Curved Gas Flow Conditioner for Bend-Induced Swirl Control
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Solution Overview
Problem
Existing gas flow conditioners for ultrasonic gas meters are limited to straight pipelines, causing flow disturbances and pressure loss when used in bends, leading to inaccurate measurements and high production costs, with no effective solution for placement in the bend of the gas flow.
Innovation Solution
A gas flow conditioner designed for use in bends, featuring one or more longitudinal plates in a segmented or arc-shaped configuration, creating a turbulent flow profile to eliminate swirls and reduce pressure loss, with the number and positioning of plates determined by numerical simulation and Particle Image Velocimetry to optimize velocity distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing flow conditioners are placed in straight pipelines upstream of ultrasonic gas meters, then flow stabilization is achieved, but flow disturbances and swirls occur when bends are present, reducing measurement accuracy
Solution Approach 1:
The flow conditioner employs curved plates with specific radii of curvature designed to match the bend geometry. The curved surfaces guide the gas flow smoothly through the bend, preventing flow separation and swirl formation. The curvature radius is optimized based on the pipe bend radius to maintain attached flow and eliminate disturbances that would otherwise occur in bent sections.
Solution Approach 2:
The flow conditioner is divided into multiple curved plates arranged in sequence along the bend. Each plate segment handles a portion of the flow conditioning task, with spacing between plates allowing gradual flow adjustment. This segmented approach provides better flow control compared to a single solid structure, reducing turbulence while maintaining measurement accuracy.
2Reliability
If existing flow conditioners are used, then flow conditioning is provided, but significant pressure loss occurs
Solution Approach 1:
The curved plate design follows the natural flow path in bent pipes, reducing flow separation and recirculation zones that cause pressure loss. The smooth curved surfaces minimize turbulence intensity and energy dissipation, maintaining lower pressure drop compared to traditional straight plates or perforated designs used in bend applications.
Solution Approach 2:
The curvature radius, plate thickness, and spacing between plates are optimized parameters that balance flow conditioning effectiveness with pressure loss minimization. By adjusting these geometric parameters, the conditioner achieves adequate flow stabilization while maintaining acceptable pressure drop levels for the specific application.
3Measurement precision
If existing flow conditioners are placed upstream at distance from meter, then flow stabilization is achieved, but complex and expensive manufacturing is required
Solution Approach 1:
The conditioner consists of multiple identical or similar curved plate segments that can be manufactured separately using standard fabrication processes and then assembled. This modular approach simplifies manufacturing compared to creating a single complex integrated structure, reducing both production complexity and cost while maintaining effective flow stabilization.
Solution Approach 2:
The curved plate design can be adapted to different pipe diameters and bend radii by scaling the geometric parameters, allowing a single design concept to serve multiple applications. This universality reduces the need for custom manufacturing for each specific case, lowering overall manufacturing complexity and cost.
4Reliability
If existing flow conditioners are used, then flow conditioning is provided, but they become clogged with particles of dirt in small openings
Solution Approach 1:
The curved plates are designed with smooth surfaces and appropriate gap dimensions that prevent particle accumulation. The local geometry at plate edges and surfaces is optimized to minimize areas where dirt particles could lodge, while maintaining sufficient flow conditioning effect. The gap size between plates is specifically chosen to be larger than typical particle sizes in the gas stream.
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 enables accurate and wide-ranging ultrasonic gas meter measurements by eliminating flow disturbances, reducing pressure loss, and allowing for cost-effective, low-maintenance production, suitable for compact installation within the gas meter, with no accumulation of dirt and extended lifespan.
Implementation Method 1
The summary of the invention is to propose a new solution for a flow conditioner, which consists of or comprises curved plates in the number of 1 to n pieces, which creates a turbulent flow, eliminating flow disturbances, such as swirls, and reducing pressure loss.
Implementation Method 2
The principle of the ultrasonic gas meter is based on measuring the velocity of ultrasonic waves, i.e. signals, in the direction and the opposite direction of the gas flow. The ultrasonic sensors are located obliquely to the pipe axis, and the flow time between the transmitter and the receiver of the signal is measured.
Implementation Method 3
The ultrasonic signals are accelerated or decelerated by the flowing gas. From the different times, the mean gas flow velocity or flow rate or flow quantity is
Data Source
AI summary
A gas flow conditioner in the flow bend in an ultrasonic flow meter has at least one longitudinal dividing plate provided in an inner space of the flow bend. The flow bend can be provided with an inlet curved section, a middle straight section, and an outlet curved section, wherein axes of the inlet curved section and the outlet curved section are in a parallel direction and connected to a pipe opening of size DN.