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Towards Real-Time Analysis of Gas-Liquid Pipe Flow: A Wire-Mesh Sensor for Industrial Applications
Philipp Wiedemann1, Felipe de Assis Dias1, Manuel Trepte2
1Institute of Fluid Dynamics, Helmholtz-Zentrum Dresden-Rossendorf, Bautzner Landstraße 400, 01328 Dresden, Germany.
Sensors (Basel, Switzerland)
|April 28, 2023
Summary
A new wire-mesh sensor monitors gas-liquid pipe flow in real-time, offering accurate phase fraction calculation and flow pattern identification for industrial applications. This robust device ensures reliable performance under harsh conditions, meeting industry demands.
Area of Science:
- Multiphase flow measurement
- Sensor technology
- Industrial process monitoring
Background:
- Real-time monitoring of gas-liquid pipe flow is critical in chemical and power engineering.
- Existing monitoring systems often lack robustness or real-time data processing capabilities for industrial environments.
Purpose of the Study:
- To design and validate a novel wire-mesh sensor with integrated data processing for industrial gas-liquid flow.
- To enable real-time phase fraction calculation, temperature compensation, and flow pattern identification.
Main Methods:
- Development of a robust wire-mesh sensor body capable of withstanding up to 400 °C and 135 bar.
- Integration of a data processing unit for real-time analysis, including phase fraction calculation and temperature compensation.
- Experimental verification using camera references for phase fraction accuracy and a two-phase flow loop for flow pattern identification.
Main Results:
- Phase fraction calculation with temperature compensation showed an average deviation of 3.9% despite temperature drifts up to 55 K.
- Automatic flow pattern identification demonstrated reasonable agreement with established flow pattern maps for both horizontal and vertical pipe orientations.
- The sensor system includes user interfaces via display and 4…20 mA connectivity for industrial integration.
Conclusions:
- The developed wire-mesh sensor system successfully meets the demands for real-time gas-liquid flow monitoring in industrial settings.
- The system's accuracy in phase fraction calculation and flow pattern identification, along with its robust design, fulfills prerequisites for industrial application.
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