U.S. patent application number 17/415552 was filed with the patent office on 2022-02-24 for flowmeters and methods of manufacture.
This patent application is currently assigned to Sensia LLC. The applicant listed for this patent is Sensia LLC. Invention is credited to Emanuel J. Gottlieb, Gopalakrishna S. Magadi.
Application Number | 20220057246 17/415552 |
Document ID | / |
Family ID | 1000005945425 |
Filed Date | 2022-02-24 |
United States Patent
Application |
20220057246 |
Kind Code |
A1 |
Gottlieb; Emanuel J. ; et
al. |
February 24, 2022 |
FLOWMETERS AND METHODS OF MANUFACTURE
Abstract
A flowmeter system that includes a flowmeter body defining a
central bore. A plurality of flanges couple to the flowmeter body.
The flowmeter body and the plurality of flanges form a one-piece
structure without welded joints. A rotor within the central bore of
the flowmeter body. A first vane within the central bore of the
flowmeter body. The first vane couples to and supports the rotor
within the flowmeter body. The flowmeter body, the flanges, the
rotor, and the first vane comprise additive structures.
Inventors: |
Gottlieb; Emanuel J.; (Upper
Saint Clair, PA) ; Magadi; Gopalakrishna S.; (The
Woodlands, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sensia LLC |
Houston |
TX |
US |
|
|
Assignee: |
Sensia LLC
Houston
TX
|
Family ID: |
1000005945425 |
Appl. No.: |
17/415552 |
Filed: |
December 17, 2019 |
PCT Filed: |
December 17, 2019 |
PCT NO: |
PCT/US2019/066952 |
371 Date: |
June 17, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16224380 |
Dec 18, 2018 |
10852173 |
|
|
17415552 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01F 15/185 20130101;
G01F 1/10 20130101; G01F 15/14 20130101 |
International
Class: |
G01F 15/14 20060101
G01F015/14; G01F 1/10 20060101 G01F001/10; G01F 15/18 20060101
G01F015/18 |
Claims
1. A flowmeter system, comprising: a flowmeter body defining a
central bore; a plurality of flanges coupled to the flowmeter body,
wherein the flowmeter body and the plurality of flanges form a
one-piece structure without welded joints; a rotor within the
central bore of the flowmeter body; a first vane within the central
bore of the flowmeter body, wherein the first vane couples to and
supports the rotor within the flowmeter body.
2. The flowmeter system of claim 1, wherein at least one of the
flowmeter body, the flanges, the rotor, and the first vane comprise
additive structures.
3. The flowmeter system of claim 1, wherein the additive structures
comprise a honeycomb structure or a lattice structure.
4. The flowmeter system of claim 1, wherein the rotor comprises
additive structures that comprise a paramagnetic material.
5. The flowmeter system of claim 2, comprising a second vane
configured to support the rotor.
6. The flowmeter system of claim 5, wherein the first vane and the
second vane comprise a respective first vane body and a second vane
body, and wherein the first vane body defines a first aperture and
the second vane body defines a second aperture.
7. The flowmeter system of claim 6, comprising a shaft configured
to extend through an aperture in the rotor, wherein a first end of
the shaft is configured to rest within the first aperture and a
second end of the shaft is configured to rest within the second
aperture.
8. The flowmeter system of claim 6, wherein the first vane
comprises a vane body and a vane fin coupled to the vane body
wherein the vane body and the vane fin comprise the additive
structures.
9. The flowmeter system of claim 1, wherein the plurality of
flanges comprises a first flange, a second flange, and a third
flange, and wherein the first flange and the second flange couple
to ends of the flowmeter body and the third flange is between the
first flange and the second flange.
10. The flowmeter system of claim 9, wherein the third flange
surrounds an aperture that extends through the flowmeter body.
11. A method of manufacturing a flowmeter system, the method
comprising: defining a configuration for at least one of a
flowmeter body, a rotor, a vane, or a flange; depositing a
feedstock into a chamber; applying an energy source to the
feedstock; and consolidating the feedstock into a layer according
to the defined configuration.
