Next Patent: Spout for dispensing liquid from a liquid container
Next Patent: Spout for dispensing liquid from a liquid container
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/528,802 filed Dec. 11, 2003, (Attorney Docket CC-0685) U.S. Provisional Patent Application No. 60/441,652 filed Jan. 22, 2003, (Attorney Docket CC-0585); U.S. Provisional Patent Application No. 60/441,395 filed Jan. 21, 2003, (Attorney Docket CC-0581); which are all incorporated herein by reference.
[0002] This invention relates to an apparatus for measuring a flow having entrained gas therein, and more particularly to an apparatus that measures the speed of sound propagating through the flow to determine the gas volume fraction of the gas in the process.
[0003] The present invention provides an apparatus and method of measuring gas volume fraction in a process flow or fluid, such as slurries used in the paper and pulp industries and in other industries. Slurries commonly used in the paper and pulp industry are mostly water and typically contain between 1% and 10% pulp content by mass. Monitoring the gas volume fraction of a slurry can lead to improved quality and efficiency of the paper production process.
[0004] Processes run in the paper and pulp industry can often, either intentionally or unintentionally, entrain gas/air. Typically, this entrained air results in measurement errors in process monitoring equipment such as volumetric flow measurements and consistency meters.
[0005] Industry estimates indicate that entrained air levels of 2-4% are common. Since most process flow monitors are unable to distinguish between air and liquid, interpreting their output as liquid flow rates would result in a overestimate of the liquid by the volumetric flow rate of the air present at the measurement location. Similarly, for the void fraction of the air within the pipe can cause errors in consistency measurements.
[0006] Thus, providing a method and apparatus for measuring entrained air in paper and pulp slurries, for example, would provide several benefits. Firstly, it would provide a means to screen the output of process instrumentation. Secondly, in addition to screening the measurements, an accurate measurement of the entrained air would provide a means to correct the output of volumetric flow meters and consistency meters. Thirdly, monitoring variations in the amount of entrained air in a given process could be indicative of process anomalies, such a worn bushing or cavitating pumps and/or valves.
[0007] Multiphase process flow rate is a critical process control parameter for the paper and pulp industry. Knowing the amounts of liquid, solids and entrained gases flowing in process lines is key to optimizing the overall the papermaking process. Unfortunately, significant challenges remain in the achieving accurate, reliable, and economical monitoring of multiphase flow rates of paper and pulp slurries. Reliability challenges arise due the corrosive and erosive properties of the slurry. Accuracy challenges stem from the multiphase nature of the slurries. Economical challenges arise from the need to reduce total lifetime cost of flow measurement, considering installation and maintenance costs in addition to the initial cost of the equipment.
[0008] Currently, there is an unmet need for multiphase flow measurement in the processing industry, such as the paper and pulp industry. Real time flow measurement is typical restricted to monitoring the total volumetric flow rate in a process line without providing information on the composition of the process mixture. For example, electromagnetic flow meters are the most widely used flow meters in the paper and pulp industry, however they provide no indication of presence of entrained air, with its presence resulting in an over prediction of the volumetric flow of process fluid by the amount of air entrained. Consistency meter provide a measurement of the percentage of solids within the process, however this technology remains more of an art than a science. Furthermore, although entrained air is known to have a large, often deleterious, impact on the paper making process, instrumentation is currently not available to provide this measurement on a real time basis.
[0009] In one embodiment of the present invention, the apparatus and method improves the determination of consistency of paper and pulp slurries. Consistency refers to the mass fraction of pulp contained in water and pulp slurries used in the paper making process. Consistency measurements are critical in the optimization of the paper making process. Currently, many companies produce consistency meters employing various technology to serve the paper and pulp industry. Unfortunately, accurate and reliable measurement of consistency remains an elusive objective. Typically, interpreting the output of a consistency meter in terms of actual consistency is more of an art than a science.
[0010] Of the various types of consistency meters on the market, microwave based meters may represent the best the solution for many applications. One such microwave-based consistency meter is manufactured by Toshiba. Microwave consistency meters essentially measure speed or velocity the microwave signal propagates through the medium being measured. For example, the speed of the microwave signal through water is approximately 0.1 time the speed of light in a vacuum (c), through air is approximately 1.0 times the speed of light in a vacuum, and through fiber (or pulp) is approximately 0.6 times the speed of light in a vacuum.
