Field commissioning for a fluid flow device
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Solution Overview
Problem
Current fluid flow measurement devices are expensive, have limited turndown ratios, and do not support accurate measuring functionality for low fluid flows, leading to inefficient energy consumption and high costs in HVAC systems.
Innovation Solution
A fluid flow device with a multi-stage damper system and advanced control mechanisms, including a variable orifice plate and actuator assembly, capable of measuring and controlling fluid flow with a high turndown ratio, utilizing new correlations to address flow phenomena and inconsistencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current flow measurement devices are used, then measurement capability is provided, but measurement precision is insufficient for low fluid flows
Solution Approach 1:
The flow measurement device is segmented into multiple measurement ranges, with different orifice plates configured for different flow ranges. This allows the device to achieve high measurement precision across a wide turndown ratio by selecting the appropriate orifice plate for the current flow condition, rather than using a single orifice plate that would compromise precision at low flows.
2Ease of operation
If standard butterfly damper is used, then flow control is provided, but Vena contracta cannot be controlled
Solution Approach 1:
The invention replaces the static butterfly damper with a dynamic multi-stage damper system where the Vena contracta position can be actively controlled. The damper blades are positioned and oriented to dynamically control the Vena contracta, allowing precise control of flow characteristics while maintaining ease of operation through automated positioning.
3Measurement precision
If large Total Pressure is used for flow measurement, then measurement capability is provided, but energy consumption increases
Solution Approach 1:
The invention changes the measurement parameters by using differential pressure measurement across optimally designed orifice plates instead of relying on large total pressure. The orifice plates are configured to create measurable pressure differentials at low flow rates, enabling accurate flow measurement without requiring large total pressure that would consume excessive energy.
4Ease of operation
If current flow measurement and control methods are used in HVAC systems, then basic operation is maintained, but energy consumption increases and comfort is hindered
Solution Approach 1:
The HVAC system incorporates feedback control where flow sensors continuously monitor actual fluid flow and provide signals to control mechanisms. This feedback enables automated adjustment of dampers and pump speeds to maintain optimal flow rates, reducing energy consumption while ensuring system operation and comfort requirements are met.
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
Enables accurate measurement and regulation of fluid flows with a turndown ratio greater than 10:1, reducing energy consumption and operational costs in HVAC systems.
Implementation Method 1
determine a pressure differential across the orifice plate based on a first pressure sensed upstream of, and a second pressure sensed downstream of, the orifice plate
Implementation Method 2
With a multistage damper such as a two-stage damper, the Vena contracta of the inner disk can be controlled
Data Source
AI summary
Variable Orifice Plate technology represents new physics for measuring fluids accurately over a dynamic range and obsoletes fixed orifice plates. Therefore, a new balancing procedure using an updated correction factor is needed to mitigate and calibrate for field systems effects. Architectures are provided that can leverage correction factor values (CFVs) that are determined from a third party device such as a TAB contractor in order to determine other CFVs for a fluid flow with a variable aperture. The fluid flow device can change state, which changes the area of the variable aperture and, accordingly, the fluid flow profile. Multiple CFVs can be determined from TAB measurements taken while the fluid flow device is in respective different states, while other CFVs for different states can be determined as a function of the known CFVs and associated states or other suitable data such as damper position, aperture area, or the like.