12. The method of claim 11, wherein the feedstock comprises a
paramagnetic material.
13. The method of claim 11, wherein at least one of the flow meter
body, the rotor, the vane, or the flange comprise an additive
structure.
14. The method of claim 11, wherein the additive structure is a
honeycomb structure or a lattice structure.
15. The method of claim 13, wherein the vane comprises a vane body
and a vane fin coupled to the vane body wherein the vane body and
the vane fin comprise the additive structure.
16. A flowmeter system, comprising: a flowmeter body defining a
central bore; a plurality of flanges coupled to the flowmeter body,
wherein the flowmeter body and the plurality of flanges form a
one-piece structure without welded joints; a rotor within the
central bore of the flowmeter body; a first vane within the central
bore of the flowmeter body, wherein the vane couples to and
supports the rotor within the flowmeter body.
17. The flowmeter system of claim 16, wherein the flowmeter body,
the flanges, the rotor, and the first vane comprise additive
structure, wherein the additive structure changes within at least
one of the flowmeter body, the flanges, the rotor, and the first
vane.
18. The flowmeter system of claim 17, wherein a pattern of the
additive structures change.
19. The flowmeter system of claim 17, wherein dimensions of the
additive structures change.
20. The flowmeter system of claim 16, wherein the rotor comprises
additive structures that comprise a paramagnetic material.
8. The flowmeter system of claim 6, wherein the first vane
comprises a vane body and a vane fin coupled to the vane body
wherein the vane body and the vane fin comprise the additive
structures.
9. The flowmeter system of claim 1, wherein the plurality of
flanges comprises a first flange, a second flange, and a third
flange, and wherein the first flange and the second flange couple
to ends of the flowmeter body and the third flange is between the
first flange and the second flange.
10. The flowmeter system of claim 9, wherein the third flange
surrounds an aperture that extends through the flowmeter body.
11. A method of manufacturing a flowmeter system, the method
comprising: defining a configuration for a flowmeter body, a rotor,
a vane, and/or a flange, wherein at least one of the flowmeter
body, the rotor, the vane, and/or the flange comprises an additive
structure; depositing a feedstock into a chamber; applying an
energy source to the feedstock; and consolidating the feedstock
into a layer according to the defined configuration.
12. The method of claim 11, wherein the feedstock comprises a
paramagnetic material.
13. The method of claim 11, wherein the additive structure is a
lattice structure.
14. The method of claim 11, wherein the additive structure is a
honeycomb structure.
15. The method of claim 11, wherein the vane comprises a vane body
and a vane fin coupled to the vane body wherein the vane body and
the vane fin comprise the additive structure.
16. A flowmeter system, comprising: a flowmeter body defining a
central bore; a plurality of flanges coupled to the flowmeter body,
wherein the flowmeter body and the plurality of flanges form a
one-piece structure without welded joints; a rotor within the
central bore of the flowmeter body; a first vane within the central
bore of the flowmeter body, wherein the vane couples to and
supports the rotor within the flowmeter body; and wherein the
flowmeter body, the flanges, the rotor, and the first vane comprise
additive structures.
17. The flowmeter system of claim 16, wherein additive structure
changes within at least one of the flowmeter body, the flanges, the
rotor, and the first vane.
18. The flowmeter system of claim 17, wherein a pattern of the
additive structures change.
19. The flowmeter system of claim 17, wherein dimensions of the
additive structures change.
20. The flowmeter system of claim 16, wherein the rotor comprises
additive structures that comprise a paramagnetic material.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. application Ser.
No. 16/224,380, filed Dec. 18, 2018, which is incorporated herein
by reference in its entirety.
BACKGROUND
[0002] This section is intended to introduce the reader to various
aspects of art that may be related to various aspects of the
present disclosure, which are described and/or claimed below. This
discussion is believed to be helpful in providing the reader with
background information to facilitate a better understanding of the
various aspects of the present disclosure. Accordingly, it should
be understood that these statements are to be read in this light,
and not as admissions of prior art.
