FLOWMETER FALSE TOTALIZING ELIMINATION DEVICES AND METHODS

Abstract

A method and apparatus for operating a flowmeter (5) is provided. A process fluid is placed in the flowmeter (5). A measured mass flow rate (221) of the process fluid is determined. The process fluid is totalized. A first flowmeter parameter is measured. The measured mass flow rate (221) is set to zero if the first flowmeter parameter differs from a pre-determined threshold by a predetermined amount, and totalizing is halted if the first flowmeter parameter differs from a predetermined threshold by a predetermined amount.

Claims

1. A method for operating a flowmeter comprising: flowing a process fluid through the flowmeter; measuring a mass flow rate of the process fluid; totalizing the process fluid flowing through the flowmeter; measuring a first flowmeter parameter; setting the measured mass flow rate to zero if the first flowmeter parameter differs from a predetermined threshold by a predetermined amount; and halting totalizing if the first flowmeter parameter differs from a predetermined threshold by a predetermined amount.

2. The method of claim 1, comprising the steps of: measuring a second flowmeter parameter; wherein the step of setting the measured mass flow rate to zero if the first flowmeter parameter differs from a predetermined threshold by a predetermined amount comprises setting the measured mass flow rate to zero if the first flowmeter parameter and the second flowmeter parameter each differ from respective predetermined thresholds by respective predetermined amounts; and wherein the step of halting totalizing if the first flowmeter parameter differs from a predetermined threshold by a predetermined amount comprises setting the measured mass flow rate to zero if the first flowmeter parameter and the second flowmeter parameter each differ from respective predetermined thresholds by respective predetermined amounts.

3. The method of claim 1, wherein the first or second flowmeter parameters comprise a drive current.

4. The method of claim 1, wherein the first or second flowmeter parameters comprise a delta t.

5. The method of claim 1, wherein the first or second flowmeter parameters comprise a voltage difference between a first pick-off sensor and a second pick-off sensor.

6. The method of claim 1, wherein the first or second flowmeter parameters comprise a calculated flow tube mass difference measured between a first pick-off sensor and a second pick-off sensor.

7. The method of claim 1, wherein the first or second flowmeter parameters comprise a calculated tube stiffness difference measured between a first pick-off sensor and a second pick-off sensor.

8. The method of claim 1, wherein the first or second flowmeter parameters comprise a density.

9. The method of claim 1, wherein the first or second flowmeter parameters comprise a drive gain.

10. Meter electronics (20) for a flowmeter (5) configured to receive a process fluid, the meter electronics (20) comprising an interface (201) configured to communicate with a flowmeter assembly of the flowmeter (5), and receive a vibrational response, and a processing system (203) coupled to the interface (201) comprising: a false totalizing routine (217) configured to: determine a measured mass flow rate (221) of the process fluid in the flowmeter (5); totalize the process fluid; measure a first flowmeter parameter; set the measured mass flow rate (221) to zero if the first flowmeter parameter differs from a predetermined threshold by a predetermined amount; and halt totalizing if the first flowmeter parameter differs from a predetermined threshold by a predetermined amount.

11. The meter electronics (20) of claim 10, wherein the false totalizing routine (217) is further configured to: measure a second flowmeter parameter; wherein setting the measured mass flow rate to zero if the first flowmeter parameter differs from a predetermined threshold by a predetermined amount comprises setting the measured mass flow rate to zero if the first flowmeter parameter and the second flowmeter parameter each differ from respective predetermined thresholds by respective predetermined amounts; and wherein halting totalizing if the first flowmeter parameter differs from a predetermined threshold by a predetermined amount comprises setting the measured mass flow rate to zero if the first flowmeter parameter and the second flowmeter parameter each differ from respective predetermined thresholds by respective predetermined amounts.

12. The meter electronics (20) of claim 10, wherein the first or second flowmeter parameters comprise a drive current.

13. The meter electronics (20) of claim 10, wherein the first or second flowmeter parameters comprise a delta t.

14. The meter electronics (20) of claim 10, wherein the first or second flowmeter parameters comprise a voltage difference between a first pick-off sensor (105) and a second pick-off sensor (105).

