In-Plant Valve Flow Prediction Using Pressure and Temperature Data

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Solution Overview

Problem

Conventional flowmeter installations in piping circuits are impractical due to high capital and operating expenses, and the inability to accurately measure fluid flowrates in turbulent conditions, especially in congested areas where hardware flowmeters cannot be installed.

Innovation Solution

A virtual flow sensing system using existing instruments like pressure and temperature sensors, and a fluid flow model to determine fluid flowrates without the need for physical flowmeters, by analyzing upstream and downstream pressure and temperature data, valve characteristics, and fluid properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional flowmeters are installed in piping circuits, then flowrate measurement capability is provided, but capital expense and operating expense are greatly increased

Engineering Contradiction:

Improveflowrate measurement capabilityVSAvoidcapital expense and operating expense

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces physical flowmeters (mechanical measurement devices) with a virtual flow sensing system that uses pressure and temperature sensors combined with fluid flow modeling. The control system calculates flowrate using the fluid flow model based on pressure differential and temperature data, eliminating the need for expensive hardware flowmeters while maintaining measurement capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a fluid flow model as an intermediary between the physical sensors and the flowrate measurement function. The model acts as a virtual mediator that translates pressure and temperature sensor readings into flowrate information, allowing flow measurement without direct physical flowmeter installation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If flowmeters are installed to measure fluid flow, then flowrate data is obtained, but the system requires maintenance and non-productive time for inspections

Engineering Contradiction:

Improveflowrate measurementVSAvoidmaintenance time and non-productive time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The virtual flow sensing system eliminates the need for manual maintenance and inspection of flow measurement hardware. The system continuously calculates flowrate using existing pressure and temperature sensors and the fluid flow model, requiring no non-productive time for inspections or preventive maintenance of dedicated flow measurement equipment

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent extracts the flow measurement function from physical flowmeter hardware and implements it virtually through software-based fluid flow modeling. This removes the component requiring maintenance while preserving the measurement capability

Inventive Principle:

Principle #2Taking out (Extraction)

3Measurement precision

If hardware flowmeters are installed in congested areas, then flowrate measurement is possible, but installation is prevented due to inadequate pipe straight length and congested area

Engineering Contradiction:

Improveflowrate measurement capabilityVSAvoidinstallation feasibility

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces physical flowmeters that require specific installation conditions (adequate pipe straight length, non-congested areas) with a virtual sensing system using pressure and temperature sensors. This allows flow measurement in congested areas where physical flowmeters cannot be installed

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The virtual flow sensing system uses existing pressure and temperature sensors that serve multiple functions in the process control system, eliminating the need for dedicated flowmeter installation and making the solution applicable to all piping circuits regardless of spatial constraints

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reduces installation costs, eliminates the need for hardware modifications, and provides accurate flowrate measurements, improving operational efficiency and reducing non-productive time, while being applicable to various fluid types and turbulent flow conditions.

Implementation Method 1

a first pressure sensor and a first temperature sensor coupled to the upstream process equipment and disposed upstream from the valve; a second pressure sensor and a second temperature sensor coupled to the downstream process equipment and disposed downstream from the valve

Methodology Applied

Scientific EffectPressure differential measurement: Pressure Gradient

Implementation Method 2

Methodology Applied

Scientific EffectTemperature measurement: Temperature Gradient

Data Source

PatentUS20230152134A1Method and system for predictive flow measurement at in-plant piping

Publication Date: 2023.05.18 SAUDI ARABIAN OIL CO

AI summary

Upstream process equipment transmits a predetermined fluid to downstream process equipment. A valve fluidly couples the upstream process equipment to the downstream process equipment. A first pressure sensor and a first temperature sensor are coupled to the upstream process equipment and upstream from the valve. A second pressure sensor and a second temperature sensor are coupled to the downstream process equipment and downstream from the valve. A control system is coupled to the first pressure sensor, the first temperature sensor, the second pressure sensor, and the second temperature sensor. The control system determines a first fluid flowrate of the predetermined fluid using a fluid flow model based on pressure data from the first pressure sensor and the second pressure sensor, temperature data from the first temperature sensor and the second temperature sensor, a size of the valve, at least one fluid parameter regarding the predetermined fluid, and a valve flow coefficient of the valve.