System and method for detecting fluid in terminal block area of field device

• US 7,521,944 B2
• Filed: 12/28/2006
• Issued: 04/21/2009
• Est. Priority Date: 12/28/2006
• Status: Active Grant

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Wehrs, David L.
• Primary Examiner(s): Nguyen; Vincent Q
• Assistant Examiner(s): NATALINI, JEFF WILLIAM
• Application Number:
  US11/648,198
• Publication Number:
  US 20080156090A1
• Time in Patent Office: 845 Days
• Field of Search: None
• US Class Current: 324/694
• CPC Class Codes: G01M 3/16 using electric detection means G01M3/045, G01M3/06, G01M3/12, G01M3/20, G01M3/24, G01M3/26 take precedence
• CPC Class Codes: G01M 3/40 by using electric means, e.g. by observing electric discharges
• CPC Class Codes: H05K 7/1462 for programmable logic controllers [PLC] for automation or industrial process control

Abstract

A field device detects the presence of fluid in the terminal block area of the field device by generating an alternating current (AC) test current signal and measuring the amplitude of the resulting AC voltage signal. The field device includes a first terminal and a second terminal adapted for connection to a control room through a twisted-wire pair current loop. Impedance of the current loop is increased by the presence of fluid between the first terminal and the second terminal. By providing an AC test current signal to the control loop and measuring a resulting AC voltage magnitude, the impedance of the control loop can be determined. Increased impedance in the control loop indicates the presence of water in the terminal block.

Claims

1. A method of detecting fluid in a terminal block of a field device, the method comprising:

measuring an initial impedance of a current loop connecting the field device to a control room when no fluid is present in the terminal block of the field device, wherein the current loop is connected to the field device by first and second terminals located in the terminal block of the field device;

selecting a threshold AC voltage magnitude value based on the measured initial impedance of the current loop in which no fluid is present in the terminal block;

applying an alternating current (AC) test signal at a selected frequency to the current loop;

measuring a resulting AC voltage magnitude in response to the AC test signal; and

detecting a change in impedance of the current loop by comparing the AC voltage magnitude measured in response to the AC test signal to the threshold AC voltage magnitude selected based on the initial impedance of the current loop, wherein a detected change in the impedance of the current loop indicates the presence of fluid in the terminal block between the first and second terminals.

2. The method of claim 1, wherein applying the AC test signal at the selected frequency to the current loop includes:

modulating the current provided to the current loop at the selected frequency using digital communication capabilities of the field device.

3. The method of claim 1, further including:

notifying the control room connected to the field device of the presence of fluid in the terminal block area of the field device.

4. The method of claim 1, wherein measuring the resulting AC voltage amplitude includes:

using a hand-held device connected to the first and second terminals of the field device.

5. A method of detecting fluid in a terminal block of a field device, the method comprising:

applying an initial AC test signal at a selected frequency to a current loop that connects the field device to a control room, wherein the two-wire current loop is connected to the field device by first and second terminals located in the terminal block of the field device -and the initial AC test signal is provided when no fluid is present within the terminal block;

measuring an initial AC voltage magnitude in response to the initial AC test signal;

applying a subsequent AC test signal at the selected frequency to the current loop;

measuring a subsequent AC voltage magnitude generated in response to the subsequent AC test signal; and

detecting a change in impedance of the current loop by comparing the initial AC voltage magnitude with the subsequent AC voltage magnitude, wherein a detected change in the impedance of the current loop indicates the presence of fluid in the terminal block between the first and second terminals.

6. The method of claim 5, further including:

storing the initial AC voltage magnitude measured in response to the initial AC test signal to memory located within the field device;

storing the subsequent AC voltage magnitude measured in response to the subsequent AC test signal to the memory located within the field device, wherein the initial AC voltage magnitude and the subsequent AC voltage magnitude measured in response to the subsequent AC test signal are made available to a microprocessor for determining whether fluid is present in the terminal block.

7. The method of claim 5, further including:

communicating the initial AC voltage magnitude measured in response to the initial AC test signal to the control room;

communicating the subsequent AC voltage magnitude measured in response to the subsequent AC test signal to the control room, wherein the control room determines whether fluid is present in the terminal block based on the initial AC voltage magnitude and the subsequent AC voltage magnitude.

