Eddy Current Minimizing Flow Plug for Flow Conditioning
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Solution Overview
Problem
Existing flow conditioners, such as orifice plates, often produce eddy currents downstream, leading to vibrations and noise, and require moving parts or power, which are undesirable in fluid flow measurement applications.
Innovation Solution
A flow plug with a radial wall and converging-diverging open flow channels, minimizing eddy currents by eliminating planar surfaces and using non-parallel central axes, which reduces downstream turbulence and noise without moving parts or power requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an orifice plate is used to condition flow, then flow measurement can be performed, but eddy currents are produced downstream causing vibrations and noise
Solution Approach 1:
The flow conditioner uses curved surfaces instead of flat planar surfaces. The body portion includes a curved outer surface that transitions from the inlet to the outlet, and the flow channels have curved cross-sections. This curvature eliminates the sharp edges and planar surfaces that generate eddy currents, thereby reducing downstream turbulence, vibrations, and noise while maintaining flow measurement capability.
Solution Approach 2:
The flow conditioner body is segmented into multiple flow channels that divide the fluid flow into separate paths. Each channel has its own curved cross-section and flow path. This segmentation allows the flow to be conditioned through multiple smaller curved surfaces rather than one large planar surface, reducing eddy current generation while maintaining effective flow measurement.
2Measurement precision
If multi-hole orifice plates are used, then flow conditioning is improved, but permanent pressure loss varies widely and coefficient of discharge is high
Solution Approach 1:
The invention changes the geometric parameters of the flow conditioner, specifically using curved surfaces with optimized radii of curvature. The outer surface has a first radius of curvature and the inner surface has a second radius of curvature, creating a controlled transition zone. This parameter optimization reduces flow separation and turbulence, thereby minimizing permanent pressure loss while maintaining effective flow conditioning and measurement.
3Ease of manufacture
If planar surfaces are present at inlet and outlet, then manufacturing is simplified, but eddy currents are generated in downstream region
Solution Approach 1:
The flow conditioner employs curved surfaces throughout, including at the inlet and outlet regions. The curved outer surface and curved inner surface eliminate planar surfaces that would generate eddy currents. While slightly more complex to manufacture than flat surfaces, the curvature can be achieved through standard casting or machining processes, and the benefit of eliminating eddy currents and downstream turbulence justifies the minimal increase in manufacturing complexity.
Data Source
AI summary
An eddy-current-minimizing flow plug has an outer radial wall with open flow channels formed between the plug's inlet and outlet. The plug has a central region coupled to the inner surface of the outer radial wall. Each open flow channel includes (i) a first portion originating at the inlet and converging to a location in the plug where convergence is contributed to by changes in thickness of the outer radial wall and divergence of the central region, and (ii) a second portion originating in the plug and diverging to the outlet where divergence is contributed to by changes in thickness of the outer radial wall and convergence of the central region. For at least a portion of the open flow channels, a central axis passing through the first and second portions is non-parallel with respect to the given direction of the flow.