Diagnostic system for detecting rupture or thinning of diaphragms

• US 20060152380A1
• Filed: 01/07/2005
• Published: 07/13/2006
• Est. Priority Date: 01/07/2005
• Status: Active Grant

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Wells, Christopher Ashley, Anderson, William Thomas
• Granted Patent: US 7,295,131 B2
• Time in Patent Office: Days
• US Class Current: 340/679
• CPC Class Codes: G01L 27/007 Malfunction diagnosis, i.e. diagnosing a sensor defect
• CPC Class Codes: G01N 27/24 Investigating the presence of flaws
• CPC Class Codes: H05K 7/1462 for programmable logic controllers [PLC] for automation or industrial process control

Abstract

A diaphragm diagnostic system for use in an industrial field device has a diaphragm and a diagnostic feature. The diaphragm is configured to couple the field device to a process fluid and has a plurality of layers. A first layer of the plurality of layers is exposed to process fluid of an industrial process. A diagnostic feature is coupled to the diaphragm to monitor an electrical parameter of the diaphragm and responsively infer an operative state of the diaphragm based on a change in the monitored electrical parameter.

Claims

1. A diaphragm diagnostic system for use in an industrial field device comprising:

a diaphragm configured to couple the field device to a process fluid, the diaphragm comprising a plurality of layers, a first layer of the plurality of layers exposed to the process fluid of an industrial process; and

a diagnostic circuit coupled to the diaphragm to monitor an electrical parameter of the diaphragm and responsively infer an operative state of the diaphragm based on a change in the monitored electrical parameter.

2. The diaphragm diagnostic system of claim 1 and further comprising:

an alarm generation feature adapted to generate an alarm signal indicative of the inferred operative state of the diaphragm if the change exceeds a predetermined limit.

3. The diaphragm diagnostic system of claim 1 wherein the electrical parameter comprises a capacitance of the diaphragm.

4. The diaphragm diagnostic system of claim 1 further comprising:

a signal generator adapted to sweep the isolating diaphragm with a time-varying signal, wherein the electrical parameter comprises a complex electrical parameter of the diaphragm.

5. The diaphragm diagnostic system of claim 4 further comprising:

complex signal analysis systems adapted to monitor the diaphragm to detect changes in the electrical parameter relative to a stored baseline signal based on the time-varying signal.

6. The diaphragm diagnostic of claim 1 wherein the plurality of layers comprises:

at least one electrically conductive layer.

7. The diaphragm diagnostic of claim 1 wherein the plurality of layers comprises:

at least one dielectric layer.

8. The diaphragm diagnostic of claim 1 wherein the plurality of layers comprises:

at least two electrically conductive layers; and

at least one dielectric layer separating the at least two electrically conductive layers.

9. The diaphragm diagnostic of claim 8 wherein the electrical parameter comprises a capacitive potential of the at least two conductive layers.

10. The diaphragm diagnostic system of claim 1 wherein an extent of the change is indicative of an extent of change in a surface area of the first conductive layer.

11. The diaphragm diagnostic system of claim 1 wherein the diagnostic circuit is adapted to monitor one or more electrical parameters of the plurality of conductive layers relative to the first layer.

12. A method for inferring an operative state of an isolating diaphragm, the method comprising:

providing an isolating diaphragm comprised of a plurality of layers, a first layer of the plurality of layers exposed directly to a process fluid;

applying an electrical signal to the isolating diaphragm; and

inferring responsively an operative state of the isolating diaphragm from a measured change in an electrical parameter of the isolating diaphragm relative to the applied electrical signal.

13. The method of claim 12 wherein the electrical signal has a time-varying component.

14. The method of claim 12 further comprising:

generating an alarm signal indicative of a non-operative state of the isolating diaphragm if the measured change exceeds a predetermined limit.

15. The method of claim 12 further comprising:

generating an alarm signal indicative of a deteriorating state of the isolating diaphragm if the measured change exceeds a predetermined limit.

16. The method of claim 12 wherein the step of applying comprises:

generating an electrical signal comprised of a range of frequencies; and

transmitting the range of frequencies over the isolating diaphragm.

17. The method of claim 12 wherein the step of inferring comprises:

monitoring an electrical parameter of the isolating diaphragm; and

calculating a change in the monitored electrical parameter relative to a stored baseline measurement.

18. The method of claim 12 wherein the electrical parameter comprises a time constant of the isolating diaphragm.

19. The method of claim 12 wherein the electrical parameter comprises a complex electrical parameter of the isolating diaphragm.

20. The method of claim 12 wherein the plurality of layers comprises at least one electrically conductive layer.

21. The method of claim 12 wherein the plurality of layers comprises at least one dielectric layer.

22. The method of claim 12 wherein the plurality of layers comprises:

at least two electrically conductive layers; and

at least one dielectric layer separating the at least two electrically conductive layers.

23. A diaphragm diagnostic system for use in an industrial field device comprising:

a capacitive element configured to couple the field device to a process fluid, the capacitive element comprised of a plurality of layers, a first layer of the plurality of layers exposed to the process fluid of an industrial process; and

a diagnostic circuit coupled to the capacitive element to monitor an electrical parameter of the capacitive element and responsively infer an operative state of the capacitive element based on a change in the monitored electrical parameter.

24. The diaphragm diagnostic system of claim 23 wherein the industrial field device comprises a vortex flow meter having a shedding bar extending into a pipe section, and wherein the capacitive element comprises a thin wall portion of the pipe section through which motion of the shedding bar due to fluid flow within the pipe is translated.

25. The diaphragm diagnostic system of claim 23 wherein the industrial field device comprises a pressure sensor coupled to a pipe section, and wherein the capacitive element comprises a flexible isolating diaphragm adapted to translate pressure from fluid flow within the pipe section through a fluid filled capillary to a remote sensor.

26. The diaphragm diagnostic system of claim 23 further comprising:

an alarm generation feature adapted to generate an alarm signal indicative of the inferred operative state for transmission to a control center.

27. The diaphragm diagnostic system of claim 23 wherein a magnitude of the change is indicative of an extent of damage to the capacitive element.

28. The diaphragm diagnostic system of claim 23 wherein the measured change comprises a complex impedance of the capacitive element.

29. The diaphragm diagnostic system of claim 23 wherein the diagnostic circuit further comprises:

a signal generator adapted to sweep the capacitive element with an electrical signal having a time-varying component; and

complex signal analysis systems adapted to monitor the capacitive element and to infer the operative state of the capacitive element based on a change in one or more electrical parameters of the capacitive element relative to a stored baseline measurement.

30. The diaphragm diagnostic system of claim 23 wherein the diagnostic circuit is adapted to monitor one or more electrical parameters of the plurality of conductive layers relative to the first layer.

31. The diaphragm diagnostic of claim 23 wherein the plurality of layers comprises:

at least one electrically conductive layer.

32. The diaphragm diagnostic of claim 23 wherein the plurality of layers comprises:

at least one dielectric layer.

33. The diaphragm diagnostic of claim 23 wherein the plurality of layers comprises:

at least two electrically conductive layers; and

at least one dielectric layer separating the at least two electrically conductive layers.

34. The diaphragm diagnostic of claim 33 wherein the at least one dielectric layer comprises a porous material.

35. The diaphragm of claim 34 wherein the operative state is inferred based on an abrupt change in the electrical parameter if the process fluid leaks through the first layer.