Abstract:
A probe is provided that combines in one housing a pressure regulator and filter/dryer element. The probe may be connected to a conduit for the transfer of a fluid sample, such as natural gas, from the conduit to provide separation of the fluid such that a gaseous component may be then subsequently transferred to an instrument or the like. If liquid is separated it may be returned to the conduit via a return line.

Description:
BACKGROUND OF INVENTION  
         [0001]    The present invention relates to an instrument feed stream processing device, e.g., an instrument probe that is used to separate certain components of a fluid and control the pressure of the fluid within the device and downstream instruments.  
           [0002]    In the transport of fluids such as hydrocarbon gas, for example, natural gas, it is desirable to sample the gas to determine its properties. Such sampling can include the measurement of the Btu value of the gas. Even though natural gas is referred to as a gas, it oftentimes includes liquids and particulate matter. In order to ensure proper operation of some instruments, a pressure regulator and a filter/dryer are interposed in the flow path between the source of gas, e.g., a natural gas pipeline and the instrument. The pressure regulator and the filter dryer are separate units joined together by couplings and then coupled between the instrument and the conduit. Although effective in controlling pressure and eliminating deleterious material, there are a large number of joints as a result of such an arrangement of components with each joint providing a potential leakage source.  
           [0003]    In addition to additional potential leak sources, each component is separately made usually from expensive materials, such as, stainless steel and aluminum alloys, increasing the cost of the total system. Separate units also utilize a large number of parts and/or assemblies.  
           [0004]    An example of filter dryers include F-4 and F-23 from Welker Engineering, Co. of Sugar Land, Tex. Examples of pressure regulators are IR-4 and IRD-4SS also from Welker Engineering.  
           [0005]    The deleterious materials, as discussed above, can include both liquid components and particulate matter. A liquid component could be detrimental, for example, if the instrument or instrument package includes a gas chromatograph. Liquid entering a gas chromatograph negatively affects its ability to perform an analysis and prevents the instrument from properly operating. It is thus desirable to separate liquid components from the natural gas and preferably exhaust those from the filter/dryer to prevent excessive accumulation. Also, particulate matter can negatively affect operation of an instrument by plugging small pores or flow channels. Thus, it is also desirable to preclude particulate matter of at least a certain size from entering the instrument. The filters to accomplish particulate separation are well known in the art and examples are identified above. A filter for particulate matter generally accumulates the particulate material on the filter element or within the filter media. The filter media is replaced or cleaned from time to time in order to ensure proper operation of the filter device and hence the downstream instrument.  
           [0006]    The pressure in some natural gas pipelines can be very high, as high as 5,000 psi although typically the pressure in a pipeline is in the range of between about 300 psi and about 1200 psi gage pressure. It is desirable to reduce this pressure to a pressure in the range of between about 10 psi and about 50 psi prior to a sample entering the instrument and filter/dryer in order to protect both units and to permit the units to be constructed of elements that do not need to sustain the forces from high pressure.  
           [0007]    As discussed, although there are commercially available devices to effect both pressure regulation and filtration/drying, there is a need for an improved device to effect both pressure regulation and filtering/drying.  
         SUMMARY OF INVENTION  
         [0008]    The present invention involves the provision of a device for use in gathering and processing fluid samples from a conduit. The device includes a separator combined with a pressure regulator in a common housing. The housing has a body and a cap that are selectively separable. A coupler is provided for attaching the device to the conduit for the extraction of a sample therefrom and subsequent transmission to an instrument for evaluation. The housing includes a flow passage that includes an interior chamber in which is mounted a separator device operable to separate a gaseous component of the natural gas from other components of the natural gas. The separator device is positioned flow wise between an inlet and a first outlet that is adapted for connection to an instrument. A second outlet can be provided for the discharge of a separated liquid component from the housing. A valve is mounted to the housing and is positioned in the flow passage, flow wise between the inlet to the housing and the outlet to the instrument. The valve is operable to selectively prevent and permit flow of fluid to the outlet to the instrument from the inlet and is automatically opened and closed in response to pressure in a portion of the housing. The separator device can be of a replaceable or cleanable type and removable from the housing. 
       
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS  
       [0009]    [0009]FIG. 1 is a sectional view of a fluid stream processing device connected to a source conduit by a coupling conduit.  
