US-12624687-B2 - Pump manifold with redundancy for gas extraction system

US12624687B2US 12624687 B2US12624687 B2US 12624687B2US-12624687-B2

Abstract

The present disclosure relates to systems and methods that include a multiple pump manifold to provide redundancy for use with high availability gas extraction system in industrial instrumentation. A method of operating a redundant pump assembly including operating a first pump of a plurality of pumps for an operation period; validating a second pump of the plurality of pumps at the end of the operation period of the first pump; validating a third pump of the plurality of pumps at the end of the operation period of the first pump; and, operating the third pump for the operation period, where the second pump and third pump are validated as operational.

Inventors

Alexandre Boivin
Marc Burnett
Dominic Michaud
Kyle Owen
Axel Meunier
John Brian Leen

Assignees

ABB SCHWEIZ AG

Dates

Publication Date: 20260512
Application Date: 20220624

Claims (20)

1 . A method for operating a redundant pump assembly comprising at least three pumps connected in parallel, the redundant pump assembly having a manifold configured to connect the at least three pumps in parallel, the manifold comprising: a first plate having a first surface and a second surface defining a thickness of the first plate, the second surface including a plurality of channels extending into the second surface, and a first aperture and second aperture extending from the plurality of channels to the first surface; and, a second plate having a first surface and a second surface defining a thickness of the second plate, the first surface of the second plate abutting the second surface of the first plate, wherein: corresponding protrusions extend from a recessed surface of the second plate, the corresponding protrusions configured to align with the plurality of channels, and the plurality of channels are configured to connect the at least three pumps in parallel via apertures extending through the corresponding protrusions; and the method comprising: operating a first pump of the at least three pumps to draw a fluid from the manifold for an operation period, wherein the operation period is a pre-determined period of time for which only one of the at least three pumps operates prior to validating a remainder of the at least three pumps, wherein the remainder of the at least three pumps is a second pump and a third pump, and wherein the remainder of the at least three pumps are inactive for the operation period of the first pump; at an end of the operation period of the first pump of the at least three pumps, and while the remainder of the at least three pumps are inactive, determining if either of the remainder of the at least three pumps may be switched from the inactive state to an operational state by performing a validation test of each of the remainder of the at least three pumps at the end of the operation period of the first pump, without operating the remainder of the at least three pumps; and if either of the remainder of the at least three pumps are determined to be suitable for the operational state, the method further comprising deactivating the first pump and activating one of the remainder of the at least three pumps such that the one of the remainder of the at least three pumps operates for the operation period to draw the fluid from the manifold while the fluid flows continuously through the manifold.
2 . The method of claim 1 , further comprising: if the third pump is activated for the operation period, at the end of the operation period of the third pump of the at least three pumps, and while the remainder of the at least three pumps includes the first pump and the second pump, wherein the remainder of the at least three pumps are inactive, determining either of the remainder of the at least three pumps may be switched from the inactive state to the operational state by performing a validation test of each of the remainder of the at least three pumps at the end of the operation period of the third pump, without operating the remainder of the at least three pumps; and if either of the remainder of the at least three pumps is determined to be suitable for the operational state, the method further comprises deactivating the third pump of the at least three pumps and activating one of the remainder of the at least three pumps such that the one of the remainder of the at least three pumps operates for the operation period.
3 . The method of claim 2 , further comprising: if the second pump is activated for the operation period, at the end of the operation period of the second pump, of the at least three pumps, and while the remainder of the at least three pumps includes the first pump and the third pump, wherein the remainder of the at least three pumps are inactive, determining either of the remainder of the at least three pumps may be switched from the inactive state to an operational state by performing a validation test of each of the remainder of the at least three pumps at the end of the operation period of the second pump, without operating the remainder of the at least three pumps; and if either of the remainder of the at least three pumps is determined to be suitable for the operational state, the method further comprises deactivating the second pump and activating one of the remainder of the at least three pumps such that the one of the remainder of the at least three pumps operates for the operation period.
4 . The method of claim 1 , wherein the operation period of each of the at least three pumps is one month.
5 . The method of claim 1 , wherein the first pump, the second pump, and the third pump of the at least three pumps are connected in parallel.
6 . The method of claim 1 , wherein a processor and memory are communicatively coupled to each of the first pump, the second pump, and the third pump of the at least three pumps, wherein the processor is configured to send instructions to each of the first pump, the second pump, and the third pump, and wherein the instructions are stored in memory.
7 . The method of claim 6 , wherein the processor is configured to: operate the first pump for the operation period; determine if the remainder of the at least three pumps may be switched from the inactive state to the operational state at the end of the operation period of the first pump of the at least three pumps; and if either of the remainder of the at least three pumps are determined to be suitable for the operational state, deactivate the first pump and activate one of the remainder of the at least three pumps such that the one of the remainder of the at least three pumps operates for the operation period.
8 . The method of claim 1 , wherein the steps of determining if a pump of the at least three pumps may be switched from the inactive state to the operational state include one or more of performing a system check to determine if one of the at least three pumps is operational and passing voltage through one pump of the at least three pumps.
9 . The method of claim 1 , wherein if while determining if either of the remainder of the at least three pumps may be switched from the inactive state to the operational state, the second pump is not determined to be suitable for the operational state and the third pump is not determined to be suitable for the operational state, the method further includes operating the first pump continuously.
10 . The method of claim 1 , wherein if one or all of the at least three pumps are not operational, the method further includes the step of sending a warning to a user interface.