[0003] Flowmeters measure flow rates of fluid. For example, mineral
extraction systems or pipeline systems carry fluids, and a
flowmeter may be used to measure a flow rate of the fluid through
them. The configuration of the flowmeter can impact the ability of
the flowmeter to accurately measure the flow rate of the fluid, and
can also impact durability of the flowmeter and installation
processes for the flowmeter. Therefore, it would be desirable to
improve the configuration of flowmeters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Various features, aspects, and advantages of the present
disclosure will become better understood when the following
detailed description is read with reference to the accompanying
figures in which like characters represent like parts throughout
the figures, wherein:
[0005] FIG. 1 is a perspective view of a flowmeter system, in
accordance with an embodiment of the present disclosure;
[0006] FIG. 2 is a perspective cross-sectional view of a flowmeter
system of FIG. 1, in accordance with an embodiment of the present
disclosure;
[0007] FIG. 3 is a perspective view of one side of a flange that
may be used in the flowmeter system of FIG. 1, in accordance with
an embodiment of the present disclosure;
[0008] FIG. 4 is a cross-sectional view of the flange of FIG. 3, in
accordance with an embodiment of the present disclosure;
[0009] FIG. 5 is a cross-sectional view of an additive structure
that may be used in the flowmeter system within line 5-5, in
accordance with an embodiment of the present disclosure;
[0010] FIG. 6 is a cross-sectional end view of another flange that
may be used in the flowmeter, in accordance with an embodiment of
the present disclosure;
[0011] FIG. 7 is a perspective cross-sectional view of a rotor, in
accordance with an embodiment of the present disclosure;
[0012] FIG. 8 is a cross-sectional view of an additive structure
that may be used in the flowmeter system, in accordance with an
embodiment of the present disclosure;
[0013] FIG. 9 is a cross-sectional view of a rotor, in accordance
with an embodiment of the present disclosure;
[0014] FIG. 10 is a perspective cross-sectional view of a vane, in
accordance with an embodiment of the present disclosure;
[0015] FIG. 11 is a perspective cross-sectional view of a vane, in
accordance with an embodiment of the present disclosure; and
[0016] FIG. 12 is a method of manufacturing the flowmeter system of
FIG. 1, in accordance with an embodiment of the present
disclosure.
DETAILED DESCRIPTION
[0017] One or more specific embodiments of the present disclosure
will be described below. These described embodiments are only
exemplary of the present disclosure. Additionally, in an effort to
provide a concise description of these exemplary embodiments, all
features of an actual implementation may not be described in the
specification. It should be appreciated that in the development of
any such actual implementation, as in any engineering or design
project, numerous implementation-specific decisions must be made to
achieve the developers' specific goals, such as compliance with
system-related and business-related constraints, which may vary
from one implementation to another. Moreover, it should be
appreciated that such a development effort might be complex and
time consuming, but would nevertheless be a routine undertaking of
design, fabrication, and manufacture for those of ordinary skill
having the benefit of this disclosure.
[0018] Certain systems, such as mineral extraction systems (e.g.,
drilling and production systems) or pipeline systems, may include
various fluid-handling components (e.g., conduits, tanks,
injectors). For example, a conduit may direct a flow of a fluid
(e.g., water, chemicals, gas, liquid, production fluid, drilling
fluid) from one location to another location. A flowmeter may be
provided to monitor a flow rate of the fluid through the
conduit.
[0019] Flowmeter systems may include a flowmeter body that is
formed by machining a solid structure (e.g., metal block) into a
generally cylindrical conduit having a central bore, which is
aligned with adjacent conduits to enable the flow of fluid across
the flowmeter. Some flowmeters may include a connector (e.g.,
annular connector) that extends radially from the flowmeter body
and that is configured to support a measurement device (e.g.,
transmitter or a flow sensor). The connector may be machined
separately and then welded to a sidewall of the flowmeter body.
