Apparatus, systems, and methods for non-invasive measurement of flow in a high temperature pipe

A method, apparatus, and system according to which first and second transducers are connected to first and second waveguides, respectively, the first and second waveguides are connected to a pipe, and ultrasonic wave signals are exchanged between the first and second transducers, said ultrasonic wave signals passing through the first and second waveguides, the pipe, and a fluid in the pipe. A temperature of the fluid flowing in the pipe may exceed about 600° C. The first and second waveguides insulate the first and second transducers from the pipe and propagate the ultrasonic wave signals between the pipe and the first and second transducers, respectively, so that the ability of the first and second transducers to exchange the ultrasonic wave signals is not adversely affected by the temperature of the fluid in the pipe. The first and second waveguides may be made of a calcium silicate technical ceramic.

BACKGROUND

The present disclosure relates generally to flow measurement and, more particularly, to apparatus, systems, and methods for measuring flow in a high temperature pipe.

DETAILED DESCRIPTION

In an exemplary embodiment, as illustrated inFIG. 1, a system is schematically illustrated and generally referred to by the reference numeral100. The system100includes a transducer105(e.g., an ultrasonic wave transducer), a waveguide110(e.g., an ultrasonic waveguide), a pipe115, a waveguide120(e.g., an ultrasonic waveguide), a transducer125(e.g., an ultrasonic wave transducer), and a control unit130. The pipe115is a tubular member including an external surface135and an internal passage140in which a fluid is adapted to flow, as indicated by arrows145. In several exemplary embodiments, the fluid145flowing within the pipe115is molten salt. In several exemplary embodiments, the temperature of the fluid145flowing within the pipe115is equal to or greater than about (i.e., +/−5% to +/−10%) 600° C. In several exemplary embodiments, the temperature of the fluid145flowing within the pipe115is equal to or greater than about 700° C. In several exemplary embodiments, the temperature of the fluid145flowing within the pipe115is equal to or greater than about 750° C. The pipe115defines an internal diameter D and a wall thickness T. The system100is operable to measure the flow velocity (and thus the mass or volumetric flow rate) of the fluid145flowing in the pipe115, as will be described in further detail below. In several exemplary embodiments, the waveguides110and120, the transducers105and125, and the control unit130form a kit usable to measure the flow velocity and the mass/volumetric flow rate of fluid flowing in pipes of varying diameters, including the pipe115.

The transducer105is connected to the waveguide110, which, in turn, is connected to the pipe115. Similarly, the transducer125is connected to the waveguide120, which, in turn, is connected to the pipe115. The control unit130is in communication with the transducers105and125via, for example, leads146and148, respectively. In addition to, or instead of, being in communication with the transducers105and125via the leads146and148, respectively, the control unit130may be in wireless communication with the transducers105and125, as shown inFIGS. 2A and 2B. In the embodiment ofFIG. 1, the transducers105and125are spaced longitudinally along the pipe115and are located in alignment with each other on the same side of the pipe115.

The transducer(s)105and/or125is/are configured to emit and receive ultrasonic wave signals (e.g., short ultrasonic wave pulses) that travel through the waveguides110and120, the pipe115, and the fluid145flowing in the pipe115. For example, as shown inFIG. 1, the transducers105and125are configured to emit and receive ultrasonic wave signals (e.g., short ultrasonic wave pulses) that travel through the waveguides110and120, the pipe115, and the fluid145flowing in the pipe115. In the embodiment ofFIG. 1, the ultrasonic wave signals are reflected off the interior wall of the pipe115opposite the transducers105and125. Due to the flow of the fluid145flowing in the pipe115, the transit time of the ultrasonic wave signals from the transducer105to the transducer125(as indicated by arrows150) is shorter than the transit time of the ultrasonic wave signals from the transducer125to the transducer105(as indicated by arrows155), and this transit time difference yields a precise measurement of the flow velocity and the mass/volumetric flow rate along the path of the ultrasonic wave signals150and155, as will be described in further detail below.

Since the transit time difference can be very small for some pipe diameters (e.g., on the scale of nanoseconds), it is important for the control unit130to be capable of ensuring the necessary time resolution to obtain an accurate measurement of the flow velocity and the mass/volumetric flow rate of the fluid145flowing in the pipe115. In several exemplary embodiments, the control unit130, which is configurable to send control signals effecting an exchange of ultrasonic wave signals between the transducers105and125and to evaluate the ultrasonic wave signals received by the transducers105and125, is capable of ensuring the necessary time resolution. In several exemplary embodiments, the transducer(s)105and/or125is/are capable of exchanging (i.e., transmitting and receiving) ultrasonic wave signals in a frequency range that is as low as possible while still maintaining the time resolution necessary for a particular pipe diameter (e.g., for a 1-inch pipe diameter, the minimum frequency required may be in the range of 500 kHz to 10 MHz). In several exemplary embodiments, the transducer(s)105and/or125and the control unit130are capable of capturing ultrasonic waveform data in the form of a standard longitudinal mode A-scan, in which echo amplitude and transit time are plotted on a simple grid with the vertical axis representing amplitude and the horizontal axis representing time.

