The present invention relates to measurement of flow of gases in pipes or flare stacks using optical means.
Gas flow measurement is a challenging technical task because its motion is influenced by various physical parameters such as pressure, temperature, density, viscosity, pipe configuration, wall roughness, and obstacles located upstream and downstream from the measurement zone. In addition to that, gas cannot accumulate in a reservoir for verification purposes, this creates a problem for the calibration of gas flow metering means. Various gas flow metering techniques have been developed to overcome these challenges, and they are based on various fundamental principles such as mechanical, thermal, ultrasonic, and optical.
Optical gas flow meters can be utilized on laser Doppler velocimeters (LDV) which measures gas velocity based on the frequency shift caused by light scattering from moving media (gas). However, light scattering in clean gases is very weak and, because of that, LDVs require particle seeding which is not practical in most situations.
The laser-two-focus method (L2F) of gas flow measurement (see U.S. Pat. No. 7,265,832 “Optical flow meter for measuring gases and liquids in pipelines”) provides better sensitivity because laser beams are focused into two bright laser sheets and, therefore, very tiny particles can be detected. As a result, flow of many industrial gases, including natural gas in pipelines, can be measured. Focusing of laser light in the L2F gas flow meters, however, creates an inherent disadvantage for the L2F method, in that it allows for measurement of gas flow only in the limited volume. This type of flow measurement is called a single-point measurement and it requires special conditions such as an ideal flow conditioning to eliminate errors caused by uncertainty of the flow profile in the pipe. U.S. Pat. No. 6,275,284 “Pipeline Optical Flow Meter” describes a multi-point L2F flow meter in which each of three sensing points are created by a separate fiber optic system. This makes the design complex and fragile. Another disadvantage is that particles are not always present in processed gases (flares) and the number of effective particles decreases at low velocities due to particles dropping to the bottom of the pipe or sticking to the walls. This limits the practical application of the L2F flow meter since it has a minimum measurable velocity of not less than 0.1 ft/s. Environmental regulations require flare gases to be measured down to 0.1 ft/s or 0.03 m/s and this is unachievable using the L2F technique.
Optical flow meters based on a scintillation effect such as those described in U.S. Pat. No. 6,611,319 “Optical Flow Sensor Using a Fast Correlation Algorithm” can measure gas flow without the presence of particles in the gas. They operate by transilluminating the pipe with collimated light and measuring the cross-correlation of scintillating light on the opposite side of the pipe by using a set of two photodetectors. The photodetectors are spaced apart along the direction of the gas flow. Light scintillation occurs due to the local changes of the refractive index of the gas (similar to flickering of the horizon line on a sunny summer day or the flickering above a warm asphalt road after rain). Despite its ability to measure transparent gases and its capability of flow averaging along the pipe diameter, the proposed solution has a number of disadvantages. Gas moving in small pipes, under ambient temperature, possesses very minuscule changes in its refractive index. As such, its flow cannot be measured accurately by light scintillation. This effect is known in the steam industry where clean steam flow is visualized by adding visual flow indicators such as turbines, balls, etc., because flow of the transparent steam itself is not seen through the observing windows due to the lack of light scintillation. Optical scintillations are increased with optical path, for same gradient of the refractive index, with the longer optical path possessing stronger scintillations. Therefore, an optical scintillation meter can be applied to very large pipes or flare stacks only where tiny angular displacements of the optical beams turn into measurable fluctuations of the light intensity at the receive aperture. Flare gas stacks typically range from a few meters to tens of centimeters. This small size is not sufficient for the reliable operation of a cross pipe optical scintillation meter. Despite transilluminating the whole pipe, optical meters based on scintillation do not provide flow averaging along the pipe diameter due to the distribution of scintillation vortices throughout the pipe. Because of heat exchange, stronger fluctuations may occur closer to the pipe wall where velocity is low. Such fluctuations will contribute largely to a cross-correlation as opposed to weaker scintillations in the middle of the pipe where flow is faster. For this reason, scintillation flow meters can be used only for flow indication rather than for flow measurement and the name “flow sensor” instead of “flow meter” was properly used by the inventor.
