example, analysis device103may combine such information to determine the number of parts per million (PPM) of moisture in the sample fluid, and analysis device103may display such information on a user interface of a connected screen or other output device. In addition, analysis device103may obtain sensor information from rotameter component110h, and display such information on the user interface as an indication that fluid analyzer system100is functioning properly and that an appropriate amount of fluid is passing through to facilitate meaningful analysis.

As one having ordinary skill in the art will readily understand, in one specific example, fluid analyzer102may include a tunable diode laser absorption spectroscopy (TDLAS) system. A TDLAS moisture analyzer may be used to determine the moisture content of a fluid. At certain specific frequencies, light energy will be absorbed by water molecules. As the concentration of water increases, the absorption also increases. A TDLAS fluid analyzer can sweep a diode laser output through a narrow spectrum of light frequencies. By measuring the return light intensity with a photo detector as compared to the incident light intensity, the fluid analyzer can provide a direct indication of the partial pressure of water. The partial pressure divided by the total pressure yields the mole ratio, which may be expressed as parts per million by volume (ppmv).

Fluid analyzer manifolds as disclosed herein may be used in a variety of applications. For instance, many applications, such as petrochemical application, require the measurement or control of fluid composition and properties, and a fluid analyzer manifold can facilitate integration of such measurement and composition control devices with the fluid source. In addition, ultrasonic flowmeters, which measure mass flow rate of a liquid or gas, may use ultrasonic transducers to conserve energy and reduce fluid loss by identifying sources of leaks into flare systems. In such a case, the ultrasonic transducers may be integrated with fluid analyzer manifold101to provide a complete system.

Various structural features of exemplary fluid analyzer manifold101facilitate the fluid analysis examples described with respect toFIG. 1. For instance, fluid analyzer manifold101includes surface openings to facilitate surface mounting of components, as well as internal chambers and channel to facilitate fluid flow between and among the components. Regarding surface features,FIGS. 2A-2Care elevational views of the front, right side, and left side, respectively, of fluid analyzer manifold101, in accordance with aspects set forth herein.

In the embodiment ofFIGS. 2A-2C, fluid analyzer manifold101includes numerous surface mounting areas120. Surface mounting areas120may comprise surface mounting areas120a-120m, and may facilitate surface mounting of components110a-110h(seeFIG. 1) to the different surfaces of fluid analyzer manifold101.

Characterizations of components110and mounting areas120as set forth herein in one embodiment are summarized with reference to Table 1.

Various types of surface mounting areas may be defined to support the requirements of various types of surface mounted components110. For instance, some surface mounting areas120, such as surface mounting areas120b,120c,120e,120g-120i, may include one or more surface openings130of fluid analyzer manifold101, as well as multiple (e.g., four) threaded holes132that allow components110to be fastened to the surface of fluid analyzer manifold101. Openings130may be surrounded by O-ring grooves131to facilitate fluid-tight sealing of components110to the surface of fluid analyzer manifold101. In such a case, a component110may be mounted over a surface mounting area120with access to multiple surface openings130to facilitate a fluid flowing from one opening130to other openings130, after component110performs its fluidic function, e.g., pressure regulation, filtration, etc.

In addition, other surface mounting areas120, such as surface mounting areas120a,120d,120f, and120j, may include a single threaded tapered opening130′, to which another style of component110may be mounted directly without being bolted to fluid analyzer manifold101using threaded holes132. For example, threaded tapered opening130′ may conform to an American Society of Mechanical Engineers (ASME) National Pipe Thread Taper (NPT) standard. Further surface mount areas120, such as surface mounting areas120k-120mmay be provided which include openings that are aligned perpendicular to the axis of the longitudinal flow channels to allow for separation of a single longitudinal channel into multiple distinct flow channel through the use of different types of plugs145ofFIG. 2E, which will be further explained below.

Turning next to the internal features,FIG. 2D-2Fare partially transparent views of fluid analyzer manifold101, in accordance with aspects set forth herein. Various flow channels140may be seen in the transparent view ofFIG. 2D, and may be described with respect to which surface mount areas120are joined by flow channels140. In addition, six different flow channels140are depicted. Further, some flow channels are substantially U-shaped, other flow channels are substantially L-shaped, and yet other flow channels are substantially straight. In other embodiments, the flow channels may have other shapes, such as I-shaped or T-shaped channels, or may be angled, such as having a V-shape instead of an L-shape, or may be more rounded, or may be offset from one another to accommodate many different flow channels which are located within close proximity.

To understand how the various flow channels may be employed, the embodiment ofFIG. 2Ddepicts multiple types of mounting areas120, which may include one, two, or three openings130,130′. Such configurations allow for different types of components110to facilitate the flow of the fluid within fluid analyzer manifold101to achieve continuous monitoring of the fluid. For example, mounting areas120c,120emay be viewed as bypass mounting areas, because each mounting area includes three different openings130of three different flow channels140. In such a case, an appropriate component110may allow change of fluid flow depending on conditions.