In several exemplary embodiments, the transducer(s)105and/or125is/are capacitive transducers. In several exemplary embodiments, the transducer(s)105and/or125have a diameter of about ½-inch. In several exemplary embodiments, the transducer(s)105and/or125is/are capable of transmitting and/or receiving 1 MHz ultrasonic wave signals. In several exemplary embodiments, the transducer(s)105and/or125is/are capable of transmitting and/or receiving 2.25 MHz ultrasonic wave signals. In several exemplary embodiments, the transducer(s)105and/or125is/are contained in threaded package(s) that is/are convenient for making good acoustic contact with the insulating waveguides110and120, respectively, as will be described in further detail below in connection withFIGS. 4A-4F. In several exemplary embodiments, the transducer(s)105and/or125is/are integrated into the material of the insulating waveguides110and120, respectively. In several exemplary embodiments, the transducer(s)105and/or125is/are Olympus Centrascan Composite Angle Beam Transducer(s) capable of transmitting and/or receiving 1.00 MHz ultrasonic wave signals, having ½-inch element diameter(s), and being of the miniature screw-in case style (i.e., Olympus Part/Item No. C539-SM).

In several exemplary embodiments, as shown inFIGS. 2A, 3A, and 3B, the shape of the waveguide(s)110and/or120is/are modified to enable mating engagement between the waveguide(s)110and/or120and the pipe115. For example, in several exemplary embodiments, the waveguide(s)110and/or120is/are machined to include surface(s)160(e.g., curved surfaces) configured to matingly engage with the external surface135of the pipe115. In other embodiments, as shown inFIGS. 2B, 3C, and 3D, the external surface135of the pipe115is machined to include surface(s)165(e.g., flat surface(s) and/or curved surface(s)) configured to matingly engage with corresponding surface(s)170(e.g., flat surface(s) and/or curved surface(s)) of the waveguide(s)110and/or120. In one such experimental embodiment in which the internal diameter D of the pipe115is sufficiently small (e.g., equal to or less than 3 inches) as compared to the contact areas between the waveguide(s)110and/or120and the pipe115, machining of the external surface135of the pipe115to include flat surface(s)165increases transmission of the ultrasonic wave signal into the pipe115by a factor of about 10. In addition to, or instead of, machining the external surface135of the pipe115, material can be added to the external surface135of the pipe115to form surface(s) (not shown but, e.g., flat surface(s) and/or curved surface(s)) configured to matingly engage with corresponding surface(s) such as, for example, flat surface(s) and/or curved surface(s) of the waveguide(s)110and/or120).

Turning back toFIG. 1, with continuing reference toFIGS. 2A-Band3A-D, the mating engagement between the waveguide(s)110and/or120and the pipe115ensures proper position and orientation of the waveguide(s)110and/or120relative to the pipe115for optimal operation of the system100. More particularly, the transducer(s)105and/or125is/are mounted to the waveguides110and120in a manner that facilitates emission and reception of ultrasonic wave signals through the waveguides110and120at an angle φ1with respect to a longitudinal axis of the pipe115. Any change to the angle φ1results in a corresponding change to an angle φ2at which the ultrasonic wave signals travel through the wall of the pipe115and an angle φ3at which the ultrasonic wave signals travel through the fluid145flowing in the pipe115. In several exemplary embodiments, the angle φ1is greater than or equal to about 70 degrees. In several exemplary embodiments, the angle φ1is greater than or equal to about 40 degrees and less than or equal to about 70 degrees. In several exemplary embodiments, the angle φ2is less than the angle φ1. In several exemplary embodiments, the angle φ3is greater than the angle φ2.

The angle φ1is carefully set to optimize acoustic transmission of the ultrasonic wave signals through and between the waveguides110and120, the pipe115, and the fluid145flowing in the pipe115; this optimal angle is characterized as the angle of maximum transmission. The angle of maximum transmission depends at least in part on the internal diameter D of the pipe115, the wall thickness T of the pipe115, the size and shape of the waveguide(s)110and/or120, the respective sound velocities of the waveguide(s)110and/or120, the pipe115, and the fluid145flowing in the pipe115, the potential for mode conversion at the interface between each waveguide110and120and the external surface135of the pipe115, and/or the potential for mode conversion at the interface between the pipe115and the fluid145flowing in the pipe115.

In an exemplary embodiment, as shown inFIGS. 3A-Dwith continuing reference toFIGS. 1 and 2, the insulative and acoustic properties of the waveguides110and120are controlled at least in part by the dimensions (i.e., the shape and size) of the waveguides110and120between the high temperature pipe115and the transducers105and125. If the working temperature of the transducers105and125exceeds a critical threshold, the transducers105and125will fail. Likewise, if the attenuation of the ultrasonic wave signal within the waveguides110and120is too large, the ultrasonic wave signal will not be detectable by the transducers105and125. The waveguides110and120are shaped to insulate the transducers105and125from the high-temperature pipe115so that the working temperature of the transducers105and125does not exceed the critical threshold while, at the same time, the inherent attenuation of the ultrasonic wave signals in the waveguides110and120is maintained at an acceptable level. For example, in several exemplary embodiments, the waveguide(s)110and/or120is/are formed in the shape of a rectangular prism, as shown inFIGS. 3A-D. The waveguide(s)110and/or120can also be tapered to reduce the hot contact area between the waveguide(s)110and/or120and the high-temperature pipe115, as shown inFIGS. 3B and 3D.

Although shown and described as being either a rectangular prism or a tapered rectangular prism, the waveguide(s)110and/or120may instead be formed in the shape of a circular prism (i.e., a cylinder), a tapered circular cylinder, a triangular prism, a tapered triangular prism, a pentagonal prism, a tapered pentagonal prism, another round prism, another tapered round prism, another polygonal prism, another tapered polygonal prism, or any combination thereof.