15. The meter electronics (20) of claim 10, wherein the first or second flowmeter parameters comprise a calculated flow tube mass difference measured between a first pick-off sensor (105) and a second pick-off sensor (105).

16. The meter electronics (20) of claim 10, wherein the first or second flowmeter parameters comprise a calculated tube stiffness difference measured between a first pick-off sensor (105) and a second pick-off sensor (105).

17. The meter electronics (20) of claim 10, wherein the first or second flowmeter parameters comprise a density.

18. The meter electronics (20) of claim 10, wherein the first or second flowmeter parameters comprise a drive gain.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIG. 1 shows a flowmeter comprising a sensor assembly and meter electronics;

[0030] FIG. 2 shows a block diagram of the meter electronics according to an embodiment;

[0031] FIG. 3 is a graph illustrating flowmeter drive current as a function of injected air;

[0032] FIG. 4 is a graph illustrating flowmeter delta t as a function of injected air;

[0033] FIG. 5 is a graph illustrating flowmeter pick-off voltages as a function of injected air;

[0034] FIG. 6 is a graph illustrating flowmeter measured flow tube mass as a function of injected air;

[0035] FIG. 7 is a graph illustrating flowmeter measured flow tube stiffness as a function of injected air;

[0036] FIG. 8 is a flow chart illustrating a method of false totalizing mitigation according to an embodiment; and

[0037] FIG. 9 is a flow chart illustrating a method of false totalizing mitigation according to an alternate embodiment.

DETAILED DESCRIPTION

[0038] FIGS. 1-9 and the following description depict specific examples to teach those skilled in the art how to make and use the best mode of the invention. For the purpose of teaching inventive principles, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations from these examples that fall within the scope of the invention. Those skilled in the art will appreciate that the features described below can be combined in various ways to form multiple variations of the invention. As a result, the invention is not limited to the specific examples described below, but only by the claims and their equivalents.

[0039] FIG. 1 shows a flowmeter 5 according to an embodiment. The flowmeter 5 comprises a sensor assembly 10 and meter electronics 20. The meter electronics 20 is connected to the sensor assembly 10 via leads 100 and is configured to provide measurements of one or more of a density, mass flow rate, volume flow rate, totalized mass flow, temperature, or other measurements or information over a communication path 26. The flowmeter 5 can comprise a Coriolis mass flowmeter or other vibratory flowmeter. It should be apparent to those skilled in the art that the flowmeter 5 can comprise any manner of flowmeter 5, regardless of the number of drivers, pick-off sensors, flow conduits, or the operating mode of vibration.

[0040] The sensor assembly 10 includes a pair of flanges 101 and 101, manifolds 102 and 102, a driver 104, pick-off sensors 105 and 105, and flow conduits 103A and 103B. The driver 104 and the pick-off sensors 105 and 105 are connected to the flow conduits 103A and 103B.

[0041] The flanges 101 and 101 are affixed to the manifolds 102 and 102. The manifolds 102 and 102 can be affixed to opposite ends of a spacer 106 in some embodiments. The spacer 106 maintains the spacing between the manifolds 102 and 102. When the sensor assembly 10 is inserted into a pipeline (not shown) which carries the process fluid being measured, the process fluid enters the sensor assembly 10 through the flange 101, passes through the inlet manifold 102 where the total amount of process fluid is directed to enter the flow conduits 103A and 103B, flows through the flow conduits 103A and 103B and back into the outlet manifold 102, where it exits the sensor assembly 10 through the flange 101.

[0042] The process fluid can comprise a liquid. The process fluid can comprise a gas. The process fluid can comprise a multi-phase fluid, such as a liquid including entrained gases and/or entrained solids, for example without limitation. The flow conduits 103A and 103B are selected and appropriately mounted to the inlet manifold 102 and to the outlet manifold 102 so as to have substantially the same mass distribution, moments of inertia, and elastic moduli about the bending axes W-W and W-W, respectively. The flow conduits 103A and 103B extend outwardly from the manifolds 102 and 102 in an essentially parallel fashion.

