Augmented Flowmeter Virtual Model Fluid Parameter Simulation
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Solution Overview
Problem
Monitoring fluid parameters in process industries faces challenges such as sensor reliability issues due to environmental factors and difficulties in measuring parameters like viscosity and core fluid temperature, which can lead to inaccurate readings and downtime.
Innovation Solution
An augmented flowmeter system connected to a remote server with a virtual model, using finite element multiphysics models like CFD for simulating fluid parameters, enabling reliable and non-invasive measurement of viscosity and temperature, and verifying sensor performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are installed within the pipe for measuring fluid parameters, then measurement capability is improved, but sensor reliability deteriorates due to high temperatures and harsh environments
Solution Approach 1:
The patent creates a virtual copy (digital twin) of the physical flowmeter and fluid system. This virtual model replicates the behavior and parameters of the physical system, allowing measurements to be taken in the virtual environment without exposing physical sensors to harsh conditions. The virtual flowmeter receives data from minimal physical sensors and uses computational models to derive additional parameters, reducing the need for direct physical sensor installation in high-temperature pipelines.
2Temperature
If sensors are installed within the pipe for measuring core fluid temperature, then temperature measurement capability is improved, but device complexity and obstruction to fluid flow increase
Solution Approach 1:
The patent replaces direct mechanical/physical temperature sensing within the fluid stream with computational thermodynamics models. Instead of installing physical temperature sensors that would obstruct flow and require complex installation, the system uses heat transfer equations and energy balance models to calculate core fluid temperature from easily measurable parameters like pipe surface temperature, fluid flow rate, and thermal properties. This substitution eliminates the need for intrusive temperature sensing.
3Measurement precision
If sampling is used for measuring fluid viscosity, then viscosity measurement is achieved, but continuous monitoring capability deteriorates
Solution Approach 1:
The patent implements continuous viscosity monitoring through computational rheology models that continuously process flow rate and pressure differential data from the flowmeter. Instead of periodic sampling, the system continuously calculates viscosity based on the relationship between flow characteristics and fluid properties. The virtual model updates viscosity measurements in real-time as new flow data becomes available, providing uninterrupted monitoring capability that enhances process control and detection of viscosity changes.
4Measurement precision
If physical flowmeters are used for monitoring fluid parameters, then direct measurement capability is improved, but susceptibility to environmental factors and deposition increases
Solution Approach 1:
The patent introduces a virtual model as an intermediary between the physical flowmeter and the measurement output. The virtual flowmeter receives data from minimal physical sensors and uses computational fluid dynamics and heat transfer models to derive comprehensive fluid parameters. This intermediary layer allows the system to maintain measurement accuracy while being less susceptible to deposition and environmental factors, as the virtual model can compensate for sensor drift and environmental variations through mathematical relationships and multiple measurement correlations.
Data Source
AI summary
The present invention relates to a flowmeter for monitoring physical parameters of fluid passing through the flowmeter. The flowmeter being installed in a plant and communicatively connected through a gateway device to a server having a virtual model. The flowmeter comprising: a processing unit for computing a first processed data of a physical parameter associated with the fluid measured by the flowmeter. The flowmeter receives a second processed data from the server having the virtual model, wherein the virtual model provides the second processed data by computing the second processed data based on the first processed data and data from at least one sensor provisioned in the plant. The present invention also provides for a system for monitoring physical parameters of fluid passing through a pipe in a plant with the flowmeter.