In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are made of a high-temperature ceramic material. In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are made of a calcium silicate material. In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are made of a calcium silicate technical ceramic, which is marketed under the trademark Duratec® (e.g., Duratec® 750). In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are made of a material having an operating temperature of up to about 1000° C. In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are made of a material having a thermal conductivity of about 0.49 watts per meter-kelvin (W/m*K) or lower at about 750° C. In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are made of a material that is machinable (i.e., able to be worked by a machine tool) or otherwise formable into an appropriate shape. In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are made of a material having a sound velocity in the range of about 2200 to 3500 meters per second (m/s). In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are made of a material having a sound velocity of about 2270 meters per second (m/s) (+/−75 m/s).

In an exemplary embodiment, as shown inFIGS. 4A-4F, the transducer(s)105and/or125is/are contained in threaded package(s) that is/are convenient for making good acoustic contact with the insulating waveguide(s)110and/or120, respectively. More particularly, the transducer(s)105and/or125is/are each connected to the waveguide(s)110and/or120, respectively, via a connector ring171. In several exemplary embodiments, the connector ring171is, includes, or is part of, the waveguide(s)110and/or120. Turning toFIG. 4E, in an exemplary embodiment, a recess172is formed in an end portion of the waveguide(s)110and/or120opposite the surface that engages the pipe115(e.g., the surface160and/or170). The recess172formed in the waveguide(s)110and/or120receives the connector ring171and the transducer(s)105and/or125, as shown inFIGS. 4A-4D. Turning toFIG. 4F, in an exemplary embodiment, the connector ring171is generally tubular and includes an external surface173and an internal threaded connection174. In several exemplary embodiments, the external surface173of the connector ring171is fitted (e.g., press-fit, interference-fit, clearance-fit, shrunk-fit, the like, or any combination thereof) into the recess172in such a manner that the connector ring171is retained within the recess172. For example, a frictional fit between the external surface173of the connector ring171and the waveguide(s)110and/or120may at least partially retain the connector ring171within the recess172. For another example, an adhesive (not shown) may at least partially retain the connector ring171within the recess172. For yet another example, a retaining ring (not shown) may at least partially retain the connector ring171within the recess172. In several embodiments, the connector ring171is made of a relatively more ductile and/or less brittle material than the waveguide(s)110and/or120. As shown inFIGS. 4A-4D, once the connector ring171is secured within the recess172, the transducer(s)105and/or125is/are threaded into the connector ring171to thereby secure the transducer(s)105and/or125to the waveguide(s)110and/or120.

In operation, as illustrated inFIG. 1, in an exemplary embodiment, the control unit130sends a control signal (e.g., a high-voltage pulse) to the transducer105(e.g., wirelessly or via the lead146) and waits for a response from the transducer125(e.g., wirelessly or via the lead148). The control signal sent to the transducer105by the control unit130causes the transducer105to emit an ultrasonic wave signal along the path150. More particularly, the transducer105emits the ultrasonic wave signal at the angle φ1into the waveguide110. The ultrasonic wave signal emitted into the waveguide110at the angle φ1travels through the waveguide110and crosses the interface between the waveguide110and the external surface135of the pipe115. After crossing the interface between the waveguide110and the external surface135of the pipe115, the ultrasonic wave signal travels through the wall of the pipe115at the angle φ2. After travelling through the wall of the pipe115, the ultrasonic wave signal travels into the fluid145flowing in the pipe115at the angle φ3. The ultrasonic wave signal is then reflected off the interior wall of the pipe115opposite the transducers105and125and travels in a similar manner through the fluid145flowing in the pipe115, through the wall of the pipe115, across the interface between the external surface135of the pipe115and the waveguide120, through the waveguide120, and into the transducer125. The transducer125sends a response (e.g., wirelessly or via the lead148) to the control unit130based on the ultrasonic wave signal. The control unit130receives the response from the transducer125, and amplifies/filters the response received from the receiving transducer125.

Before, during, or after the control unit130sends the control signal to the transducer105(e.g., wirelessly or via the lead146) and waits for the response from the transducer125(e.g., wirelessly or via the lead148), the control unit130sends a control signal (e.g., a high-voltage pulse) to the transducer125(e.g., wirelessly or via the lead148) and waits for a response from the transducer105(e.g., wirelessly or via the lead146). The control signal sent to the transducer125by the control unit130causes the transducer125to emit an ultrasonic wave signal along the path155in a manner similar to that described above with respect to the ultrasonic wave signal emitted along the path150by the transducer120, and therefore will not be described in further detail. Once the ultrasonic wave signal has traveled along the path155, the transducer105sends a response (e.g., wirelessly or via the lead146) to the control unit130based on the ultrasonic wave signal. The control unit130receives the response from the transducer105, and amplifies/filters the response received from the receiving transducer105. The controller130then calculates the transit time and the transit time difference between the ultrasonic wave signal that travelled along the path150and the ultrasonic wave signal that travelled along the path155to determine the flow velocity (and thus the mass or volumetric flow rate) of the fluid145flowing in the pipe115.

In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are sized, shaped, and/or made of material(s) having acceptable acoustic and insulative properties so that, during operation: (i) the transducer(s)105and/or125can be mounted to the waveguide(s)110and/or120, respectively, (ii) the waveguide(s)110and/or120can be mounted on the external surface135of the high temperature pipe115, and (iii) the transducer(s)105and/or125can be used to non-invasively and accurately measure the flow rate of the fluid145flowing in the pipe115, notwithstanding the high temperature (e.g., ≥600° C., ≥700° C., and/or 750° C.) of the fluid145flowing in the pipe115. In several exemplary embodiments, at least respective portions of the waveguides110and120are sized, shaped, and/or made of material(s) having acceptable acoustic properties so that, during operation, the transducers105and125can send and receive ultrasonic wave signals to/from each other. In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are sized, shaped, and/or made of material(s) having acceptable insulative properties so that, during operation, the ability of the transducers105and125to exchange the ultrasonic wave signals is not adversely affected by the high temperature (e.g., ≥600° C., ≥700° C., and/or ≥750° C.) of the fluid145flowing in the pipe115. In several exemplary embodiments, at least respective portions of the waveguide(s)110and/or120are sized, shaped, and/or made of material(s) having acceptable insulative properties so that, during operation, the transducer(s)105and/or125do not act as “heat sink(s)” drawing excessive heat out of the pipe115.

