High-Pressure Magmeter Assembly for Corrosive Slurry Service
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Solution Overview
Problem
Magnetic flowmeters used in harsh environments, such as the hydraulic fracturing industry, face premature failure due to erosion and corrosion from high pressures and aggressive chemicals, leading to shortened lifespans and non-compliance with safety standards in hazardous locations.
Innovation Solution
A magnetic flowmeter design featuring a partially stabilized magnesium zirconia ceramic liner and tungsten carbide electrodes, with an electrically conductive pipe section, that withstands high pressures and corrosive slurries, and is compatible with various secondary electronics, ensuring compliance with Class I Division 2 hazardous location requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If alumina ceramic is used as the inner lining of the magnetic flowmeter, then the flowmeter can withstand corrosive chemicals, but the lining wears out easily and corrodes due to high temperatures and pressures
Solution Approach 1:
The patent applies composite materials by combining multiple ceramic layers with different properties. The inner layer uses alumina ceramic for corrosion resistance, while the outer layer uses a more abrasion-resistant ceramic material. This composite structure allows the flowmeter to simultaneously withstand both corrosion from chemicals and wear from abrasive slurries, resolving the contradiction between corrosion resistance and durability under high temperature and pressure conditions.
Solution Approach 2:
The patent changes the material parameters by selecting ceramics with specific hardness, toughness, and chemical resistance properties. The outer ceramic layer is specifically chosen to have higher abrasion resistance while the inner layer maintains optimal corrosion resistance. This parameter optimization allows the liner assembly to withstand extreme conditions including high temperatures, pressures, and aggressive chemicals without premature failure.
2Adaptability or versatility
If the flowmeter is designed to withstand high pressures and abrasive liquids, then it can be used in hydraulic fracturing applications, but the electrode seal and flow tube design becomes more complex
Solution Approach 1:
The patent segments the electrode seal design into distinct functional components: an electrode body, a separate seal element, and a mounting structure. This segmentation allows each component to be optimized independently - the seal element can be designed specifically for high-pressure containment while the electrode body maintains electrical functionality. The modular approach simplifies assembly and maintenance while enabling the flowmeter to withstand hydraulic fracturing pressures.
Solution Approach 2:
The patent introduces an intermediary seal element that mediates between the electrode assembly and the flow tube. This seal acts as a buffer that maintains electrical isolation while withstanding high pressures and abrasive slurries. The intermediary component protects the electrode from direct exposure to harsh conditions while maintaining measurement accuracy, thus reducing overall system complexity despite the demanding application requirements.
3Temperature
If traditional liner materials are used in harsh environments with high temperatures and pressures, then the flowmeter can operate in these conditions, but the useful life is significantly shortened
Solution Approach 1:
The patent employs composite ceramic materials that combine the thermal stability of alumina with the high-temperature strength of other advanced ceramics. This composite liner structure maintains structural integrity at elevated temperatures while resisting thermal cycling fatigue, thereby extending the flowmeter's useful life in high-temperature applications such as hydraulic fracturing where traditional single-material liners would fail prematurely.
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 design extends the lifespan of the flowmeter, maintains accurate measurements, and meets safety standards in severe applications, providing reliable operation in the fracking industry.
Implementation Method 1
Magnetic flowmeters functionally vary from other flow measurement technologies in that velocity flow is measured by application of Faraday's Law capitalizing upon electromagnetic interactions of charged particles within a fluid as it passes through a magnetic field orthogonal to the direction of flow.
Implementation Method 2
the shrink fit of the lining material into the bore of the meter that results in an abrasion resistant liner that is under compression from the shrink fit
Data Source
AI summary
The present invention relates to magnetic flowmeters. More particularly, the present invention relates to a magnetic flowmeter designed for oil and gas exploration and production, including offshore fracking, onshore hydraulic fracturing, and onshore and offshore non-fracking applications that is capable of withstanding high pressures and a variety of corrosive slurries, acids, bases, and solvents.