Clamp-On Ultrasonic Flow Sensing for Thick-Walled High-Pressure Pipes
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Solution Overview
Problem
High-pressure systems face challenges in accurately measuring fluid flow due to low flow rates, material density changes, pressure pulsations, and complex geometry, leading to measurement inaccuracies and production interruptions, especially in applications like polymerization and high-pressure pasteurization.
Innovation Solution
Employing a clamp-on ultrasonic measuring device externally on high-pressure pipes to measure fluid flow speed, using ultrasonic runtime difference and noise trek methods, which provides a stable and engagement-free measurement without system modifications, minimizing wear and pressure loss, and enabling accurate determination of flow control variables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measuring devices (apertures, differential pressure meters, magnetic-inductive flowmeters, vortex meters, Coriolis meters) are used in high-pressure systems, then flow measurement can be performed, but measurement precision deteriorates due to wear from toxic and corrosive media, requiring frequent maintenance and causing production interruptions
Solution Approach 1:
The patent replaces conventional mechanical measuring devices with an ultrasonic measuring device that uses acoustic waves to measure flow. This substitution eliminates mechanical contact with the fluid, preventing wear from toxic and corrosive media, thereby maintaining measurement precision while improving system reliability by eliminating maintenance interruptions
Solution Approach 2:
The patent introduces ultrasonic waves as an intermediary medium to measure flow characteristics. Instead of direct mechanical contact, the ultrasonic waves transmit through the fluid to carry measurement information, enabling non-intrusive measurement that avoids wear and maintains accuracy in harsh high-pressure environments
2Measurement precision
If conventional instruments are installed in high-pressure lines, then flow measurement is possible, but pressure loss increases and device complexity increases, reducing system availability and profitability
Solution Approach 1:
The patent replaces complex mechanical flow measurement systems with a simpler ultrasonic measurement system. The ultrasonic device measures flow based on acoustic wave propagation characteristics rather than mechanical obstruction or direct contact, thereby reducing device complexity and pressure loss while maintaining measurement capability
3Reliability
If clamp-on ultrasonic measuring devices are used externally on high-pressure pipes, then maintenance needs are reduced and pressure loss is minimized, but measurement precision deteriorates due to pressure pulsations and material density changes in high-pressure systems
Solution Approach 1:
The patent employs feedback mechanisms to compensate for measurement disturbances caused by pressure pulsations and material density changes. The system continuously monitors and adjusts measurements based on real-time process conditions, thereby maintaining measurement precision despite the challenging high-pressure environment and external placement of the measuring device
Solution Approach 2:
The patent accounts for and compensates for changes in physical parameters (pressure, density) when calculating flow measurements. By dynamically adjusting measurement interpretations based on actual process parameters, the system maintains accuracy despite the varying conditions inherent in high-pressure systems
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 and continuous measurement of fluid flow in high-pressure systems, reducing maintenance needs and production interruptions, while ensuring process reliability and safety by dynamically adjusting flow control to meet setpoint values.
Implementation Method 1
measuring the flow speed of the fluid flow flowing through the pipe by means of at least one ultrasonic measuring device, in particular an externally arranged ultrasonic measuring device, to obtain a measurement result of the flow speed
Implementation Method 2
The propagation speed of sound in the medium is significantly changed
Implementation Method 3
using ultrasonic runtime difference and noise trek methods
Data Source
AI summary
A method and a high-pressure system for determining a flow control variable of a fluid flow flowing through a high-pressure-side high-pressure pump outlet of a high-pressure pump are provided. An externally arranged ultrasonic measuring device measures a flow speed of a fluid flow flowing through a pipe of the high-pressure-side high-pressure pump outlet. A use of an ultrasonic measuring device is provided for determining a flow value to be achieved of a fluid flow flowing through a thick-walled pipe. The ultrasonic measuring device is arranged on the outside on the thick-walled pipe of the high-pressure pump outlet. The pipe has a ratio of the internal diameter to the external diameter of 1:1.5 to 1:5. The ultrasonic measuring device dynamically measures the flow speed of the fluid flow and transmits this measured flow speed to an evaluation unit to compute a current flow value and the flow control variable.