Examples of size(s) and/or shape(s) in which at least respective portions of the waveguide(s)110and/or120may be formed in order to exhibit the acceptable acoustic and insulative properties described above include, but are not limited to, the size(s) and/or shape(s) shown inFIGS. 3A-3D and 4A-4F. Examples of material(s) from which at least respective portions of the waveguide(s)110and/or120may be made in order to exhibit the acceptable acoustic and insulative properties described above include, but are not limited to, high-temperature ceramic material(s), calcium silicate material(s), calcium silicate technical ceramic(s), material(s) having an operating temperature of up to about 1000° C., material(s) having a thermal conductivity of about 0.49 watts per meter-kelvin (W/m*K) or lower at about 750° C., material(s) that is/are machinable, material(s) having a sound velocity in the range of about 2200 to 3500 meters per second (m/s) (e.g., having a sound velocity of about 2270 meters per second (m/s) (+/−75 m/s)), or any combination thereof. Other important acoustic properties of material(s) from which at least respective portions of the waveguide(s)110and/or120may be made in order to exhibit the acceptable acoustic and insulative properties described above include, but are not limited to, acoustic attenuation, which must be small enough to permit ultrasonic wave signals from one of the transducers105or125to pass through the waveguides110and120and be detected by the other of the transducers105or125.

In several exemplary embodiments, the control signal(s) sent to the transducer(s)105and/or125by the control unit130are single wave high voltage pulse(s). In one such embodiment, the leads146and148from the control unit130to the transducers105and125are physically switched to measure the transit time of the ultrasonic wave signals with and against the flow of the fluid145flowing in the pipe115(i.e., along the paths150and155, respectively). In several exemplary embodiments, the control signal(s) sent to the transducer(s)105and/or125by the control unit130is/are high amplitude pulse(s) of about 250 V.

In other embodiments, the control signal(s) sent to the transducer(s)105and/or125by the control unit130have a high voltage wave-pulse train (e.g., 5-10 oscillations) to enable more accurate measurement of the time difference between the ultrasonic wave signals with and against the flow of the fluid145flowing in the pipe115(i.e., along the paths150and155, respectively). The known frequency of the high voltage wave-pulse train allows for easier detection of the ultrasonic wave signals by the receiving transducer(s)105and/or125. In several exemplary embodiments, the high voltage wave-pulse train sent to the transducer(s)105and/or125by the control unit130contains high amplitude pulses of up to about 300 V. To facilitate generation of the high voltage wave-pulse train, the control unit130includes electronics (e.g., hardware and/or software) capable of receiving power from a USB or AC wall plug and generating a high-frequency (e.g., 1 MHz, or another frequency matching that of the transducer(s)105and/or125) high-voltage wave-pulse train. The control unit130may also include electronics (e.g., hardware and/or software) capable of automatically switching between send and receive modes so that no physical connection(s) need to be changed in order to measure the transit time of the ultrasonic wave signals travelling in opposite directions with respect to the flow of the fluid145flowing in the pipe115(i.e., along the paths150and155). The control unit130may also include electronics (e.g., hardware and/or software) capable of determining the velocity (and thus the mass or volumetric flow rate) of the fluid145flowing in the pipe115based on the time difference between the ultrasonic wave signals propagating in opposite directions with respect to the flow of the fluid145in the pipe115(i.e., along the flow paths150and155).

In an exemplary embodiment, as illustrated inFIG. 5with continuing reference toFIGS. 1, 2A-B,3A-D, and4A-F, the control unit130includes a processor175and a non-transitory computer readable medium180operably coupled thereto. A plurality of instructions are stored on the non-transitory computer readable medium180, the instructions being accessible to, and executable by, the processor175. In several exemplary embodiments, as shown inFIGS. 1, 2A-B, and5, the control unit130is in communication with the transducers105and125. In several exemplary embodiments, a plurality of instructions, or computer program(s), are stored on the non-transitory computer readable medium180, the instructions or computer program(s) being accessible to, and executable by, one or more processors (e.g., the processor175). In several exemplary embodiments, the one or more processors (e.g., the processor175) execute the plurality of instructions (or computer program(s)) to operate in whole or in part the above-described embodiments. In several exemplary embodiments, the one or more processors (e.g., the processor175) is/are part of the control unit130, one or more other computing devices, or any combination thereof. In several exemplary embodiments, the non-transitory computer readable medium180is part of the control unit130, one or more other computing devices, or any combination thereof.

In an exemplary embodiment, as illustrated inFIG. 6, a system is schematically illustrated and generally referred to by the reference numeral200. The system200includes one or more feature(s)/component(s) that are substantially identical to corresponding feature(s)/component(s) of the system100, which substantially identical feature(s)/component(s) are given the same reference numerals. However, the waveguide120and the transducer125are omitted from the system200and replaced with a waveguide205(e.g., an ultrasonic waveguide) and a transducer210(e.g., an ultrasonic wave transducer). The transducer210is connected to the waveguide205, which, in turn, is connected to the pipe115. The control unit130is in wireless communication with the transducers105and210, as shown inFIG. 6. In addition to, or instead of, being in wireless communication with the transducers105and210, the control unit130may be in communication with the transducers105and210via leads (not shown but, e.g., substantially identical to the leads146and148shown inFIG. 1). The transducers105and210are spaced longitudinally along the pipe115and are located diagonally offset from each other on opposing sides of the pipe115. In several exemplary embodiments, the waveguide205the transducer210of the system200are substantially identical to the waveguide120and the transducer125, respectively, of the system100, except for their differing location(s) on the pipe115.