[0011] The velocity of the microwave signal propagating through the paper pulp slurry is measure by the conductive effects of the slurry, in accordance with the following equation:
[0012] Where V is the velocity of the microwave signal propagating through the slurry, c is the speed of light in a vacuum, and E is the relative conductivity of the material. Typical values of relative conductivity for material comprising a paper/pulp slurry, for example, are:
[0013] Water relative conductivity=80;
[0014] Air relative conductivity=1; and
[0015] Fiber relative conductivity=3.
[0016] These meters typically work well in the absence of entrained air. With entrained air present, the air displaces water and looks like additional pulp fiber to the microwave meter. Thus, uncertainty in the amount of entrained air translates directly into uncertainty in consistency.
[0017] Objects of the present invention include an apparatus having a device for determining the speed of sound propagating within a pipe to determine the gas volume fraction of a process fluid or flow flowing within a pipe.
[0018] According to the present invention, an apparatus for measuring the gas volume fraction process flow flowing within a pipe is provided. The apparatus includes at least one sensor for providing a sound measurement signal indicative of the speed of sound propagating within the pipe. A processor determines the gas volume fraction of the flow, in response to the sound measurement signal.
[0019] According to the present invention, a method of measuring the gas volume fraction process flow flowing within a pipe comprises measuring the speed of sound propagating within the pipe, and determining the gas volume fraction of the flow, in response to the measured speed of sound.
[0020] The foregoing and other objects, features and advantages of the present invention will become more apparent in light of the following detailed description of exemplary embodiments thereof.
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[0027]
[0028]
[0029]
[0030] Referring to
[0031] The following approach may be used with any technique that measures the sound speed of a flow or speed at which sound propagates through the flow
[0032]
[0033] A flow chart
[0034] Other information relating to the gas volume fraction in a fluid and the speed of sound (or sonic velocity) in the fluid, is described in “Fluid Mechanics and Measurements in two-phase flow Systems”, Institution of mechanical engineers, proceedings 1969-1970 Vol. 184 part 3C, Sept. 24-25, 1969, Birdcage Walk, Westminster, London S.W. 1, England, which is incorporated herein by reference.
[0035]
[0036] In an embodiment of the present invention shown in
[0037] The apparatus
[0038] Generally, the apparatus
[0039] The apparatus in
[0040] The apparatus
[0041] In accordance with one embodiment of the present invention, the speed of sound propagating through the mixture
[0042] As shown in
[0043] The frequency signals P
[0044] The data from the array of sensors
[0045] One such technique of determining the speed of sound propagating through the flow
[0046] The signal processor
[0047] The flow meter of the present invention uses known array processing techniques, in particular the Minimum Variance, Distortionless Response (MVDR, or Capon technique), to identify pressure fluctuations, which convect with the materials flowing in a conduit and accurately ascertain the velocity, and thus the flow rate, of said material. These processing techniques utilize the covariance between multiple sensors
[0048] To calculate the power in the k-ω plane, as represent by a k-ω plot (see
[0049] In the case of suitable acoustic pressures being present, the power in the k-ω plane shown in a k-ω plot of
[0050] The array processing unit
[0051] The prior art teaches many algorithms of use in spatially and temporally decomposing a signal from a phased array of sensors, and the present invention is not restricted to any particular algorithm. One particular adaptive array processing algorithm is the Capon method/algorithm. While the Capon method is described as one method, the present invention contemplates the use of other adaptive array processing algorithms, such as MUSIC algorithm. The present invention recognizes that such techniques can be used to determine speed of sound propagating through the fluid
[0052] Also, some or all of the functions within the processor
[0053] It is within the scope of the present invention that the pressure sensor spacing may be known or arbitrary and that as few as two sensors are required if certain information is known about the acoustic properties of the process flow
[0054] Based on the above discussion, one may use a short length scale aperture to measure the sound speed. For example, the characteristic acoustic length scale is: λ=c/f; where c is the speed of sound in a mixture, f is frequency and λ is wavelength.
[0055] If Aperture=L and if L/λ is approx. constant.
[0056] Then Lwater/λwater=Lwater*f/C
[0057] Therefore: L
[0058] Thus for SOS of water (Cwater=5,000 ft/sec), and SOS of the Gas volume fraction (C GVF=500 ft/sec) and a length aperture of L water=5 ft (which we have shown is sufficient to accurately measure the SOS of water), the length aperture for a gas volume fraction L
[0059] The entrained gas processing unit
[0060] wherein x is the speed of sound, A=1+rg/rl*(K
[0061] Effectively,
[0062] Gas Voulume Fraction (GVF)=(−B+sqrt(B{circumflex over ( )}2−4*A*C))/(2*A)
[0063] Alternatively, the sound speed of a mixture can be related to volumetric phase fraction (φ
[0064] One dimensional compression waves propagating within a mixture
[0065] Note: “vacuum backed” as used herein refers to a situation in which the fluid surrounding the pipe externally has negligible acoustic impedance compared to that of the mixture internal to the pipe
[0066] The mixing rule essentially states that the compressibility of a mixture (1/(ρa
[0067] Conversely, however, detailed knowledge of the liquid/slurry is not required for entrained air measurement. Variations in liquid density and compressibility with changes in consistency have a negligible effect on mixture sound speed compared to the presence of entrained air.
