Contoured Insert for Flow Verification in Piping Systems
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Solution Overview
Problem
Existing fluid flow measurement systems in piping require separate devices that increase space and pressure head loss, and are prone to scale buildup, affecting accuracy and performance.
Innovation Solution
A contoured insert calibrated to the pipe size is installed in the fluid flow path to measure volumetric flow rate, minimizing additional components and head loss, with pressure taps to determine flow by measuring pressure differential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flow measurement devices (orifice plates, venturi meters) are installed in the fluid flow stream, then flow rate verification is achieved, but head loss increases and additional space is required
Solution Approach 1:
The flow measurement function is segmented from traditional separate devices and integrated into the valve body itself. The contoured insert is divided into specific geometric sections (contour portion, flat backside, pressure tap locations) that work together to provide flow verification without requiring standalone measurement devices, thereby reducing head loss while maintaining measurement capability
Solution Approach 2:
The flow measurement feature is merged with the valve body by integrating the contoured insert directly into the valve structure. This combines the flow control function of the valve with the flow measurement function, eliminating the need for separate permanent flow measurement devices and reducing overall head loss in the system
2Measurement precision
If permanent flow measurement devices are installed, then flow verification is provided, but scale buildup adversely affects performance and increases head loss
Solution Approach 1:
The contoured insert employs curved surfaces including a contour portion and a flat backside that creates streamlined flow paths. These curved geometries prevent stagnant flow zones where scale would accumulate, making the measurement feature resistant to scale buildup while maintaining accurate flow verification capability
Solution Approach 2:
The design converts the potential harm of scale buildup into a benefit by creating a contoured surface that actively resists scale accumulation. The specific geometry (contour portion directing flow, flat backside maintaining static pressure zone) transforms what would be a problematic surface into a scale-resistant feature that maintains measurement accuracy over time
3Measurement precision
If contoured insert creates artificial pressure increase for measurement, then measurement accuracy improves, but pressure differential increases
Solution Approach 1:
The contoured insert applies local quality by creating an artificial pressure increase only at the specific location of the upstream pressure tap. The contour portion directs fluid flow stream toward the upstream tap to amplify pressure locally for accurate measurement, while the flat backside maintains a static pressure zone downstream, ensuring the pressure differential remains localized and does not significantly impact overall system head loss
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides accurate flow measurement with minimal invasive impact on pressure head loss and resistance to scale buildup, improving measurement accuracy and reducing system complexity.
Implementation Method 1
configured with a contour to create an artificial increase in an upstream pressure measurement resulting in a locally amplified pressure drop reading across the contoured insert that is directly proportional to a dynamic pressure component at the location
Implementation Method 2
Flow is determined by applying the measured pressure differential between the upstream and downstream taps in relation to the flow coefficient of the calibrated contoured insert
Data Source
Figure 1A~1
Figure 2A~2
Figure 3~4A
AI summary
The present invention provides for a device or feature that incorporates a technique or means for flow measurement in a fluid flow system. By way of example, a contoured insert may be specifically calibrated to the pipe line size to ensure the desired accuracy of the flow measurement, irrespective of pipe length between the device and other fluid system components that would negatively influence other flow rate measurement devices. This in turn reduces the total number of components needed in a system.