         [0010]    [0010]FIG. 2 is a sectional view of a processing device similar to that of a FIG. 1, but is connected directly to the source conduit by a coupler.  
         [0011]    [0011]FIG. 3 is a sectional view of a processing device in combination with an automatic insertion device which is operable to move an intake into and out of the flow stream in the conduit. The end of the intake is shown in a retracted position.  
         [0012]    [0012]FIG. 4 is a sectional view similar to view FIG. 3, but shows the intake end in an extended position in the flow stream within the conduit. 
     
    
       [0013]    Like numbers throughout the various Figures designate like or similar parts.  
       DETAILED DESCRIPTION  
       [0014]    The present invention involves a fluid stream processing device or probe designated generally  1  (which is shown in two forms in FIG. 1 and FIG. 2), which comprises a housing, designated generally  3 , that contains a separator device, designated generally  5 , a pressure regulator, designated generally  7 , and means, designated generally  9 , for attaching the device  1  to the a conduit. The housing  3  includes a body designated generally  11  and a cap designated generally  13  removably mounted on the body. The body  11  is in the form of a hollow cup with an interior chamber  15 , that forms part of flow passage, designated generally  17 , that is branched. The body  11  has a generally round transverse cross-section and a side wall  19  with an upper open end  21 . The body  11  also includes a bottom wall  23 . The chamber  15  is defined by an interior side wall surface  24  and an interior bottom wall surface  25 . The upper portion of the interior and the exterior of the side wall  19  may be internally and externally threaded as at  26  and  27 , respectively, for a purpose later described. The flow passage  17  includes a branch  17 A through the bottom wall and that opens into the chamber  15  which chamber is also part of the flow passage. A first outlet passage branch  177 B includes an outlet port  29  through the side wall  19  for feeding fluid to a sampling device such as an instrument sampling cylinder or the like. The passage  17  also includes a second outlet branch  17 C that includes a second outlet port  30 . The branch  17 C as shown, opens into the branch  17 A and provides at the branch  17 A both an inlet for the intake of fluid and for discharge of liquid separated from the fluid to be exhausted through the outlet port  30 . Both of the outlet ports  29 ,  30  are threaded to accept couplers (not shown) as are known in the art. The outlet port  29  is connected in flow communication to an instrument shown schematically as  33 . A shutoff value  35  may be provided in the connecting conduit  37 , connecting the outlet port  29  to the instrument  33 . The outlet port  30  can be connected for exhaust of the separated liquid by a conduit shown schematically as  39  to atmosphere or a collection device  42 . A valve  41  may be interposed in the conduit  39  to regulate flow of exhausted liquid with the valve  41  not only being capable of controlling flow, but also terminating flow of liquid to the atmosphere or collection device  42 . The branch  17 A includes an intake port  43  that is adapted for the receipt of a coupler  45 . The coupler  45  is seen in FIG. 1 is connected to a source conduit  40  via a conduit  47  that is suitably attached to the coupler  45  and the conduit  40  as by fittings  48 . The conduit  47  includes an intake member  49  that is shown as a single type intake, however it is to be understood that any form of intake member  49  may be utilized such as a pitot tube type intake.  
         [0015]    The housing  3  includes the cap  13 . The cap  13  has a depending flange  51  that is internally threaded for mutual threaded engagement with the externally threaded section  27  of the body  11  for removably securing the cap  13  to the body  11 . The flange  51  is an integral part with and depends from cover portion  53 . The cover portion  53  has an interior wall  54  that in combination with the interior of the flange  51  forms a recess  55  for the receipt of an upper portion of the side wall  19  therein when the cap  13  and body  11  are secured together. The cover  53  has an internal pocket  57  therein for a purpose later described. The cap  13  forms part of the housing  3  for the pressure regulator  7  and includes a hollow and preferably integral shroud designated generally  59  comprising a side wall  61  and an end wall  62 .  