Furthermore, some flowmeters may include flanges at ends of the
flowmeter body to facilitate coupling of the flowmeter to adjacent
conduits. The flanges may also be machined separately and then
welded to the flowmeter body.
[0020] In some cases, it may be desirable to form the flowmeter,
the connector, and/or the flanges from high strength materials,
such as a nickel-based alloy (e.g., Inconel 718) or a stainless
steel material (e.g., martensitic precipitation hardened stainless
steel, such as 17-4 PH). However, such materials may be difficult
to properly or efficiently weld without local failures (e.g.,
cracking). Accordingly, the manufacturing process may be lengthy
and complex, and the flowmeters produced via welding processes may
be frequently identified as noncompliant with regulatory standards
during testing and final inspections. Furthermore, the use of
additional connectors to support multiple sensors (e.g., ultrasonic
sensors or other flow sensors) may be inappropriate due to limited
space about the flowmeter body to support additional separate
welded joints, as well as due to the increased risk of local
failures and noncompliant flowmeters from the additional welded
joints. Furthermore, the flowmeter may be a solid, heavy component,
which in turn, may make transport, installation, and maintenance of
the flowmeter challenging.
[0021] Accordingly, certain disclosed embodiments relate to
flowmeters having a flowmeter body assembly with a flowmeter body,
a connector configured to support a measurement device (e.g.,
transmitter having an electronic controller) to facilitate accurate
measurement of the flow rate of the fluid. Some or all of the
flowmeter body, the connector, a rotor, and vanes may be formed as
a one-piece structure without welded joints with an additive
structure (e.g., open cell structure, non-solid structure,
non-continuous structure, or framework). For example, the additive
structure may include through holes that extend between opposed
axially-facing surfaces of a flange. The additive structure may
reduce the weight of the flowmeter (e.g., as compared to flowmeters
having solid flanges manufactured via traditional techniques),
thereby facilitating transport, installation, and/or maintenance of
the flowmeter. For example, in some embodiments, a flange having an
additive structure may weigh at least 10, 20, 30, 40, or 50 percent
less than the flange without the additive structure (e.g., solid
flange).
[0022] In certain embodiments, the flowmeter system may be
manufactured via additive manufacturing techniques. Such techniques
may enable construction of the flowmeter system from computer
models, without difficult machining steps. In general, additive
manufacturing techniques involve applying a source of energy, such
as a laser or electron beam, to deposited feedstock (e.g., powder
or wire) in order to grow a part having a particular shape and
features. The flowmeter disclosed herein may be utilized as part of
any suitable fluid-handling system, such as an energy-acquisition
or processing system (e.g., a hydrocarbon-production or processing
system, such as a subsea or surface oil or gas well, a pipeline, a
natural-gas processing terminal, a refinery, or a natural-gas
powered electrical plant).
[0023] Turning now to the figures, FIG. 1 is a perspective view of
a flowmeter system 10. The flowmeter system 10 includes a flowmeter
body 12 (e.g., main or primary annular conduit), a flange 14 (e.g.,
annular flange), a downstream flange 16 (e.g., annular flange), and
a connector 18 (e.g., radial connector). The flowmeter system 10
may also include additional connectors (e.g., radial connectors).
In some embodiments, the connector 18 may include a flange 20. The
connector 18 may be configured to support a controller 22 that
couples to a sensor 24. The controller 22 may include a processor
26 that communicates with a memory 28.
[0024] As will be discussed in more detail below, some or all of
the components of the flowmeter system 10 may be formed via an
additive manufacturing process. Thus, the components of the
flowmeter system 10 may be formed together as a one-piece structure
(e.g., a gaplessly continuous one-piece structure) that is devoid
of welded joints.