[0043] The flow conduits 103A and 103B are driven by the driver 104 in opposite directions about the respective bending axes W and W and at what is termed the first out of phase bending mode of the flowmeter 5. The driver 104 may comprise one of many well-known arrangements, such as a magnet mounted to the flow conduit 103A and an opposing coil mounted to the flow conduit 103B. An alternating current is passed through the opposing coil to cause both conduits to oscillate. A suitable drive signal is applied by the meter electronics 20 to the driver 104 via lead 110. Other driver devices are contemplated and are within the scope of the description and claims.

[0044] The meter electronics 20 receives sensor signals on leads 111 and 111, respectively. The meter electronics 20 produces a drive signal on lead 110 which causes the driver 104 to oscillate the flow conduits 103A and 103B. Other sensor devices are contemplated and are within the scope of the description and claims.

[0045] The meter electronics 20 processes the left and right velocity signals from the pick-off sensors 105 and 105 in order to compute a flow rate, among other things. The communication path 26 provides an input and an output means that allows the meter electronics 20 to interface with an operator or with other electronic systems. The description of FIG. 1 is provided merely as an example of the operation of a flowmeter and is not intended to limit the teaching of the present invention. In embodiments, single tube and multi-tube flowmeters having one or more drivers and pickoffs are contemplated.

[0046] The meter electronics 20 in one embodiment is configured to vibrate the flow conduit 103A and 103B. The vibration is performed by the driver 104. The meter electronics 20 further receives resulting vibrational signals from the pickoff sensors 105 and 105. The vibrational signals comprise a vibrational response of the flow conduits 103A and 103B. The meter electronics 20 processes the vibrational response and determines a response frequency and/or phase difference. The meter electronics 20 processes the vibrational response and determines one or more flow measurements, including a mass flow rate and/or density of the process fluid. Other vibrational response characteristics and/or flow measurements are contemplated and are within the scope of the description and claims.

[0047] In one embodiment, the flow conduits 103A and 103B comprise substantially omega-shaped flow conduits, as shown. Alternatively, in other embodiments, the flowmeter can comprise substantially straight flow conduits, U-shaped conduits, delta-shaped conduits, etc. Additional flowmeter shapes and/or configurations can be used and are within the scope of the description and claims.

[0048] FIG. 2 is a block diagram of the meter electronics 20 of a flowmeter 5 according to an embodiment. In operation, the flowmeter 5 provides various measurement values that may be outputted including one or more of a measured or averaged value of mass flow rate, volume flow rate, individual flow component mass and volume flow rates, and total flow rate, including, for example, both volume and mass flow.

[0049] The flowmeter 5 generates a vibrational response. The vibrational response is received and processed by the meter electronics 20 to generate one or more fluid measurement values. The values can be monitored, recorded, saved, totaled, and/or output.

[0050] The meter electronics 20 includes an interface 201, a processing system 203 in communication with the interface 201, and a storage system 204 in communication with the processing system 203. Although these components are shown as distinct blocks, it should be understood that the meter electronics 20 can be comprised of various combinations of integrated and/or discrete components.

[0051] The interface 201 is configured to communicate with the sensor assembly 10 of the flowmeter 5. The interface 201 may be configured to couple to the leads 100 (see FIG. 1) and exchange signals with the driver 104, pickoff sensors 105 and 105, and temperature sensors (not shown), for example. The interface 201 may be further configured to communicate over the communication path 26, such as to external devices.