         [0016]    The pressure regulator  7  is preferably spring and pressure operated. In the illustrated structure, the pressure regulator  7  includes a compression spring  64  mounted in the interior of the shroud  59  and has one end in engagement with an adjuster  66  that is in threaded engagement with the end wall  62  and is selectively longitudinally movable in a direction along the longitudinal axis of the compression spring  64 . The adjuster  66  may be utilized to selectively adjust the amount of preload force in the compression spring  64  which will allow for adjustment of the pressure needed to open and close a valve assembly designated generally  69  and described below. The adjuster  66  may be secured in any desired position, as for example with a lock nut  67 . A diaphragm  71  is provided to seal the interior of the shroud  59  from the flow passage  17  and is flexible to allow operation of the valve assembly  69  as is known for spring actuated pressure regulators. The diaphragm  71  is captured between a portion of the cover  53  and a retainer  73 . The retainer  73  has a portion thereof positioned within the pocket  57 .  
         [0017]    The retainer  73  has a threaded external side wall  75  that is in mutual threaded engagement with the internally threaded portion  26  of the side wall  19 . A seal  76 , such as an o-ring, seals the retainer  73  to the side wall  19  adjacent the upper end of the side wall to prevent leakage between the cap  13  and the body  11 . The retainer  73  has a passage in the form of a through bore  78  providing for flow through the retainer into a chamber  79 , which is on one side of the diaphragm  71  and opposite to the side of the spring  64  is on. The pressure of the fluid contained within the chamber  79  applies a force, via the diaphragm  71 , to the spring directed opposite to that of that from the pre-load force applied by the spring  64 . An actuator rod  81  engages the diaphragm  71  and extends through the bore  78  to the valve assembly  69 .  
         [0018]    The valve assembly  69  for convenience of manufacturing has a portion thereof mounted in the coupler  45  and a portion mounted in the body  11 . As shown, the valve assembly  69  includes a valve element  83 , movably mounted in a recess  85 . A resilient member  87 , such as a coil spring, biases the valve element  83  to a closed position in seating engagement with a valve seat  89 , which is preferably removably mounted in a pocket  91  in the body  11 . Preferably, the valve seat  89  is removably mounted for ease of repair and replacement. The valve element  83  and valve seat  89  have interengagable tapered (truncated cone shaped) seating surfaces, which when in engagement seal the branch  17 A and hence the flow passage  17  from receiving fluid from the conduit  40 . Preferably, the valve element  83  is attached to an end of the actuator rod  81  and is movable therewith under the influence of either the diaphragm  71  or spring  64 , depending on whether it is moving from an open position to a closed position or from a closed position to an open position. The spring  64  moves the valve element  83  to an open position while the diaphragm  71  and the spring  87  operate to effect movement of the valve element  83  to a closed position. Adjustment of the pressure needed to move the valve element  83  to a closed position is adjustable via the pre-load force in the spring  64 . Also, when the valve element  83  is in a closed position, it will seal the passage branch  17 C from the source conduit  40  allowing drainage of liquid from housing  3 .  
         [0019]    The probe device  1  includes a separator designated generally  5 . The separator  5  is constructed to be interposed, flow wise, between the intake port  43  and the instrument outlet port  29 . It is constructed to remove liquid and/or particulate matter from the incoming fluid prior to exiting through the outlet port  29 . It is also constructed to permit, if liquid is separated from the incoming fluid, the discharge of liquid through the outlet port  30 . As shown, the separator  5  is in the form of a cartridge having top and bottom walls  93 ,  94  respectively. The top wall  93  is sealed to the retainer  73  via a seal member  95 , such as an o-ring contained within a groove  96 , preferably in the retainer  73 . Means may also be provided in the top wall  93  to facilitate the removal of the separator  5  from the body  11 . As shown, threaded holes  97 , in which a puller, such as threaded rods or bolts may be removably inserted for extracting the separator  5  from the body  11 . The bottom wall  94  rests on the bottom wall  25  and is sealed thereto radially outwardly from the actuator rod  81 , as for example with a seal  99 , such as an o-ring, retained within a groove  100 . The seals  95 ,  99  prevent fluid coming in the intake port  43  from flowing into the chamber  15 , except through a separating portion of the separator  5 . The separator  5  has a through bore  98 . A pair of tubular walls  102 ,  104  extend between and are secured to the walls  93 ,  94  forming an annular cavity  106  therebetween. The walls  102 ,  104  are made of a porous material, as for example linear polyethylene, which may be used to separate liquid from the incoming fluid, allowing it to drain through the bore  98  and through the bottom wall  94  into the passage branch  17 C for discharge through outlet port  30 . The material of the walls  102 ,  104  may also be used to separate particulate matter from the incoming fluid prior to discharge into the outlet port  29 . The cavity  106  may, as an option, contain a desiccant material to remove liquid from the incoming fluid, in which event the outlet port  30  may not be necessary for drainage of liquid. The cavity  106 , as another alternative, may have a filter element therein to filter out particulate material while the wall  104  may be of a material, such as a porous Teflon® membrane, that can be used to separate liquid from the incoming fluid for discharge through the outlet port  30 . Additionally, the separator  5  may be in the form of a diaphragm extending across the chamber  15  and interposed flow wise between the inlet port  43  and the outlet port  29 . It would be suitably sealed to the rod  81  passing therethrough. Such a membrane can be porous, as is known in the art, to separate the liquid from the incoming fluid and also act as a particulate matter filter.  
