Ultrasonic Meter Pipe Roughness Trending
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Solution Overview
Problem
Ultrasonic flow meters in the oil and gas industry generate abundant diagnostic data but current methods are inefficient in interpreting shifts, leading to uncertain and costly routine maintenance and recalibration schedules, failing to predict system performance beyond the flow meter, such as upstream pipe conditions.
Innovation Solution
An ultrasonic meter system that determines pipe roughness by analyzing diagnostic data from acoustic signals, including asymmetry, cross flow, and profile factors, trending these parameters over time to identify changes in pipe roughness, with a spool piece and transducer pairs to assess fluid flow characteristics and calculate velocity profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed routine maintenance and mandatory recalibration intervals are implemented, then meter reliability is maintained, but maintenance cost and time consumption increase
Solution Approach 1:
The patent transitions from fixed static maintenance intervals to dynamic condition-based maintenance scheduling. The system continuously monitors diagnostic parameters (asymmetry ratio, cross flow ratio, swirl ratio) and adjusts maintenance timing based on actual meter condition, allowing extension of maintenance intervals when the meter is performing well and triggering earlier maintenance when degradation is detected.
Solution Approach 2:
The system implements feedback loops where diagnostic data from the ultrasonic flow meter is continuously analyzed and fed back to determine maintenance needs. The trending analysis of diagnostic parameters provides feedback on meter condition, enabling proactive maintenance scheduling before performance degradation occurs, rather than following predetermined fixed intervals.
2Reliability
If fixed routine maintenance and mandatory recalibration intervals are implemented, then meter reliability is maintained, but maintenance cost increases
Solution Approach 1:
The system implements dynamic maintenance scheduling that adjusts maintenance frequency and resource allocation based on actual meter condition. When diagnostic parameters indicate stable performance, maintenance intervals are extended, reducing maintenance costs. When parameters indicate degradation, the system triggers targeted maintenance activities, optimizing the balance between reliability and cost.
Solution Approach 2:
The ultrasonic flow meter performs self-diagnostics by continuously monitoring its own diagnostic parameters (asymmetry ratio, cross flow ratio, swirl ratio). This self-service capability allows the meter to identify its own maintenance needs without external intervention, enabling more efficient allocation of maintenance resources and reducing unnecessary maintenance costs.
3Measurement precision
If diagnostic data is collected and analyzed, then pipe roughness prediction capability is improved, but data interpretation complexity increases
Solution Approach 1:
The patent segments the complex diagnostic data into three distinct, easily interpretable parameters: asymmetry ratio (indicating flow profile symmetry), cross flow ratio (indicating lateral flow components), and swirl ratio (indicating rotational flow). Each parameter is calculated independently and can be analyzed separately, simplifying the interpretation process while maintaining comprehensive diagnostic capability for pipe roughness detection.
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 enables more efficient use of diagnostic data, reducing unnecessary maintenance and calibration, while effectively predicting pipe roughness and system performance, thereby optimizing maintenance schedules and improving operational efficiency.
Implementation Method 1
acoustic signals transmitted between the first transducer pair
Implementation Method 2
acoustic signals transmitted between the first transducer pair (wherein the diagnostic data comprises an asymmetry of the flow of fluids in the spool piece, a cross flow of the flow of fluids in the spool piece, and a profile factor of the flow of fluids in the spool piece)
Data Source
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Figure 4
AI summary
A method and ultrasonic meter system for determining pipe roughness. At least some of the illustrative embodiments are ultrasonic meters comprising a spool piece, and a first transducer pair mechanically mounted to the spool piece. The ultrasonic meter is configured to determine diagnostic data based on acoustic signals transmitted between the first transducer pair. The ultrasonic meter is configured to determine changes in the roughness of a pipe mechanically coupled to the ultrasonic meter based on a trend of the diagnostic data (wherein the trend comprises a substantially constant value of about unity for both asymmetry and cross flow and a substantially changing value for profile factor).