The transducer(s)105and/or210of the system200is/are configured to emit and receive ultrasonic wave signals that travel through the waveguides110and205, the pipe115, and the fluid145flowing in the pipe115. For example, as shown inFIG. 6, the transducers105and210of the system200are configured to emit and receive ultrasonic wave signals that travel through the waveguides110and205, the pipe115, and the fluid145flowing in the pipe115. In the embodiment ofFIG. 6, the ultrasonic wave signals of interest are not reflected off the interior wall of the pipe115opposite the transducer105, but instead pass through the fluid145directly from the interior wall of the pipe115proximate the transducer105to the interior wall of the pipe115proximate the transducer210. Due to the flow of the fluid145flowing in the pipe115, the transit time of the ultrasonic wave signals from the transducer105to the transducer210(as indicated by arrows215) is shorter than the transit time of the ultrasonic wave signals from the transducer210to the transducer105(as indicated by arrows220), and this transit time difference yields a precise measurement of the flow velocity and the mass/volumetric flow rate along the path of the ultrasonic wave signals215and220.

The operation of the system200is substantially identical to the operation of the system100, except that, rather than reflecting off the interior wall of the pipe115opposite the transducers105and125and traveling through the fluid145flowing in the pipe115along the paths150and155, the ultrasonic wave signals generated by the transducer(s)105and/or210pass through the fluid145directly from the interior wall of the pipe115proximate the transducer105to the interior wall of the pipe115proximate the transducer210along the paths215and220. Therefore, the operation of the system200will not be described in further detail.

In an exemplary embodiment, as illustrated inFIG. 7, a system is schematically illustrated and generally referred to by the reference numeral250. The system250includes one or more feature(s)/component(s) that are substantially identical to corresponding feature(s)/component(s) of the system100, which substantially identical feature(s)/component(s) are given the same reference numerals. However, the waveguides110and120and the transducers105and125are omitted from the system250and replaced with waveguides255and260(e.g., ultrasonic waveguides) and transducers265and270(e.g., ultrasonic wave transducers). The transducer265is connected to the waveguide255, which, in turn, is connected to the pipe115. Similarly, the transducer270is connected to the waveguide260, which, in turn, is connected to the pipe115. More particularly, in the embodiment ofFIG. 7, the pipe115includes a U-bend defining opposing corners275aand275bat which the waveguides255and260, respectively, are connected to the external surface135of the pipe115. The control unit130is in wireless communication with the transducers255and260, as shown inFIG. 7. In addition to, or instead of, being in wireless communication with the transducers255and260, the control unit130may be in communication with the transducers255and260via leads (not shown but, e.g., substantially identical to the leads146and148shown inFIG. 1). The transducers255and260are spaced along the pipe115and are located in alignment with each other at the opposing corners275aand275bof the pipe115. In several exemplary embodiments, the waveguides255and260and the transducers265and270of the system250are substantially identical to the waveguides110and120and the transducers105and125, respectively, of the system100and/or the waveguides110and205and the transducers105and210, respectively, of the system200, except for their differing location(s) on the pipe115.

The transducer(s)265and/or270of the system250is/are configured to emit and receive ultrasonic wave signals that travel through the waveguides255and260, the pipe115, and the fluid145flowing in the pipe115. For example, as shown inFIG. 7, the transducers265and270of the system250are configured to emit and receive ultrasonic wave signals that travel through the waveguides255and260, the pipe115, and the fluid145flowing in the pipe115. However, in the embodiment ofFIG. 7, the ultrasonic wave signals of interest are not reflected off the interior wall of the pipe115, nor do they travel diagonally across the fluid145flowing through the pipe115. Instead, the ultrasonic wave signals of interest pass through the fluid145directly from the interior wall of the pipe115at the corner275aproximate the transducer265to the interior wall of the pipe115at the corner275bproximate the transducer270. Due to the flow of the fluid145flowing in the pipe115, the transit time of the ultrasonic wave signals from the transducer265to the transducer270(as indicated by arrow280) is shorter than the transit time of the ultrasonic wave signals from the transducer270to the transducer265(as indicated by arrow285), and this transit time difference yields a precise measurement of the flow velocity and the mass/volumetric flow rate along the path of the ultrasonic wave signals280and285. In several exemplary embodiments, the ultrasonic wave signals280and285travel in a parallel relation to the fluid145flowing in the pipe115for at least a portion of their transit between the interior wall of the pipe115at the corner275aproximate the transducer265and the interior wall of the pipe115at the corner275bproximate the transducer270.

The operation of the system250is substantially identical to the operation of the system200, except that, rather than passing through the fluid145directly from the interior wall of the pipe115proximate the transducer105to the interior wall of the pipe115proximate the transducer210along the paths215and220, the ultrasonic wave signals generated by the transducer(s)265and/or270pass through the fluid145directly from the interior wall of the pipe115at the corner275aproximate the transducer265to the interior wall of the pipe115at the corner275bproximate the transducer270along the paths280and285. Therefore, the operation of the system250will not be described in further detail.