8. The method of claim 5, further including:

notifying a control room connected to the field device of the presence of fluid in the terminal block area of the field device.

9. The method of claim 5, wherein measuring the resulting AC voltage amplitude includes:

using a hand-held device connected to the first and second terminals of the field device.

10. A field device which detects fluid within a terminal block area of the field device, the field device comprising:

a terminal block area;

a first terminal and a second terminal enclosed within the terminal block area of the field device, wherein the field device receives power and communicates with a control room by way of a two-wire pair that is connected to the first terminal and the second terminal, respectively, to form a current loop, wherein an accumulation of fluid within the terminal block causes fluid to come into contact with the first terminal and the second terminal;

a sensor device for sensing a process variable;

a current regulation circuit connected between the first terminal and the second terminal for communicating the sensed process variable over the current loop to the control and for generating on the current loop an alternating current (AC) test signal at a selected frequency; and

an AC measurement device connected to measure a resulting AC voltage magnitude generated in response to the AC test signal provided by the current regulation circuit, wherein the presence of fluid within the terminal block area, characterized by a change in impedance of the current loop caused by the presence of fluid between the first terminal and the second terminal, is detected based on the measured AC voltage magnitude.

11. The field device of claim 10, wherein the AC measurement device includes:

a resistive element; and

an AC coupled receiving device connected across the resistive element to measure the resulting AC voltage magnitude.

12. The field device of claim 10, further including:

a microprocessor connected to receive input from the AC measurement device regarding the measured AC voltage magnitude, wherein the microprocessor determines whether fluid is present in the terminal block based on the measured AC voltage magnitude.

13. The field device of claim 12, wherein the microprocessor determines whether fluid is present in the terminal block by comparing an initial AC voltage magnitude measured in response to an initial AC test signal generated on the current loop and characterized by a first impedance in which no fluid is present between the first and second terminals to a subsequent AC voltage magnitude measured in response to a subsequent AC test signal.

14. The field device of claim 12, wherein the microprocessor determines whether fluid is present in the terminal block by comparing the resulting AC voltage magnitude measured in response to the AC test signal to a threshold AC voltage magnitude selected based on an initial impedance associated with the current loop upon initialization of the system.

15. A system for detecting the presence of fluid in a terminal block area of a field device, the system comprising:

a terminal block area;

a first terminal and a second terminal enclosed within the terminal block area of the field device, wherein the field device receives power and communicates with a control room by way of a two-wire pair that is connected to the first terminal and the second terminal, respectively, to form a current loop, wherein the accumulation of fluid within the terminal block causes fluid to come into contact with the first terminal and the second terminal;

means for applying an alternating current (AC) test signal at a selected frequency to the current loop;

means for measuring a resulting AC voltage magnitude in response to the AC test signal; and

means for detecting the presence of fluid in the terminal block, characterized by a change in impedance of the current loop caused by the presence of fluid between the first terminal and the second terminal, that is detected based on the measured AC voltage magnitude.

16. The system of claim 15, wherein the means for applying the AC test signal between the first and second terminals includes:

a current regulation circuit located within the field device that modulates the current provided to the current loop at the selected frequency using digital communication capabilities of the field device.

17. The system of claim 15, wherein the means for applying an AC test signal and the means for measuring a resulting AC voltage magnitude are located on a communication chipset within the field device.

18. The system of claim 15, wherein the means for measuring a resulting AC voltage magnitude includes:

a measurement resistor connected to receive the AC test signal generated by the means for applying an AC test signal; and

an AC coupled measurement device for measuring the AC voltage magnitude generated across the measurement resistor.

19. The system of claim 15, wherein the means for detecting the presence of fluid in the terminal block compares the AC voltage magnitude measured in response to the AC test signal to a threshold AC voltage magnitude selected based on the initial impedance of the current loop to detect a change in impedance associated with the current loop.

20. The system of claim 15, wherein the means for detecting the presence of fluid in the terminal block compares the AC voltage magnitude measured in response to the AC test signal to an initial AC voltage magnitude measured in response to an initial AC test signal to detect a change in impedance of the current loop.

21. The system of claim 20, further including:

means for storing the initial AC voltage magnitude measured in response to the initial AC test signal to memory located within the field device; and

means for storing the AC voltage magnitude measured in response to the AC test signal to the memory located within the field device.