In-line Flow Meter Verification Using Virtual Pipe Diameter
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Solution Overview
Problem
Existing flow meter calibration and verification methods are time and cost intensive due to the need for specialized rigs, and in-line verification with ultrasonic clamp-on flow meters is limited by high measurement uncertainty, making it difficult to ensure measurement accuracy during long-term operation.
Innovation Solution
A method involving a preparatory phase to calibrate and set up both the flow meter and ultrasonic clamp-on flow meter with a virtual pipe diameter to minimize measurement differences, followed by a verification phase to detect deviations and issue alerts based on standard measurement uncertainty, reducing uncertainty and allowing for in-line verification without interrupting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If re-calibration is performed using specially designed calibration rigs, then measurement accuracy is ensured, but production process interruption and time cost increase
Solution Approach 1:
A portable calibration rig is introduced as an intermediary device that can be transported to the measurement site. This portable rig serves as a mediator between the flow meter to be calibrated and the reference standards, enabling calibration without interrupting the production process at the original measurement location.
Solution Approach 2:
The portable calibration rig is prepared and transported to the measurement site in advance before the scheduled re-calibration. This preliminary action allows the calibration process to be set up without disrupting ongoing production, and the calibration can be completed during planned maintenance windows or even during operation.
2Ease of operation
If ultrasonic clamp on flow meters are used for in line verification, then ease of installation and no production interruption are achieved, but measurement uncertainty increases
Solution Approach 1:
The measurement parameters of the ultrasonic clamp on flow meter are optimized by adjusting the ultrasonic frequency, transducer positioning, and signal processing parameters. This parameter optimization reduces measurement uncertainty while maintaining the ease of installation advantage of clamp-on technology.
Solution Approach 2:
A feedback mechanism is implemented where the ultrasonic clamp on flow meter measurements are continuously compared against reference values or historical data. This feedback allows for real-time correction of measurement deviations, reducing overall measurement uncertainty while maintaining the non-invasive installation advantage.
3Reliability
If flow meters are re-calibrated regularly, then measurement accuracy during long term operation is ensured, but time and cost intensity increase
Solution Approach 1:
Instead of frequent regular re-calibrations, the system implements periodic verification using the portable calibration rig at optimized intervals. This periodic approach maintains measurement accuracy by catching drift before it becomes significant, while reducing the overall time lost to calibration activities compared to frequent re-calibrations.
Solution Approach 2:
The portable calibration rig is designed to be easily transported and set up by site personnel without requiring specialized calibration facility resources. This self-service capability reduces the time and cost burden of re-calibration while maintaining measurement accuracy through periodic verification.
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
This approach reduces the measurement uncertainty in flow meter verification, enabling more accurate and cost-effective in-line verification, allowing for extended time intervals between recalibrations and enhancing confidence in measurement accuracy.
Implementation Method 1
ultrasonic flow meters, comprising ultrasonic transducers to be clamped on the outside of the pipe
Implementation Method 2
ultrasonic flow meters operating on the Doppler principle or operating on the travel time difference principle
Data Source
AI summary
A method of in line verification of a flow meter installed in a flow line by means of one or two ultrasonic clamp on flow meters to be installed in line with the flow meter u<o ostyle="single">Δ</o>, comprising a preparatory phase, during which a virtual pipe diameter is determined, which if it had been applied during the simultaneous measurements would have minimized the differences between the measured flow indications of the flow meter and the measured flow indications, and comprising a verification phase, during which the ultrasonic flow meters are set up to determine their measured flow indications based on the virtual pipe diameter, during which simultaneously derived measured flow indications of the flow meter and the ultrasonic flow meters are recorded, and during which an alert is issued in case a deviation between simultaneously derived measured flow indications of the flow meter and the ultrasonic flow meter or between measured flow indications of the flow meter and averages of the measured flow indications of the ultrasonic flow meters respectively exceeds a predetermined deviation limit, which was set based on a measurement uncertainty inherent to the determination of the deviation.