An object of the present invention is to provide an improved optical gas flow meter which can operate in clean gases without particle seeding.
Another object of the invention is to provide an optical gas flow meter which can measure gas flow at multiple points across the pipe, thus making the gas flow meter less dependent on the flow profile.
Yet another object of the invention is to provide an optical gas flow meter which can measure very slow gas flow, in the order of one centimeter per second, to comply with recent environmental regulations.
According to the present invention, at least two narrow parallel beams of light are delivered through transparent windows in the pipe. The beams are spaced apart along the direction of the flow. A thin rod is placed along the light beams and the rod is placed in front of the beams so gas hits the rod before it reaches the light beams. A number of electrical heaters are located on the rod which can operate independently from each other. The location of the heaters is known, for example, they can be equidistantly located along the rod.
Each heater creates a local disturbance in the refractive index of the gas which is much stronger than the weak natural vortices found throughout the pipe. The heaters can be powered one by one in a consecutive fashion, with only one heater being on at any one given time. Using this approach, strong scintillations are created at each predetermined location and gas flow velocity can be measured at multiple points using cross-correlation techniques.
The signal-to-noise ratio is also improved by using spatial filtering. Spatial light filtering is the blocking of straight light being emitted from the light source while allowing only scattered and deflected light to be detected and processed.
A schematic presentation of prior art described in U.S. Pat. No. 6,611,319 is provided in
V=d/τ (1)
where τ is the lapse time between two stochastic electrical signals from photodetectors 15 and 16.
The schematic in
the light source 9 is a single laser diode or LED (light emitting diode);
the transmit optics 11 represents a collimating lens having a diameter of about one inch or Dt=25.4 mm;
the receive optics 12 and 14 represent receiving lenses of two inches in diameter each or Dr1=Dr2=50.8 mm.
It become apparent from
Improvements should therefore provide a constant spacing dz along the pipe diameter as is shown in
According to second embodiment, the optical gas flow meter that takes into account the scintillation effect includes the spatial filtering means 26 and 28 which are preferably independent of each detection channel. The spatial filtering means improves the signal-to-noise ratio by reducing the amount of straight light. Only light scattered at local disturbances will reach the photodetecting means 29 and 30. Straight light from the light source is blocked by the spatial filtering means. Increasing the signal-to-noise ratio from the primary sensors allows improved accuracy of the whole device. The need for using spatial filtering is dictated by the short path length which is limited by the size of the flare stack. The intensity of the light fluctuations from a point light source collected at the receive optics is defined (see Equation (1) in U.S. Pat. No. 6,496,252) as:
where λ is the wavelength, L is the path length, Cn2 is the refractive-index structure parameter. From equation (2), one can see that light oscillation is changed with the path length as L2. The above mentioned paper by Ting-Wang et al. provides a similar formula for σ in which the oscillation intensity is proportional to L11/6. Without giving too many theoretical details on which power in L is to be used, it becomes apparent that scintillations are rapidly reduced with shortening the path length. The path length L is equal to pipe diameter, Dp, in a round flare stack if light is delivered perpendicular to the flow direction.
Spatial filtering can be accomplished in a number of ways such as using schlieren techniques, for example. The advantage of detecting weak oscillations by using schlieren methods is described by T. I. Arsen'yan et al, “Application of schlieren methods in recording weak variations of the intensity of coherent optical radiation in the atmosphere”, Sov. J. Quant. Electron. v. 5, No. 6 p. 650-652. A practical application of the spatial filtering based on two gratings for measurement of crosswind is disclosed in U.S. Pat. No. 5,159,407 “Single-ended dual spatial filter detector for the passive measurement of winds and turbulence aloft”. Spatial filtering can be effectively applied for improving the performance of the optical gas flow meters in a passive way.