         [0020]    [0020]FIG. 2 illustrates a device similar to that shown and described to the device of FIG. 1, but the probe device  1  is attached directly to the conduit via the coupler  45 , preferably through mutual threaded engagement as at  110 . Additionally, an intake  112  is secured to the coupler  45  and extends into the interior of the conduit  40 .  
         [0021]    [0021]FIGS. 3 and 4 show a modified form of the invention in which the device  1  is connected to an automatic insertion device, designated generally  116 . FIG. 3 illustrates a retracted position and FIG. 4 illustrates an extended position. The automatic insertion device  116  is mounted through a flange and/or screw arrangement as are known in the art. As shown, the mounting is by a coupled flange arrangement  119 , comprising a mounting flange  121  secured to a conduit flange  122  as with flange bolts and nuts  123  and sealed to one another as with a seal  127  such as an o-ring in a groove. The flange  122  is secured to the conduit  40  as by welding or threaded engagement as is known in the art. The flange  122  has a through passage  124  for receipt therethrough of a distal end  125  of a carrier  126 . The automatic insertion device  116  includes the carrier  126  that is secured to the coupler  128  which in turn is secured to the body  11 . The carrier  126  is in the form an elongate hollow rod, receiving therethrough the actuator rod  81 . The valve assembly  69  is attached to the carrier  126  by a connector  130 . A portion of the carrier  126  and the connector  130  extend through a bore  131  through the flange  121 . The automatic insertion device  116  further includes a linear motion drive cylinder, designated generally  133 , which may be moved to an extended position as seen in FIG. 4 by pressurizing the cylinder  133  on the back side of a piston  135  through an inlet port  137 . The inlet port  137  is connected in flow communication to the conduit  40  via conduit  139  with an infeed flow control valve  140  therein. The conduit  139  is connected to the port  45  which in turn is connected in flow communication with the conduit  40  via the bore  131 . By venting the back side of the piston  135  to atmosphere via an exhaust flow control valve  141 , the carrier  126  will move to its retracted position from the force applied to the carrier end  125  from the conduit  40 . A lock collar  142  is provided to limit the movement of the carrier  126  to an extended position in an adjustable manner and may also be used to lock the carrier  126  in an extended position by securement to the cylinder  133 , as is known in the art.  
         [0022]    In operation of the devices shown, fluid from the conduit  40  is transferred into the probe  1 . The fluid has liquid and/or particulate matter separated therefrom by the separator  5 . If liquid is separated, it may be exhausted through the outlet port  30  and the gaseous portion may be exhausted through the outlet port  29  to an instrument, such as a gas chromatograph or the like. The pressure regulator  7  is operable for controlling pressure within the housing  3  under the influence of the springs  64 ,  87 . When it is desired or necessary to change the separator  5 , the cap  13  is removed from the body  11 . The retainer  73  may then be separated from the body  11  exposing the top wall  93 . The actuator rod  81  is preferably separable from either the diaphragm  71  or the valve element  83  to facilitate removal of the separator  5  from the body  11 . A new separator may be installed and the actuator rod  81  re-engaged with both the diaphragm  71  and the valve element  83 , and the cap  13  reinstalled after installation of the retainer  73 .  
         [0023]    Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. Many changes, modifications, variations and other uses and applications of the present constructions will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.