11 . A redundant pump manifold assembly for use with a measurement instrument comprising: a first plate having a first surface and a second surface defining a thickness of the first plate, the second surface including a plurality of channels extending into the second surface, and a first aperture and second aperture extending from the plurality of channels to the first surface; and, a second plate having a first surface and a second surface defining a thickness of the second plate, the first surface of the second plate abutting the second surface of the first plate, wherein: the first surface of the second plate includes a recessed surface configured to receive a gasket positioned between the first plate and second plate creating a fluid seal between the first plate and second plate, corresponding protrusions extend from the recessed surface of the second plate, the corresponding protrusions configured to align with the plurality of channels, and the plurality of channels are configured to connect at least three pumps in parallel via apertures extending through the corresponding protrusions.
12 . The assembly of claim 11 , wherein the corresponding protrusions extend to the first surface of the second plate.
13 . The assembly of claim 11 , wherein the corresponding protrusions have a width smaller than a width of the plurality of channels such that the gasket can expand into a gap between the corresponding protrusion of the second plate and the gasket, wherein the gap allows for both lateral and medial expansion of the gasket and the gasket does not expand into the plurality of channels.
14 . The assembly of claim 11 , wherein the first surface of the first plate abuts a main manifold of the measurement instrument, the main manifold including an inlet aperture and an outlet aperture, the inlet aperture and outlet aperture aligned with the first aperture and second aperture of the plurality of channels of the first plate such that the inlet aperture and outlet aperture are in fluid communication with the first aperture and second aperture, wherein the first surface of the first plate and the main manifold create a seal.
15 . The assembly of claim 11 further comprising a plurality of pumps in contact with the second surface of the second plate, wherein each of the pumps have an inlet and an outlet, the inlet and outlet of each of the pumps in fluid communication with apertures extending through the thickness of the second plate, the apertures of the second plate aligning with the plurality of channels of the first plate.
16 . A method for operating a redundant pump assembly comprising at least three pumps connected in parallel, the redundant pump assembly having a manifold configured to connect the at least three pumps in parallel, the manifold comprising: a first plate having a first surface and a second surface defining a thickness of the first plate, the second surface including a plurality of channels extending into the second surface, and a first aperture and second aperture extending from the plurality of channels to the first surface; and, a second plate having a first surface and a second surface defining a thickness of the second plate, the first surface of the second plate abutting the second surface of the first plate, wherein: the first surface of the second plate includes a recessed surface for receiving a gasket positioned between the first plate and second plate creating a fluid seal between the first plate and second plate, corresponding protrusions extend from the recessed surface of the second plate, the corresponding protrusions configured to align with the plurality of channels, and the plurality of channels are configured to connect the at least three pumps in parallel via apertures extending through the corresponding protrusions; and the method comprising: operating a first pump of the at least three pumps to draw a fluid from the manifold for an operation period, wherein the operation period is a pre-determined period of time for which only one of the at least three pumps operates prior to validating a remainder of the at least three pumps, wherein the remainder of the at least three pumps is a second pump and a third pump, and wherein the remainder of the at least three pumps are inactive for the operation period of the first pump; at an end of the operation period of the first pump of the at least three pumps, and while the remainder of the at least three pumps are inactive, determining if either of the remainder of the at least three pumps may be switched from the inactive state to an operational state by performing a validation test of each of the remainder of the at least three pumps at the end of the operation period of the first pump, without operating the remainder of the at least three pumps; and if either of the remainder of the at least three pumps are determined to be suitable for the operational state, the method further comprising deactivating the first pump and activating one of the remainder of the at least three pumps such that the one of the remainder of the at least three pumps operates for the operation period to draw the fluid from the manifold while the fluid flows continuously through the manifold.
17 . The method of claim 16 , further comprising: if the third pump is activated for the operation period, at the end of the operation period of the third pump of the at least three pumps, and while the remainder of the at least three pumps includes the first pump and the second pump, wherein the remainder of the at least three pumps are inactive, determining either of the remainder of the at least three pumps may be switched from the inactive state to the operational state by performing a validation test of each of the remainder of the at least three pumps at the end of the operation period of the third pump, without operating the remainder of the at least three pumps; and if either of the remainder of the at least three pumps is determined to be suitable for the operational state, the method further comprises deactivating the third pump of the at least three pumps and activating one of the remainder of the at least three pumps such that the one of the remainder of the at least three pumps operates for the operation period.
18 . The method of claim 16 , further comprising: if the second pump is activated for the operation period, at the end of the operation period of the second pump, of the at least three pumps, and while the remainder of the at least three pumps includes the first pump and the third pump, wherein the remainder of the at least three pumps are inactive, determining either of the remainder of the at least three pumps may be switched from the inactive state to an operational state by performing a validation test of each of the remainder of the at least three pumps at the end of the operation period of the second pump, without operating the remainder of the at least three pumps; and if either of the remainder of the at least three pumps is determined to be suitable for the operational state, the method further comprises deactivating the second pump and activating one of the remainder of the at least three pumps such that the one of the remainder of the at least three pumps operates for the operation period.
19 . The method of claim 16 , wherein a processor and memory are communicatively coupled to each of the first pump, the second pump, and the third pump of the at least three pumps, wherein the processor is configured to send instructions to each of the first pump, the second pump, and the third pump, and wherein the instructions are stored in memory.
20 . The method of claim 19 , wherein the processor is configured to: operate the first pump for the operation period; determine if the remainder of the at least three pumps may be switched from the inactive state to the operational state at the end of the operation period of the first pump of the at least three pumps; and if either of the remainder of the at least three pumps are determined to be suitable for the operational state, deactivate the first pump and activate one of the remainder of the at least three pumps such that the one of the remainder of the at least three pumps operates for the operation period.