[0052] The processing system 203 can comprise any manner of processing system. The processing system 203 is configured to retrieve and execute stored routines in order to operate the flowmeter 5. The storage system 204 can store routines including a flowmeter routine 205, a mass-weighted density/viscosity routine 209, a mass-weighted temperature routine 211, a gas entrainment detect routine 213, a measurement confidence routine 215, and a false totalizing routine 217. The measurement confidence routine 215 and/or false totalizing routine 217 may compare any signal, such as drive gain 306, vibrational frequency, vibrational amplitude, power, temperature 224, etc. between right and left pick-off sensors 105, 105. Other measurement/processing routines are contemplated and are within the scope of the description and claims. The storage system 204 can store measurements, received values, working values, and other information. In some embodiments, the storage system stores a mass flow ({dot over (m)}) 221, a density () 225, a viscosity () 223, a temperature (T) 224, a drive gain 306, a drive gain threshold 303, a gas entrainment threshold 244, a gas entrainment fraction 248, and any other variables known in the art.

[0053] The flowmeter routine 205 can produce and store fluid quantifications and flow measurements. These values can comprise substantially instantaneous measurement values or can comprise totalized or accumulated values. For example, the flowmeter routine 205 can generate mass flow measurements and store them in the mass flow 221 storage of the storage system 204, for example. The flowmeter routine 205 can generate density 225 measurements and store them in the density 225 storage, for example. The mass flow 221 and density 225 values are determined from the vibrational response, as previously discussed and as known in the art. The mass flow and other measurements can comprise a substantially instantaneous value, can comprise a sample, can comprise an averaged value over a time interval, or can comprise an accumulated value over a time interval. The time interval may be chosen to correspond to a block of time during which certain fluid conditions are detected, for example a liquid-only fluid state, or alternatively, a fluid state including liquids and entrained gas. In addition, other mass flow and related quantifications are contemplated and are within the scope of the description and claims.

[0054] As noted, drive gain may be utilized as the signal that indicates a no-flow/false totalizing condition. A drive gain threshold may be used to distinguish between periods of flow and no flow. It should be noted that, for purposes of the embodiments provided herein, that the term drive gain may, in some embodiments, refer to drive current, pickoff voltage, or any signal measured or derived that indicates the amount of power needed to drive the flow conduits 103A, 103B at a particular amplitude. In related embodiments, the term drive gain may be expanded to encompass any metric utilized to detect multi-phase flow, such as noise levels, standard deviation of signals, damping-related measurements, and any other means known in the art to detect a no-flow condition. Any of these metrics may be compared across the pick-off sensors 105 and 105 to detect a no-flow condition.

[0055] In general, the source of false totalizing is asymmetry, thus the embodiments provided herein utilize diagnostic approaches that report the magnitude of asymmetry to detect false flow conditions. In an embodiment, a diagnostic relates to the difference between pick-off sensors 105 and 105 voltages, which is fundamentally a measurement of relative amplitude of vibration between the inlet and outlet of the sensor assembly 10.

[0056] Like pick-off voltage, which can be measured at inlet and outlet sides of the sensor assembly 10, meter verification provides a measurement of stiffness and/or mass at the inlet and outlet sides of the sensor assembly 10. Asymmetries such as the build-up of asymmetric flow conduit coating have been shown to be detectable with left and right meter verification measurements, and it is based upon this principle that a relative measurement of stiffness and mass may be utilized to detect false flow.

[0057] Turning to FIGS. 3-7, graphs 300, 400, 500, 600, and 700 illustrate experiments conducted to characterize false flow totalization. It should be noted that the values provided are merely examples for a particular flowmeter under test, and that different flowmeters, based on size, configuration, geometry, test fluids, etc. will likely provide different values. A flowmeter 5 was mounted vertically, and was completely filled with water to ensure no air bubbles were present. A known amount of air was injected proximate one pick-off sensor 105, but not the other pick-off sensor 105. Due to the shape of the flowmeter 5, and the mounting orientation, the injected gas resided proximate the pick-off sensor 105, thus creating a repeatable experimental setup to study a problem that is usually quite unrepeatable.

