Non-Invasive Flow Meter Using Pressure Sensor Array
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Solution Overview
Problem
Existing flow process monitoring and control systems require numerous invasive meters, burdening central processors and necessitating frequent isolation of flow processes for installation and maintenance, which increases operational expenses and downtime.
Innovation Solution
A system utilizing a spatial array of pressure sensors along a pipe to measure unsteady pressures, with a signal processor generating flow, diagnostic, and control signals without direct contact with the fluid, reducing the need for multiple meters and invasive installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If numerous invasive meters are used for monitoring and control, then measurement precision and control capability are improved, but device complexity and operational expenses increase
Solution Approach 1:
A single non-invasive meter with an array of pressure sensors performs multiple functions including flow measurement, density measurement, composition analysis, and diagnostic monitoring, replacing what would traditionally require multiple specialized meters
Solution Approach 2:
The patent combines multiple sensing functions into one integrated non-invasive meter device, merging flow measurement, density measurement, and diagnostic capabilities into a single unit that uses pressure sensor arrays and signal processing
2Measurement precision
If invasive meters are installed through piping, then measurement accuracy is improved, but ease of installation and maintenance deteriorates due to required isolation
Solution Approach 1:
The non-invasive meter uses the pipe wall as an intermediary medium to transmit pressure signals from the fluid to external sensors, eliminating the need for direct sensor contact with the fluid while still enabling accurate measurements
Solution Approach 2:
The patent replaces the mechanical intrusion of traditional meters (physical contact with fluid) with a non-contact acoustic/pressure wave measurement system that detects fluid properties through the pipe wall
3Measurement precision
If multiple specialized meters are used, then measurement precision for different parameters is improved, but ease of operation deteriorates due to burdening the central processor
Solution Approach 1:
A single non-invasive meter with an array of pressure sensors performs multiple functions including flow measurement, density measurement, composition analysis, and diagnostic monitoring, replacing what would traditionally require multiple specialized meters
Solution Approach 2:
The patent combines multiple sensing functions into one integrated non-invasive meter device, merging flow measurement, density measurement, and diagnostic capabilities into a single unit that uses pressure sensor arrays and signal processing
4Measurement precision
If invasive meters are used, then measurement precision is improved, but productivity deteriorates due to shutdown time for installation and maintenance
Solution Approach 1:
The non-invasive meter uses the pipe wall as an intermediary medium to transmit pressure signals from the fluid to external sensors, eliminating the need for direct sensor contact with the fluid while still enabling accurate measurements
Solution Approach 2:
The patent replaces the mechanical intrusion of traditional meters (physical contact with fluid) with a non-contact acoustic/pressure wave measurement system that detects fluid properties through the pipe wall
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 decreases the number of meters required, reduces operational expenses by minimizing shutdowns, and enables non-invasive monitoring and control of flow processes, improving diagnostic accuracy and operational efficiency.
Implementation Method 1
a spatial array of at least two pressure sensors disposed at different axial locations along an pipe in the flow process, with each of the at least two pressure sensors providing a pressure signal indicative of unsteady pressure within the pipe
Data Source
AI summary
A system for monitoring, diagnosing, and/or controlling a flow process uses one or more flow meters based on an array of pressure sensors. A signal processor outputs at least one of a flow signal, a diagnostic signal, and a control signal in response to the pressure signals from the pressure sensors. The flow signal indicates the at least one parameter of the fluid, the diagnostic signal indicates a diagnostic condition of a device in the flow process, and the control signal is effective in adjusting an operating parameter of at least one device in the flow process. The system may be arranged as a distributed control system (DCS) architecture for monitoring a plurality of flow meters based on array-processing installed at various locations throughout a flow process.