Description

BACKGROUND The field of the disclosure relates generally to systems of a multiple pump manifold with to provide redundancy in gas extraction systems, and more particularly, to systems and methods that include a multiple pump manifold to provide redundancy for use with high availability gas extraction system in industrial instrumentation. Whenever fuel gas such as natural gas, coal syngas, or biogas, is generated, transferred, or used, an assessment and understanding of the levels of contaminants is typically required in order to effectively transfer or use the desired fuel gas in an associated process. The measurement of various contaminants, e.g., H2S, H2O, O2, and CO2, is an important process step that aids in the prevention of infrastructure damage due to corrosion or chemical reactivity that in-part is a product of fuel gas contaminants. Natural gas producers must clean extracted gas to remove contaminants and then verify residual contaminant levels before introducing natural gas into a pipeline. Desulfurizer bed, used as fuel reformers to remove a variety of fuel gas contaminants must be periodically replaced or regenerated to prevent H2S breakthrough into the reformed fuel product, reinforcing the need for frequent contaminant level monitoring in fuel gas. The systems and instruments for measurement of contaminants are often stored in inaccessible and harsh environments. Such systems require continuous control of the flow and pressure of the component that is to be measured. Pumps are used to deliver the controlled flow at a stable under-pressure. However, pumps and pumping systems have a limited lifetime, limiting the reliability of the measurement system. Because the volume of gas in the extraction system can be significant, when a pump fails, the measurement response times, and accuracy will be negatively impacted which will yield the consumption (and exhaust to atmosphere) of relatively large volumes of fuel gas. Continuous operation of the system is essential in preventing catastrophic failure of the instrumentation and of the pipeline. Therefore, there exists a need in the art to provide for a pump manifold with redundancies for gas extraction systems and instrumentation. BRIEF DESCRIPTION In one aspect, a method of operating a redundant pump assembly is disclosed. The method includes operating a first pump of a plurality of pumps for an operation period; validating a second pump of the plurality of pumps at the end of the operation period of the first pump; validating a third pump of the plurality of pumps at the end of the operation period of the first pump; and, operating the third pump for the operation period, where the second pump and third pump are validated as operational. In another aspect, redundant pump manifold assembly for use with a measurement instrument is disclosed. The assembly includes a first plate having a first surface and a second surface defining a thickness of the first plate, the second surface including a plurality of channels extending into the second surface, and a first aperture and second aperture extending from the plurality of channels to the first surface; and, a second plate having a first surface and a second surface defining a thickness of the first plate, the first surface of the second plate abutting the second surface of the first plate, wherein the first surface of the second plate includes a recessed surface for receiving a gasket positioned between the first plate and second plate creating a fluid seal between the first plate and second plate. The corresponding protrusions extend from the recessed surface of the second plate, the corresponding protrusions configured to align with the plurality of channels. DRAWINGS These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings. FIG. 1 is a schematic diagram of an exemplary measurement assembly in accordance with one or more embodiments of the present disclosure; FIG. 2 illustrates a perspective view of the main measurement assembly of FIG. 1; FIG. 3 illustrates a translucent perspective view of a main manifold of the measurement assembly of FIG. 1; FIG. 4 illustrates a side view of a second surface of the main manifold of FIG. 3; FIG. 5 illustrates a cross-sectional view of the main manifold of FIG. 3 taken along line A-A′ of FIG. 4; FIG. 6 illustrates a side view of a third surface of the main manifold of FIG. 3; FIG. 7 illustrates a method of operating a redundant pump manifold assembly of the measurement assembly of FIG. 1; FIG. 8 illustrates a perspective view of a redundant pump manifold assembly in accordance with one or more embodiments of the present disclosure; FIG. 9 illustrates an exploded view of the redundant pump manifold assembly of FIG. 8; FIG. 10 illustrates a side view of a first plat