[0058] Measurements were taken at increasing amounts of gas injection 302 (x-axis) to study potential asymmetry. In FIG. 3, drive current was measured 304 (y-axis) in graph 300, and delta t 404 was measured in graph 400 of FIG. 4. As expected, both drive current 304 and delta t 404 increase with the increase in damping caused by the air injection. At around 6 cubic centimeters of air injected, there is no further increase in damping because the bubble void is taking up the entire flow conduit cross-section, resulting in no further decoupling. On larger meters, or in different bubble distribution scenarios, the drive current and delta t would keep increasing because the decoupling of the bubbles would keep increasing with void fraction.

[0059] Note that drive current 304 only increases slightly from 4 mA to 13 mA. This is a small increase, of the order which can be caused by changes in viscosity, temperature, etc. Normal detection of gas is seen with huge increases in drive current, such as up to even 75 mA, for example. Even though drive current barely increases, delta t 404 increases a large amount.

[0060] A low-flow threshold 406 for the flowmeter under test, is shown on the graph of FIG. 4 in terms of delta t. This low-flow threshold 406 corresponds to 0.5 lb/min flow. As a reference, 1.610.sup.6 seconds corresponds to 10 lb/min flow. It will be clear that using drive gain or current as a method to detect false totalizing is possible, but it may not be, by itself, particularly accurate, as very little asymmetric damping causes large false flow because flow is extremely sensitive to symmetry, while drive gain does not exhibit such sensitivity.

[0061] FIG. 5 illustrates a graph 500, that compares the pick-off voltage 504 (left y-axis) between pick-off sensor 105, and pick-off sensor 105. It will be clear that there is a voltage offset of about 0.005 mV (1.5%), even with zero injected air. This is expected, and is due to slight differences in magnet strength or the number of wire windings in the coil during manufacturing. This shift can be normalized out during calibration or once the flowmeter is installed in the field, for the purposes of detecting asymmetry and false flow. Additionally, the voltages are seen to track with each other. When one rises, the other does too. This is expected, as slight changes in the temperature or other conditions will lead to changes in frequency, magnet strength, and other parameters which will affect pick-off sensor 105 and pick-off sensor 105equally.

[0062] As air is injected, the spread between pick-off sensor 105 and pick-off sensor 105 increases. Trace 506 represents the calculated percentage difference 508 (right y-axis) between pick-off sensor 105 and pick-off sensor 105. A 3% shift (1.5 to 4.5%) in the pick-off voltage from pick-off sensor 105 to pick-off sensor 105 is observed. This is easily measureable through the noise, and is clearly a diagnostic that can predict asymmetry and false totalizing. In an embodiment, a ratio of mV/Hz instead of just pick-off voltage is utilized, as the sensor assembly 10 may be driven to a constant voltage/frequency, and not pick-off voltage. This mV/Hz value is found by dividing pick-off voltage by the measured drive frequency. This has the benefit of normalizing out the expected frequency variation with temperature and density over time. Because temperature and density do not change during the illustrated test, the mV/Hz results are the same as the pick-off results illustrated.

[0063] Meter Verification diagnostics (which includes flow tube mass and flow tube stiffness measurements) are also contemplated for use in the detection and prevention of false totalizing. Like pick-off voltage, meter verification diagnostics have the benefit of offering independent measurements between pick-off sensor 105 and pick-off sensor 105, thus asymmetry detection is possible.

[0064] As indicated by FIG. 6, a graph 600 illustrating flow tube 105, 105 mass measurements 604 (left y-axis) provides a clear indication of the asymmetry in the flowmeter 5. Trace 606 indicates the percent of mass shift (right y-axis). The stiffness measurement 704 (y-axis) behaves similarly, as illustrated by graph 700 of FIG. 7. Trace 706 indicates the percent of stiffness shift (right y-axis). A marked shift is evident for both tube mass and stiffness between pick-off sensor 105 and pick-off sensor 105, and thus is yet another appropriate means for detecting false totalizing.

[0065] The detectability of false totalizing is therefore implemented using either pickoff voltage differences between the inlet pickoff 105 and the outlet pickoff 105 or via calculated mass and/or stiffness difference from inlet pickoff 105 to outlet pickoff 105. These diagnostics are easily measured and are more sensitive to asymmetry than drive gain, which is the typical prior art approach for entrained gas detection.

