SONAR Flow Measurement with CFD Correction for Multiphase Pipes
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Solution Overview
Problem
Existing clamp-on SONAR flow meters struggle to accurately measure fluid flow rates in non-fully developed and non-well-mixed conditions, particularly in multiphase flows, due to uncertainties in the relationship between convective flow disturbance velocity and volumetric flow rate, especially in applications like oil and gas well testing.
Innovation Solution
A method and system combining strain-based SONAR flow meters with time-accurate Computational Fluid Dynamics (CFD) analysis to simulate fluid flow conditions, using error functions to adjust flow rates based on measured and simulated data, incorporating pressure drop measurements to enhance accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If clamp-on SONAR flow meters are used to measure fluid flow rate, then the measurement can be performed in non-ideal conditions (non-fully developed and non-well-mixed flows), but the accuracy deteriorates due to uncertainties in the relationship between convective flow disturbance velocity and volumetric flow rate
Solution Approach 1:
The patent introduces CFD simulation as an intermediary computational model that bridges the gap between SONAR measurements and actual flow rates. The CFD model acts as a virtual mediator that translates measured convective velocities into accurate volumetric flow rates by accounting for complex flow field characteristics that cannot be directly observed
Solution Approach 2:
The patent implements an iterative feedback mechanism where CFD simulation results are compared with actual flow measurements, and the discrepancy is used to refine the relationship model. This feedback loop continuously improves the accuracy of flow rate calculations in non-ideal conditions by learning from measurement errors
2Measurement precision
If conventional in-line flow meters are used, then measurement accuracy can be maintained, but installation cost and complexity increase significantly
Solution Approach 1:
The patent creates a virtual copy of the physical flow system through CFD simulation. Instead of using complex physical in-line meters, the system creates a digital twin of the flow field that can be analyzed computationally, providing accurate measurements without physical intrusion into the flow system
Solution Approach 2:
The patent replaces the mechanical in-line flow meter system with a computational system. The physical mechanical measurement device is substituted with a combination of external SONAR sensors and computational fluid dynamics modeling, eliminating the need for intrusive mechanical components in the flow path
3Measurement precision
If CFD simulation is used to enhance measurement accuracy, then measurement precision improves to within +/-2%, but computational resources and processing time increase
Solution Approach 1:
The patent performs preliminary CFD simulations to establish the relationship between convective velocities and volumetric flow rates before actual measurements are taken. By pre-computing the flow field characteristics and storing the relationship models, the system avoids performing full CFD simulations during real-time measurement, thus reducing processing time while maintaining accuracy
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
Improves the accuracy of fluid flow rate measurement in non-ideal conditions by up to +/-2% accuracy, enabling precise control of fluid flow in pipes with undeveloped and mixed fluid flows.
Implementation Method 1
These flow meters measure strain within the pipe at multiple axial locations and then utilize array processing techniques to measure the speed at which coherent disturbances convect past the array of strain-based sensors attached to the pipe
Implementation Method 2
a time-accurate Computational Fluid Dynamics (CFD) analysis device configured to simulate data representative of coherent flow disturbances
Implementation Method 3
The simulated data may then be compared with data produced using a SONAR flow meter (i.e., 'measured data') to define one or more error functions (or other compensation factors) that represent the difference between the simulated data and measured data
Data Source
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AI summary
A system for measuring a velocity or volumetric fluid flow rate of a fluid flow passing within a pipe includes a SONAR flow meter configured to determine a measured velocity or volumetric rate of a fluid flow passing within a pipe. The system further includes a CFD analysis device configured to produce a simulated velocity or volumetric rate of the fluid flow passing within the pipe. The system further includes a processing unit in communication with the CFD analysis device and the SONAR flow meter. The processing unit is configured to produce at least one error function based on the measured velocity or volumetric fluid flow rate and the simulated velocity or volumetric fluid flow rate, and is configured to determine an adjusted velocity or volumetric fluid flow rate using the at least one error function and the measured velocity or volumetric fluid flow rate.