In an exemplary embodiment, as illustrated inFIG. 8with continuing reference toFIGS. 1, 2A-B,3A-D,4A-F,5,6, and7, a method is generally referred to by the reference numeral300. In several exemplary embodiments, the method300includes connecting the first and second transducers (e.g.,105and125,105and210, or265and270) to the first and second waveguides at a step305, connecting the first and second waveguides (e.g.,110and120,110and205, or255and260) to the pipe115at a step310, and exchanging ultrasonic wave signals between the first and second transducers, said ultrasonic wave signals passing through the first and second waveguides, the pipe115, and the fluid145flowing in the pipe115at a step315. In several exemplary embodiments, a temperature of the fluid145flowing in the pipe115exceeds about 600° C. In several exemplary embodiments, the first and second waveguides insulate the first and second transducers from the pipe115and propagate the ultrasonic wave signals between the pipe115and the first and second transducers, respectively, so that the ability of the first and second transducers to exchange the ultrasonic wave signals is not adversely affected by the temperature of the fluid145flowing in the pipe115. In several exemplary embodiments, the method300also includes placing the control unit130in communication with the first and second transducers at a step320, sending, using the control unit130, control signals to the first and second transducers, said control signals effecting the exchange of the ultrasonic wave signals between the first and second transducers at a step325, receiving, using the control unit130, data from the first and second transducers based on the exchange of the ultrasonic wave signals between the first and second transducers at a step330, and determining, using the control unit130, a flow rate of the fluid145flowing in the pipe115based on the data received from the first and second transducers at a step335.

In several exemplary embodiments, each of the system100, the system200, the system250, and the method300is suitable for measuring flow rates (and hence volumetric rates) at higher temperatures without mechanical measurements inside the pipe115. Accordingly, each of the system100, the system200, the system250, and the method300overcomes mechanical limitations imposed by the higher temperature ranges, enabling sonic measurements at higher temperature measurements of flow rates via the waveguides110and120,110and205, or255and260and their properties.

In an exemplary embodiment, as illustrated inFIG. 9with continuing reference toFIGS. 1, 2A-B,3A-D,4A-F,5,6,7, and8, a computing device400for implementing one or more embodiments of one or more of the above-described systems (100,200, and/or250), control units (e.g.,130), methods (e.g.,300) and/or steps (e.g.305,310,315,320,325,330, and/or335), and/or any combination thereof, is depicted. The computing device400includes a microprocessor400a, an input device400b, a storage device400c, a video controller400d, a system memory400e, a display400f, and a communication device400gall interconnected by one or more buses400h. In several exemplary embodiments, the storage device400cmay include a floppy drive, hard drive, CD-ROM, optical drive, any other form of storage device and/or any combination thereof. In several exemplary embodiments, the storage device400cmay include, and/or be capable of receiving, a floppy disk, CD-ROM, DVD-ROM, or any other form of computer-readable medium that may contain executable instructions. In several exemplary embodiments, the communication device400gmay include a modem, network card, or any other device to enable the computing device to communicate with other computing devices. In several exemplary embodiments, any computing device represents a plurality of interconnected (whether by intranet or internet) computer systems, including without limitation, personal computers, mainframes, PDAs, smartphones and cell phones.

In several exemplary embodiments, one or more of the components of the above-described embodiments include at least the computing device400and/or components thereof, and/or one or more computing devices that are substantially similar to the computing device400and/or components thereof. In several exemplary embodiments, one or more of the above-described components of the computing device400include respective pluralities of same components.

In several exemplary embodiments, a computer system typically includes at least hardware capable of executing machine readable instructions, as well as the software for executing acts (typically machine-readable instructions) that produce a desired result. In several exemplary embodiments, a computer system may include hybrids of hardware and software, as well as computer sub-systems.

In several exemplary embodiments, hardware generally includes at least processor-capable platforms, such as client-machines (also known as personal computers or servers), and hand-held processing devices (such as smart phones, tablet computers, personal digital assistants (PDAs), or personal computing devices (PCDs), for example). In several exemplary embodiments, hardware may include any physical device that is capable of storing machine-readable instructions, such as memory or other data storage devices. In several exemplary embodiments, other forms of hardware include hardware sub-systems, including transfer devices such as modems, modem cards, ports, and port cards, for example.

In several exemplary embodiments, software includes any machine code stored in any memory medium, such as RAM or ROM, and machine code stored on other devices (such as floppy disks, flash memory, or a CD ROM, for example). In several exemplary embodiments, software may include source or object code. In several exemplary embodiments, software encompasses any set of instructions capable of being executed on a computing device such as, for example, on a client machine or server.

In several exemplary embodiments, combinations of software and hardware could also be used for providing enhanced functionality and performance for certain embodiments of the present disclosure. In an exemplary embodiment, software functions may be directly manufactured into a silicon chip. Accordingly, it should be understood that combinations of hardware and software are also included within the definition of a computer system and are thus envisioned by the present disclosure as possible equivalent structures and equivalent methods.

In several exemplary embodiments, computer readable mediums include, for example, passive data storage, such as a random access memory (RAM) as well as semi-permanent data storage such as a compact disk read only memory (CD-ROM). One or more embodiments of the present disclosure may be embodied in the RAM of a computer to transform a standard computer into a new specific computing machine. In several exemplary embodiments, data structures are defined organizations of data that may enable an exemplary embodiment of the present disclosure. In an exemplary embodiment, a data structure may provide an organization of data, or an organization of executable code.

In several exemplary embodiments, any networks and/or one or more portions thereof, may be designed to work on any specific architecture. In an exemplary embodiment, one or more portions of any networks may be executed on a single computer, local area networks, client-server networks, wide area networks, internets, hand-held and other portable and wireless devices and networks.