[0066] Turning to FIG. 8, according to an embodiment, a method for identifying false totalizing is provided. In step 800, the voltage difference between inlet pickoff 105 and outlet pickoff 105 is determined. In step 802, this difference is compared to a predetermined threshold. If the difference between inlet pickoff 105 and outlet pickoff 105 is less than the predetermined threshold, step 800 may be repeated. If, however, the difference between inlet pickoff 105 and outlet pickoff 105 is greater than the predetermined threshold, then the measured mass flow rate should be set to zero, and totalizing should be halted, as shown in step 804. In an embodiment, step 800 should be repeated thereafter. It should be noted that thresholds will differ from meter to meter and may even differ from application to application.

[0067] As noted above, meter verification diagnostics (mass or stiffness) may, in an embodiment, be used instead of, or in addition to, the pick-off measurements discussed above. In an embodiment, sources of asymmetry are parsed out. Since entrained gas leads to an increase in drive gain and a drop in density, a combination of these parameters may be used to identify false totalizing more specifically compared to a conduit coating-based asymmetry.

[0068] Turning to FIG. 9, according to an embodiment, another method for identifying false totalizing is provided. In step 900, the voltage difference between inlet pickoff 105 and outlet pickoff 105 is determined. In step 902, this difference is compared to a predetermined threshold. If the difference between inlet pickoff 105 and outlet pickoff 105 is less than the predetermined threshold, step 900 may be repeated. If, however, the difference between inlet pickoff 105 and outlet pickoff 105 is greater than the predetermined threshold, then it should be determined whether the process fluid density is less than a predetermined threshold, as in step 904. If the process fluid density is less than the predetermined threshold, then it should be determined whether the drive gain is greater than a predetermined threshold, as in step 906. If the drive gain is greater than a predetermined threshold, then the measured mass flow rate should be set to zero, and totalizing should be halted, as shown in step 908.

[0069] In these embodiments, a situation may be detected where drive gain has increased above its nominal value, yet density has decreased from its nominal value. This may be found during a time period when flow tube asymmetry is not detected. Only when these conditions are met and the pick-off or Meter Verification asymmetry is detected is a halt to the totalizers initiated. Since false totalizing is extremely common, but coating and erosion are relatively uncommon, it may be appropriate, in an embodiment, to assume that asymmetries are from false totalizing instead of coating or erosion.

[0070] It should be noted that, in an embodiment, step 904 may be omitted. It should be noted that, in an embodiment, step 906 may be omitted. It should be noted that, in an embodiment, step 904 and 906 may be omitted and replaced with a tube mass comparison. It should be noted that, in an embodiment, step 904 and 906 may be omitted and replaced with a tube stiffness comparison. It should be noted that, in an embodiment, in step 902, a pickoff amplitude value (e.g. mV/Hz) may be used instead of voltage alone. It should be noted that, in an embodiment, steps 802 and 902 may be in addition to the step of comparing delta t to a predetermined delta t value. It should be noted that, in an embodiment, steps 802 and 902 may be substituted for the step of comparing delta t to a predetermined delta t value. Of these steps, any combination is contemplated. In an embodiment, once the measured mass flow rate is set to zero, and totalizing is halted, as shown in step 908, step 800 is repeated thereafter.

[0071] The detailed descriptions of the above embodiments are not exhaustive descriptions of all embodiments contemplated by the inventors to be within the scope of the invention. Indeed, persons skilled in the art will recognize that certain elements of the above-described embodiments may variously be combined or eliminated to create further embodiments, and such further embodiments fall within the scope and teachings of the invention. It will also be apparent to those of ordinary skill in the art that the above-described embodiments may be combined in whole or in part to create additional embodiments within the scope and teachings of the invention.

[0072] Thus, although specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. The teachings provided herein may be applied to other embodiments than those described above and shown in the accompanying figures. Accordingly, the scope of the invention is determined from the following claims.