[0025] FIG. 2 is a perspective cross-sectional view of a flowmeter
system 10 of FIG. 1. As shown, the flowmeter body 12 defines a bore
30 (e.g., central bore), which may be aligned with respective bores
of adjacent conduits (e.g., pipe sections) when the flowmeter
system 10 is coupled to the adjacent conduits via the flanges 14,
16. In the illustrated embodiment, the flange 14 and the downstream
flange 16 are positioned at opposite ends (e.g., end portions) of
the flowmeter body 12 to facilitate coupling of the flowmeter
system 10 to the adjacent conduits. Thus, a fluid 32 (e.g., water,
chemicals, gas, liquid, production fluid, drilling fluid) may enter
at an upstream end 34 (e.g., end portion) of the flowmeter body 12,
flow through the bore 30, and then exit through a downstream end 36
(e.g., end portion) of the flowmeter body 12. As used herein, the
terms upstream and downstream are defined with respect to a flow
path of the fluid 32. For example, in the illustrated embodiment,
the upstream end 34 is upstream from the downstream end 36 because
the fluid 32 flows from the upstream end 34 toward the downstream
end 36. It should be understood that in certain embodiments the
flow path of the fluid 32 may be in the opposite direction.
[0026] As shown, the connector 18 includes the flange 20, which
enables the controller 22 to couple to the flowmeter body 12. The
flange 20 couples to a conduit 38, which in turn couples to the
flowmeter, body 12. The conduit 38 defines a bore 40 in
communication with an aperture 42 in the flowmeter body 12. The
sensor 24 may rest within the aperture 42 to enable the sensor 24
to detect rotation of the rotor 44. The rotor 44 rotates in
response to the flow of the fluid 32 across the blades 46. The
rotational speed of the rotor 44 depends on the speed of the fluid
32 flowing through the bore 30 of the flowmeter body 12. In other
words, changes in the flow rate of the fluid 32 change the
rotational speed of the rotor 44. In order to detect the rotation
of the rotor 44, the sensor 24 may be a magnetic sensor that
detects the presence of the blades 46. For example, the blades 46
may include paramagnetic materials. Accordingly, as the blades 46
rotate, the magnetic sensor 24 is able to detect and count each
blade 46 as it rotates past the aperture 42. By counting the number
blades 46 that rotate past the aperture 42, the controller 22 is
able to determine the rotations per minute of the rotor 44. The
rotational speed of the rotor 44 is then correlated to a flow rate
of the fluid 32 through the flowmeter system 10.
[0027] The rotor 44 is supported by a shaft 48 that extends through
a rotor body 50. The shaft 48 defines ends 52 and 54, which are
supported by vanes 56 and 58 that rest within the bore 30 of the
flowmeter body 12. More specifically, the ends 52 and 54 of the
shaft 48 are supported in respective vane bodies 60 and 62. To
facilitate rotation of the shaft 48, the vanes 56 and 58 may
include bearings 64 and 66, which enable the shaft 48 to rotate
relative to the vanes 56 and 58. The vanes 56 and 58 include one or
more fins 68 that extend from the vane bodies 60 and 62. As
illustrated, the fins 68 extend from the vane bodies 60, 62 and may
contact an interior surface 70 of the flowmeter body 12. This may
center the vane bodies 60, 62 and thus center the rotor 44 within
the bore 30 of the flowmeter body 12.
[0028] As illustrated, various components and portions of the
flowmeter system 10 may include additive structures 72 (e.g., open
cell lattice structure, non-solid structure, or non-continuous
structure). For example, in the flowmeter system 10 of FIG. 1, the
flanges 14, 16, 20; rotor 44; and/or vanes 56 and 58 include the
additive structure 72. The additive structures 72 may have any of a
variety of forms including lattice, honeycomb, etc. The additive
structures 72 are formed via an additive manufacturing process.
Thus, some of or all of the components of the flowmeter system 10
may be formed as a one-piece structure (e.g., a gaplessly
continuous one-piece structure) that is devoid of welded joints. To
facilitate discussion, the flowmeter system 10 and the components
therein may be described with reference to the axial axis or
direction 74, a radial axis or direction 76, and/or a
circumferential axis or direction 78.
[0029] FIG. 3 is a perspective view of one side of a flange (e.g.,
14, 16, 20) that may be used in the flowmeter system 10 of FIG. 1.