In several exemplary embodiments, a database may be any standard or proprietary database software. In several exemplary embodiments, the database may have fields, records, data, and other database elements that may be associated through database specific software. In several exemplary embodiments, data may be mapped. In several exemplary embodiments, mapping is the process of associating one data entry with another data entry. In an exemplary embodiment, the data contained in the location of a character file can be mapped to a field in a second table. In several exemplary embodiments, the physical location of the database is not limiting, and the database may be distributed. In an exemplary embodiment, the database may exist remotely from the server, and run on a separate platform. In an exemplary embodiment, the database may be accessible across the internet. In several exemplary embodiments, more than one database may be implemented.

In several exemplary embodiments, a plurality of instructions stored on a non-transitory computer readable medium may be executed by one or more processors to cause the one or more processors to carry out or implement in whole or in part the above-described operation of each of the above-described embodiments of the system100, the system200, the system250, the method300, and/or any combination thereof. In several exemplary embodiments, such a processor may include one or more of the microprocessor400a, the processor175, and/or any combination thereof, and such a non-transitory computer readable medium may include the storage device400c, the system memory400e, the computer readable medium180, and/or may be distributed among one or more components of the system100, the system200, and/or the system250. In several exemplary embodiments, such a processor may execute the plurality of instructions in connection with a virtual computer system. In several exemplary embodiments, such a plurality of instructions may communicate directly with the one or more processors, and/or may interact with one or more operating systems, middleware, firmware, other applications, and/or any combination thereof, to cause the one or more processors to execute the instructions.

The present disclosure introduces an apparatus, the apparatus including: first and second waveguides adapted to be connected to a pipe; and first and second transducers adapted to be connected to the first and second waveguides, respectively, and to exchange ultrasonic wave signals through the first and second waveguides, the pipe, and a fluid flowing in the pipe; wherein a temperature of the fluid flowing in the pipe exceeds about 600° C.; and wherein, when the first and second transducers are connected to the first and second waveguides, respectively, and the first and second waveguides are connected to the pipe, the first and second waveguides insulate the first and second transducers from the pipe and propagate the ultrasonic wave signals between the pipe and the first and second transducers, respectively, so that the ability of the first and second transducers to exchange the ultrasonic wave signals is not adversely affected by the temperature of the fluid flowing in the pipe. In several exemplary embodiments, the apparatus further includes a control unit adapted to be in communication with the first and second transducers; wherein, when the control unit is in communication with the first and second transducers, the control unit is further adapted to send control signals to the first and second transducers, said control signals effecting the exchange of the ultrasonic wave signals between the first and second transducers, to receive data from the first and second transducers based on the exchange of the ultrasonic wave signals between the first and second transducers, and to determine a flow rate of the fluid flowing in the pipe based on the data received from the first and second transducers. In several exemplary embodiments, at least respective portions of the first and second waveguides are made of a high-temperature ceramic material. In several exemplary embodiments, at least respective portions of the first and second waveguides are made of a calcium silicate technical ceramic. In several exemplary embodiments, when the first and second transducers are connected to the first and second waveguides, respectively, and the first and second waveguides are connected to the pipe, the first and second waveguides support the first and second transducers in a manner that permits propagation of the ultrasonic wave signals through the first and second waveguides at an angle greater than or equal to about 40 degrees and less than or equal to about 70 degrees with respect to a longitudinal axis of the pipe. In several exemplary embodiments, the first and second waveguides are each formed in the shape of a prism. In several exemplary embodiments, the first and second waveguides are each tapered so that contact areas between each of the first and second waveguides and the pipe are smaller than contact areas between the first and second waveguides and the first and second transducers, respectively. In several exemplary embodiments, the first and second waveguides are each machined to include a surface configured to matingly engage an external surface of the pipe. In several exemplary embodiments, the apparatus further includes the pipe, wherein either: an external surface of the pipe is machined to include surfaces configured to matingly engage the first and second waveguides; or material is added to an external surface of the pipe to form surfaces configured to matingly engage the first and second waveguides. In several exemplary embodiments, the first transducer is connected to the first waveguide via a connector ring; a recess in which the connector ring extends is formed in a portion of the first waveguide; and the connector ring: is made of a material more ductile and/or less brittle than a material of which the portion of the first waveguide is made, and/or includes an internal threaded connection threadably engaged by the first transducer. In several exemplary embodiments, the apparatus further includes the pipe, wherein the pipe includes a U-bend defining opposing first and second corners at which the first and second waveguides, respectively, are connected to the pipe; wherein the ultrasonic wave signals pass through the fluid flowing in the pipe directly from a first interior wall of the pipe at the first corner to a second interior wall of the pipe at the second corner. In several exemplary embodiments, the ultrasonic wave signals travel in a parallel relation to the fluid flowing in the pipe during at least a portion of their passage between the first interior wall of the pipe at the first corner and the second interior wall of the pipe at the second corner.