The path length, L, can be increased by applying various designs, a practical way is to use a prism system as shown in
Unlike the L2F method, the optical scintillation method allows for a longitudinal optical path. An example of the schematic of the longitudinal arrangement is shown in
The lapse time τ calculated from the cross-correlation function of the signals from photodetecting means 62 should account for the effective beam spacing to be used in equation (1):
where d is the geometrical spacing between the beams 46 and 48.
Since typical flare stacks are high, the vertical part of the flaring system can be effectively used for increasing the path length L as is shown in
Yet another embodiment of the present invention includes an active means for improving the signal strength. Even in the largest flare stacks which have diameters of a few meters, scintillations are not noticeable, in particular, when flare gas flows under ambient temperature. Usually flaring occurs under minimum possible flows (a fraction of meters per second) in order to reduce gas waste. Environmental regulations in California required the measurement flow of flare gases down to 0.1 ft/s or 0.03 m/s. Measurement of such slow gas flows by optical means requires the generation of optical scintillations in the pipe.
Means for generating optical scintillations allows for the measuring of gas flow at multiple points across the pipe. An example of multiple point measurement is shown in
This feature is not achievable by any other flow metering techniques including ultrasonic flow meters and multi-point Pitot tubes which all provide only integrated velocity. Another advantage of the distributed heating shown in
In smaller pipes where knowledge of flow profile is not as important as in the large flare stacks and average Vbulk is sufficient, the means for creating optical scintillations can be located circularly on the wall either inside (
Means for generating scintillations shown in
where ρ is the gas density; A is the reference area of the rod; C is the drag coefficient. Assuming that heater is ¼ inch or 6.35 mm in diameter, the stack has diameter Dp=1.0 m, and ρ=1 kg/m3 (this is close to density of the air at normal conditions), the maximum drag force during the blow-up event at Vmax=100 m/s will be only Fd=20N. Regular stainless steel tubing with outer diameter of ¼ inch withstands this force.
A wire or a rod inserted in the flare stack causes flow vortices which are in many cases sufficient for detecting optical scintillation without heating the insert. In this case, the inset is functioning as a regular bluff body. This fluid dynamic effect is particularly pronounced at velocities above 10 m/s where mechanically induced turbulence dominates over thermally induced turbulences. The latter is reduced because the inserts are cooled at high velocity similarly to cooling of the heated contacts in thermal mass flow meters.
With reference to
Preferably the local velocity Vz is calculated based on lapse time r determined from the location of the peak of cross-correlation function K(τ) between signals U1(t), and U2(t) from photodetecting means 29 and 30:
where T is the integration time. The exact algorithm can be performed digitally in a number of ways including those described in U.S. Pat. No. 6,611,319; this is not critical considering the modern capabilities of fast DSP.
beam spacing d=18 mm;
receive and transmit optics Dr=Dt=5 mm;
ambient air temperature Ta=20° C.;
heater temperature Th=35° C.;
heater diameter ⅛ inch or 3.1 mm;
reference flow meter, ultrasonic 4-path fiscal gas meter;
pipe reduction system from 36 inch to 4 inch coupling to ultrasonic meter.
The setup provided 9:1 pipe reduction which is equivalent to 81:1 velocity increase across the ultrasonic reference meter. The test data clearly indicates the capability of the proposed optical flow meter to measure ultra-low gas flow, down to centimeters per second range.
Optical scintillations increased with shorter wavelength according to equation (2). With this respect, blue and UV LED are particularly advantageous for use in the scintillation optical flow meters. Short wavelength LED with a center line at 405 nm and UV LED with maximum intensity at 375 nm are commonly available and they provide significant optical power. Such light sources are spectrally matched with the PMT which provides the best signal-to-noise ratio among all photodetectors.
Although the present invention has been described by way of examples thereof, it should be pointed out that any modifications to these examples, within the scope of the appended claims, are not deemed to change or alter the nature and scope of the present invention.