During the discussion below, the flange illustrated in FIG. 3 will
be referred to as flange 14. However, it should be understood that
the discussion below is equally applicable to the flanges 16 and 20
as well as other components of the flowmeter system 10. As shown,
the flange 14 is a generally annular cylindrical structure that
defines a first end 100 and a second end 102. The flange 14 has an
outer wall 104 (e.g., solid wall, radially-outer annular wall,
cylindrical wall) and an inner wall 106 (e.g., solid wall,
radially-inner annular wall, cylindrical wall). The inner wall 106
defines an opening 108 (e.g., bore or aperture) in the flange 14.
When the flange 14 is used as part of the flowmeter system 10, the
opening 108 is aligned with and enables fluid to flow into the bore
30 of the flowmeter body 12.
[0030] In the illustrated embodiment, the flange 14 includes
multiple openings 110 (e.g., through holes) that are configured to
receive fasteners to couple the flange 14 to an adjacent flange. As
shown, the flange 14 includes four openings 110 positioned about
the circumference of the flange 14; however, any suitable number
(e.g., 2, 3, 4, 5, 6, 7, 8, or more) openings 110 may be provided
in the flange 14.
[0031] In the illustrated embodiment, the flange 14 includes the
additive structure 72. As shown, the additive structure 72 may be
in an interior portion of the flange 14. For example, the additive
structure 72 may be provided between the outer wall 104 and the
inner wall 106 of the flange 14. In the illustrated embodiment, at
least some of the additive structure 72 is visible after the
construction of the flange 14 is complete. However, in some
embodiments, some or all of the additive structure 72 may not be
visible after construction of the flange 14 is complete.
[0032] In the illustrated embodiment, the additive structure 72
define openings 111 that extend along the axial axis 74 (e.g., a
central longitudinal axis of the openings 111 is parallel to the
axial axis 74 of the flange 14). The openings 111 may be through
holes that extend axially across the flange 14. For example, at
least some of the openings 111 may extend between the first end 100
and the second end 102 and be open at the first end 100 and the
second end 102. In the illustrated embodiment, at least some of the
openings 111 have a hexagonal cross-sectional shape.
[0033] The configurations disclosed herein may reduce the weight of
the flange 14 (e.g., by 10, 20, 30, 40, 50 percent or more), while
maintaining adequate strength for use in pressure-containing
components of a mineral-extraction system or a pipeline system, for
example. For example, with reference to FIG. 4, the outer wall 104
may have a thickness 112 (e.g., a radial thickness that is solid
and devoid of the additive structure 72) and the inner wall 106 may
have a thickness 114 (e.g., a radial thickness that is solid and
devoid of the additive structure 72). In some embodiments, the
thicknesses 112, 114 may be between approximately 1 to 10, 2 to 9,
3 to 8, or 4 to 7 millimeters (mm). As shown, each opening 110 may
be defined or surrounded by an opening wall 116 (e.g., annular
wall) having a radial thickness 118 (e.g., a radial thickness that
is solid and devoid of the additive structure 72), which may be
between approximately 1 to 10, 2 to 9, 3 to 8, or 4 to 7
millimeters (mm). In some embodiments, some or all of the radial
thicknesses 112, 114, 118 of the walls 104, 106, 116, respectively,
may be equal to or greater than approximately 1, 2, 3, 4, 5, 6, 7,
8, 9, or 10 mm. Furthermore, a maximum diameter 120 of the flange
14 may be between approximately 100 to 200, 135 to 175, or 140 to
160 mm, and/or a diameter 122 of the bore 30 may be between
approximately 30 to 100, 40 to 80, or 50 to 70 mm. With reference
to FIG. 5, the openings 111 of the additive structure 72 have a
hexagonal cross-sectional shape. As shown, adjacent openings 111
may be separated by a width 130 that is between approximately 1 to
10, 2 to 8, or 3 to 5 mm, and a width 132 of the opening 111 may be
between approximately 1 to 10, 3 to 9, or 5 to 8 mm.
