Institute of Fluid Dynamics, Helmholtz-Zentrum Dresden-Rossendorf, Bautzner Landstraße 400, 01328 Dresden, Germany.
Teletronic Rossendorf GmbH, Bautzener Landstraße 45, 01454 Radeberg, Germany.
Sensors (Basel). 2023 Apr 18;23(8):4067. doi: 10.3390/s23084067.
Real-time monitoring of gas-liquid pipe flow is highly demanded in industrial processes in the chemical and power engineering sectors. Therefore, the present contribution describes the novel design of a robust wire-mesh sensor with an integrated data processing unit. The developed device features a sensor body for industrial conditions of up to 400 °C and 135 bar as well as real-time processing of measured data, including phase fraction calculation, temperature compensation and flow pattern identification. Furthermore, user interfaces are included via a display and 4…20 mA connectivity for the integration into industrial process control systems. In the second part of the contribution, we describe the experimental verification of the main functionalities of the developed system. Firstly, the calculation of cross-sectionally averaged phase fractions along with temperature compensation was tested. Considering temperature drifts of up to 55 K, an average deviation of 3.9% across the full range of the phase fraction was found by comparison against image references from camera recordings. Secondly, the automatic flow pattern identification was tested in an air-water two-phase flow loop. The results reveal reasonable agreement with well-established flow pattern maps for both horizontal and vertical pipe orientations. The present results indicate that all prerequisites for an application in industrial environments in the near future are fulfilled.
在化工和动力工程等工业过程中，对气液管流的实时监测有很高的要求。因此，本研究介绍了一种具有集成数据处理单元的新型耐用金属丝网格传感器的设计。所开发的设备适用于高达 400°C 和 135 巴的工业条件，并且可以实时处理测量数据，包括相分数计算、温度补偿和流型识别。此外，通过显示和 4…20 mA 连接还包括用户接口，以便集成到工业过程控制系统中。在本研究的第二部分，我们描述了所开发系统的主要功能的实验验证。首先，测试了沿横截面平均相分数的计算和温度补偿。考虑到高达 55 K 的温度漂移，通过与摄像记录的图像参考进行比较，发现整个相分数范围内的平均偏差为 3.9%。其次，在空气-水两相流回路中测试了自动流型识别。结果表明，对于水平和垂直管道方向，与成熟的流型图具有很好的一致性。目前的结果表明，未来不久在工业环境中应用的所有前提条件都已满足。
