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 
       [0001]    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 
       [0002]    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 
       [0003]    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: 
         [0004]    1) Pipe or Valve Temperature 
         [0005]    2) Ambient Air Temperature 
         [0006]    3) Pipe or Valve Size information 
         [0007]    4) Type and Thickness of Insulation 
         [0000]    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. 
         [0008]    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. 
         [0009]    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 
       [0010]    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 
         [0011]    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: 
           [0012]      FIG. 1  is a top view of the thermal insulation jacket; 
           [0013]      FIG. 2  is a side view of the skirt of the thermal insulation jacket in flattened condition; 
           [0014]      FIG. 3  is a perspective view of the cap of the thermal insulation jacket; 
           [0015]      FIG. 4  is a side view of the insulation jacket, partially cut away, when used in conjunction with a valve casing; 
           [0016]      FIG. 5  is an end view of the insulation jacket in the assembled position; 
           [0017]      FIG. 6  is a schematic diagram of the insulation jacket system; 
           [0018]      FIG. 7  is a conceptual illustration of the ad-hoc network; and 
           [0019]      FIG. 8  is a semi-exploded view of the advanced diagnostics embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    The disclosed invention integrates advanced electronics, sensing, and software directly into traditional removable insulation products. 
         [0021]    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. 
         [0022]    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. 
         [0023]    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. 
         [0024]    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. 
         [0025]      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. 
         [0026]    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. 
         [0027]    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&#39;s hands to wrap and strap the jacket. 
         [0028]      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. 
         [0029]      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. 
         [0030]    The cap may further be provided with mating Velcro sections  59   a  and  59   b  in cutaway section  58  to provide for further ease of assembly. 
         [0031]      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. 
         [0032]    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. 
         [0033]    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. 
         [0034]      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. 
         [0035]    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. 
         [0036]    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 
       [0037]    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. 
         [0038]    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. 
         [0039]    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. 
         [0040]    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. 
         [0041]    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. 
         [0042]    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 
       [0043]    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 . 
         [0044]    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. 
         [0045]    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 
       [0046]    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. 
         [0047]    For example, a networked smart jacket with visual or thermal cameras could monitor pipe performance and serve a facility security function as well. 
         [0048]    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. 
         [0049]    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. 
         [0050]    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. 
         [0051]    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 
       [0052]    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). 
         [0053]    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. 
         [0054]    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. 
         [0055]    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.