The present disclosure also introduces a system, including a non-transitory computer readable medium; and a plurality of instructions stored on the non-transitory computer readable medium and executable by one or more processors, the plurality of instructions including: instructions that cause the one or more processors to send control signals to first and second transducers, said control signals effecting an exchange of ultrasonic wave signals between the first and second transducers, and said ultrasonic wave signals passing through first and second waveguides, a pipe, and a fluid flowing in the pipe; instructions that cause the one or more processors to receive data from the first and second transducers based on the exchange of the ultrasonic wave signals between the first and second transducers; and instructions that cause the one or more processors to determine a flow rate of the fluid flowing in the pipe based on the data received from the first and second transducers; wherein a temperature of the fluid flowing in the pipe exceeds about 600° C. In several exemplary embodiments, the system further includes the first and second waveguides, which are adapted to be connected to the pipe; and the first and second transducers, which are adapted to be connected to the first and second waveguides, respectively; wherein the first and second waveguides insulate the first and second transducers from the pipe and propagate the ultrasonic wave signals between the pipe and the first and second transducers, respectively, so that the ability of the first and second transducers to exchange the ultrasonic wave signals is not adversely affected by the temperature of the fluid flowing in the pipe. In several exemplary embodiments, the system further includes a control unit including the non-transitory computer readable medium and the one or more processers, the control unit being adapted to be in communication with the first and second transducers. In several exemplary embodiments, at least respective portions of the first and second waveguides are made of a high-temperature ceramic material. In several exemplary embodiments, at least respective portions of the first and second waveguides are made of a calcium silicate technical ceramic. In several exemplary embodiments, the first and second waveguides are each formed in the shape of a prism. In several exemplary embodiments, the first and second waveguides are each tapered so that contact areas between each of the first and second waveguides and the pipe are smaller than contact areas between the first and second waveguides and the first and second transducers, respectively. In several exemplary embodiments, the first transducer is connected to the first waveguide via a connector ring; a recess in which the connector ring extends is formed in a portion of the first waveguide; and the connector ring: is made of a material more ductile and/or less brittle than a material of which the portion of the first waveguide is made, and/or includes an internal threaded connection threadably engaged by the first transducer. In several exemplary embodiments, the system further includes the pipe, wherein the pipe includes a U-bend defining opposing first and second corners at which the first and second waveguides, respectively, are connected to the pipe; wherein the ultrasonic wave signals pass through the fluid flowing in the pipe directly from a first interior wall of the pipe at the first corner to a second interior wall of the pipe at the second corner. In several exemplary embodiments, the ultrasonic wave signals travel in a parallel relation to the fluid flowing in the pipe during at least a portion of their passage between the first interior wall of the pipe at the first corner and the second interior wall of the pipe at the second corner.

The present disclosure also introduces a method, the method including: connecting first and second transducers to first and second waveguides, respectively; connecting the first and second waveguides to a pipe; and exchanging ultrasonic wave signals between the first and second transducers, said ultrasonic wave signals passing through the first and second waveguides, the pipe, and a fluid flowing in the pipe; wherein a temperature of the fluid flowing in the pipe exceeds about 600° C.; and wherein the first and second waveguides insulate the first and second transducers from the pipe and propagate the ultrasonic wave signals between the pipe and the first and second transducers, respectively, so that the ability of the first and second transducers to exchange the ultrasonic wave signals is not adversely affected by the temperature of the fluid flowing in the pipe. In several exemplary embodiments, the method further includes: placing a control unit in communication with the first and second transducers; sending, using the control unit, control signals to the first and second transducers, said control signals effecting the exchange of the ultrasonic wave signals between the first and second transducers; receiving, using the control unit, data from the first and second transducers based on the exchange of the ultrasonic wave signals between the first and second transducers; and determining, using the control unit, a flow rate of the fluid flowing in the pipe based on the data received from the first and second transducers. In several exemplary embodiments, at least respective portions of the first and second waveguides are made of a high-temperature ceramic material. In several exemplary embodiments, at least respective portions of the first and second waveguides are made of a calcium silicate technical ceramic. In several exemplary embodiments, the method further includes supporting the first and second transducers in a manner that permits propagation of the ultrasonic wave signals through the first and second waveguides at an angle greater than or equal to about 40 degrees and less than or equal to about 70 degrees with respect to a longitudinal axis of the pipe. In several exemplary embodiments, the first and second waveguides are each formed in the shape of a prism. In several exemplary embodiments, the first and second waveguides are each tapered so that contact areas between each of the first and second waveguides and the pipe are smaller than contact areas between the first and second waveguides and the first and second transducers, respectively. In several exemplary embodiments, the method further includes machining the first and second waveguides to include a surface configured to matingly engage an external surface of the pipe. In several exemplary embodiments, the method further comprises either: machining an external surface of the pipe to include surfaces configured to matingly engage the first and second waveguides; or adding material to an external surface of the pipe to form surfaces configured to matingly engage the first and second waveguides. In several exemplary embodiments, connecting the first and second waveguides to the pipe includes connecting the first transducer to the first waveguide via a connector ring; wherein the connector ring: extends within a recess formed in the first waveguide and includes an internal threaded connection with which the first transducer is threadably engageable, and/or is made of a material more ductile and/or less brittle than a material of which the portion of the first waveguide is made. In several exemplary embodiments, connecting the first and second waveguides to the pipe includes connecting the first and second waveguides to the pipe at opposing first and second corners, respectively, defined by a U-bend of the pipe so that the ultrasonic wave signals pass through the fluid flowing in the pipe directly from a first interior wall of the pipe at the first corner to a second interior wall of the pipe at the second corner. In several exemplary embodiments, the ultrasonic wave signals travel in a parallel relation to the fluid flowing in the pipe during at least a portion of their passage between the first interior wall of the pipe at the first corner and the second interior wall of the pipe at the second corner.

In the present disclosure, the term “about” is used to indicate the value stated immediately thereafter, but also may include a range of values above or below the stated value (e.g., +/−1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, or 25%).

It is understood that variations may be made in the foregoing without departing from the scope of the present disclosure.

In several exemplary embodiments, the elements and teachings of the various embodiments may be combined in whole or in part in some or all of the embodiments. In addition, one or more of the elements and teachings of the various embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various embodiments.

Although several exemplary embodiments have been described in detail above, the embodiments described are illustrative only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes, and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.