[0068] For paper and pulp slurries, the conditions are such that for slurries with non-negligible amounts of entrained gas, say <0.01%, the compliance of standard industrial piping (Schedule
[0069]
[0070]
[0071] For the sound speed measurement, the apparatus
[0072] As before, k is the wave number, defined as k=2π/λ, ω is the temporal frequency in rad/sec, and a
[0073] In one embodiment of the present invention as shown in
[0074] The piezoelectric film sensors include a piezoelectric material or film to generate an electrical signal proportional to the degree that the material is mechanically deformed or stressed. The piezoelectric sensing element is typically conformed to allow complete or nearly complete circumferential measurement of induced strain to provide a circumferential-averaged pressure signal. The sensors can be formed from PVDF films, co-polymer films, or flexible PZT sensors, similar to that described in “Piezo Film Sensors Technical Manual” provided by Measurement Specialties, Inc., which is incorporated herein by reference. A piezoelectric film sensor that may be used for the present invention is part number 1-1002405-0, LDT4-028K, manufactured by Measurement Specialties, Inc.
[0075] Piezoelectric film (“piezofilm”), like piezoelectric material, is a dynamic material that develops an electrical charge proportional to a change in mechanical stress. Consequently, the piezoelectric material measures the strain induced within the pipe
[0076] Another embodiment of the present invention include a pressure sensor such as pipe strain sensors, accelerometers, velocity sensors or displacement sensors, discussed hereinafter, that are mounted onto a strap to enable the pressure sensor to be clamped onto the pipe. The sensors may be removable or permanently attached via known mechanical techniques such as mechanical fastener, spring loaded, clamped, clam shell arrangement, strapping or other equivalents. These certain types of pressure sensors, it may be desirable for the pipe
[0077] Instead of single point pressure sensors
[0078] The pressure sensors
[0079] In certain embodiments of the present invention, a piezo-electronic pressure transducer may be used as one or more of the pressure sensors
[0080] The pressure sensors incorporate a built-in MOSFET microelectronic amplifier to convert the high-impedance charge output into a low-impedance voltage signal. The sensor is powered from a constant-current source and can operate over long coaxial or ribbon cable without signal degradation. The low-impedance voltage signal is not affected by triboelectric cable noise or insulation resistance-degrading contaminants. Power to operate integrated circuit piezoelectric sensors generally takes the form of a low-cost, 24 to 27 VDC, 2 to 20 mA constant-current supply. A data acquisition system of the present invention may incorporate constant-current power for directly powering integrated circuit piezoelectric sensors.
[0081] Most piezoelectric pressure sensors are constructed with either compression mode quartz crystals preloaded in a rigid housing, or unconstrained tourmaline crystals. These designs give the sensors microsecond response times and resonant frequencies in the hundreds of kHz, with minimal overshoot or ringing. Small diaphragm diameters ensure spatial resolution of narrow shock waves.
[0082] The output characteristic of piezoelectric pressure sensor systems is that of an AC-coupled system, where repetitive signals decay until there is an equal area above and below the original base line. As magnitude levels of the monitored event fluctuate, the output remains stabilized around the base line with the positive and negative areas of the curve remaining equal.
[0083] It is also within the scope of the present invention that any strain sensing technique may be used to measure the variations in strain in the pipe, such as highly sensitive piezoelectric, electronic or electric, strain gages and piezo-resistive strain gages attached to the pipe
[0084] It is also within the scope of the present invention that any other strain sensing technique may be used to measure the variations in strain in the tube, such as highly sensitive piezoelectric, electronic or electric, strain gages attached to or embedded in the tube
[0085] While a number of sensor have been described, one will appreciate that any sensor the measures the speed of sound propagating through the fluid may be used with the present invention, including ultrasonic sensors.
[0086] It should be understood that any of the features, characteristics, alternatives or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein.
[0087] Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein and thereto without departing from the spirit and scope of the present invention.