For example, selection valve component110e(FIG. 1) may be mounted to mount area120e, which includes openings130of flow channels140ce,140ef, and140eg. In such a case, selection valve component110emay be configured to allow fluid to flow either from flow channel140ceto flow channel140eg, to facilitate fluid analysis. Alternately, selection valve component110emay be configured to restrict flow from flow channel140ceand allow fluid to flow from flow channel140efto flow channel140eg, to facilitate the use of a service gas in calibrating the fluid analysis system. In an analogous manner, each of the mounting areas may be used, with an appropriate component, such as a flow component, to direct fluid flow to any of the included flow channels that have openings at the mounting area. For example, characterizations of flow channels140and connections as set forth herein in one embodiment are summarized with reference to Table 2.

Returning to internal features,FIGS. 2E & 2Fare partially transparent views of the front side and the right side, respectively, of fluid analyzer manifold101, in accordance with aspects set forth herein. As compared withFIGS. 2A & 2F, internal channels and chambers of fluid analyzer manifold101are depicted.

Regarding fabrication methods and techniques, in order to fabricate flow channels140, deep hole formation techniques, such as gundrilling, may be employed. For example, in one embodiment, fluid analyzer manifold may include channels that have an aspect ratio, e.g., ratio of length to diameter, of up to 400:1, the formation of which may not be feasible using certain drilling techniques. In one example, a cutting process may be employed in which a cutting tool is provided with a mechanism for delivering coolant to the tip of a drill, so that the chips are removed from the hole to facilitate the formation of a straight, deep hole. In the illustrated embodiment, surface mounting areas120k-120mallow for the provision of plugs145to separate a single longitudinally drilled flow channel into multiple flow channels140, in order to achieve U-shaped flow channels. Other style plugs may be used so that a flow channel is not fully blocked by the plug, such as a situation in which it is desired for the plug to direct flow into an appropriate channel.

In one embodiment of a process for forming fluid analyzer manifold101, a solid bar of material, such as metal bar stock, may be obtained and machined, using gundrilling or other deep hole formation techniques, to form flow channels140, surface openings130, etc. In addition, other machining techniques may be used to form the other external and internal features of fluid analyzer manifold101, including threaded holes132and tapered openings130′. Advantageously, the formation of fluid analyzer manifold101, starting from a solid block of metal, eliminates the possibility that numerous parts such as tubes, pipes, fittings, flanges, etc., may be incorrectly assembled when a fluid analyzer system is deployed, because the connections are made during the fabrication process which may be carefully controlled and monitored. As another advantage, fluid analyzer manifolds101may be readily mass produced. In another embodiment, an additive manufacturing process (e.g., 3D printing) may be used to form fluid analyzer manifold101. For example, successive layers of metal or a metal alloy may be formed using an appropriate controller to create fluid analyzer manifold101.

In the embodiment ofFIGS. 2E & 2F, fluid analyzer manifold101includes an analysis chamber125. For example, analysis chamber125may be connected to a bottom mounting area126and a top mounting area127, which may be used to mount fluid analyzer102(seeFIG. 1) to fluid analyzer manifold101. For example, a TDLAS system may be provided by mounting a laser source to top mounting area127and a mirror component to bottom mounting area126. In other applications, fluid analyzer manifold101may be configured with application-dependent mounting areas, application-dependent flow channels, and one or more application-dependent analysis chambers. In such a case, the chambers and/or flow channels may be configured to facilitate connection with the appropriate sensors, to accommodate access of the fluid analyzer and sensors thereof to the sampling region or analysis chambers.

In an additional embodiment, fluid analyzer manifold101may include an input flow channel140-I and an output flow channel140-O. In the embodiment ofFIG. 2F, for example, flow channels140-I,140-O may be in fluid communication with analysis chamber125.

In a further embodiment, fluid analyzer manifold101may include a heating channel128, which is not in fluid communication with the analysis chamber125. For instance, heating channel128may be spaced apart from analysis chamber125, and may extend for a majority of the length thereof. In addition, heating channel128may allow for the provision of a heater. In such a case, because of the unibody metal construction of fluid analyzer manifold101, heat from the heater may readily conduct throughout fluid analyzer manifold101, and transfer to the fluid being analyzed. For example, the heater may uniformly heat the fluid within analysis chamber125because of the disposition of heating channel128along analysis chamber125. Advantageously, by allowing for all fluid connections to be made by flow channels140, which are within fluid analyzer manifold101, a heater deployed in heating channel128may allow for a fluid analyzer system to be installed in harsh conditions, such as temperatures that range below −40° C. For example, a ⅛″ diameter electric cartridge heater may be deployed within heating channel128. Depending upon the requirements, the metal or metal alloy of fluid analyzer manifold101may be selected to provide appropriate thermal conductivity to facilitate the heating functionality. For example, in one specific embodiment, fluid analyzer manifold may be formed from stainless steel, so that the manifold has the required strength and anti-corrosion properties needed for deployment with sample fluids.

To the extent that the claims recite the phrase “at least one of” in reference to a plurality of elements, this is intended to mean at least one or more of the listed elements, and is not limited to at least one of each element. For example, “at least one of an element A, element B, and element C,” is intended to indicate element A alone, or element B alone, or element C alone, or any combination thereof. “At least one of element A, element B, and element C” is not intended to be limited to at least one of an element A, at least one of an element B, and at least one of an element C.