[0034] The dimensions provided above are intended to be exemplary,
and it should be appreciated that the relative dimensions may scale
with the overall size of the flange 14 and/or may vary based on the
application. For example, the thickness 112 of the outer wall 104,
the thickness 114 of the inner wall 106, and/or the thickness 118
of the opening wall 116 may be between approximately 1 to 25, 2 to
20, or 3 to 5 percent of the maximum diameter 120 of the flange 14.
In some embodiments, the thickness 112 of the outer wall 104, the
thickness 114 of the inner wall 106, and/or the thickness 118 of
the opening wall 116 may be equal to or greater than approximately
1, 2, 3, 4, or 5 percent of the maximum diameter 120 of the flange
14. Additionally or alternatively, the width 130 between openings
111 of the additive structure 72 may be between approximately 1 to
25, 2 to 20, or 3 to 10 percent of the maximum diameter 120 of the
flange 14. Additionally or alternatively, the width 132 of the
openings 111 of the additive structure 72 may be between
approximately 1 to 10, 2 to 8, or 3 to 5 percent of the maximum
diameter 120 of the flange 14. Additionally or alternatively, the
width 130 may be may be approximately 10 to 150, 30 to 100, 40 to
80, or 50 to 60 percent of the width 132, for example.
[0035] Furthermore, the geometry of the flange 14 and the additive
structure 72 shown in FIGS. 3-5 is merely exemplary. It should be
appreciated that the openings 111 may not be through holes and/or
may have any of a variety of cross-sectional shapes, such as
squares, triangles, rectangles (e.g., non-square), diamonds,
pentagons, octagons, or circles. It should be appreciated that the
openings 111 may be arranged to have various orientations relative
to the axial axis 74 as well.
[0036] Moreover, it should be appreciated that the flange 14 may
have various configurations. For example, FIG. 6 is a
cross-sectional end view of another embodiment of the flange 14
that may be used in the flowmeter system 10. In FIG. 10, the
additive structure 72 has different dimensions (e.g., widths 130,
132) or relative dimensions (e.g., ratio between widths 130, 132;
ratio between widths 130, 132 and the maximum diameter 120). It
should also be appreciated that the downstream flange 16 may have
any of the features illustrated and described with respect to FIGS.
3-6. It should also be appreciated that the flanges (e.g., the
flanges 14, 16) disclosed herein may be part of any of a variety of
other components, such as valves (e.g., choke valves, ball valves,
gate valves), pipe sections, or the like, that utilize flanges to
couple to adjacent components.
[0037] FIG. 7 is a perspective cross-sectional view of the rotor
44. As illustrated, the blades 46 couple to a rotor hub 150. The
rotor hub 150 defines an aperture 152 that extends through the
rotor 44 to enable the rotor 44 to receive the shaft 48. The rotor
hub 150 has an outer wall 154 (e.g., solid wall, radially-outer
annular wall, cylindrical wall) and an inner wall 156 (e.g., solid
wall, radially-inner annular wall, cylindrical wall). The inner
wall 156 defines the aperture 152 (e.g., bore or aperture) in the
rotor hub 150. As illustrated, the rotor hub 150 includes the
additive structure 72. For example, the additive structure 72 may
be provided between the outer wall 154 and the inner wall 156 of
the rotor hub 150. In the illustrated embodiment, the additive
structure 72 defines a square and/or rectangular lattice structure.
However, and as explained above, the additive structure 72 may have
any variety of cross-sectional shapes, such as squares, triangles,
rectangles (e.g., non-square), diamonds, pentagons, octagons, or
circles. It should be appreciated that the openings 158 may be
arranged to have various orientations relative to the longitudinal
axis 160 of the rotor hub 150.
[0038] The additive structure 72 may reduce the weight of the rotor
44 (e.g., by 10, 20, 30, 40, 50 percent or more), while maintaining
adequate strength. For example, the outer wall 154 may have a
thickness 162 (e.g., a radial thickness that is solid and devoid of
the additive structure 72) and the inner wall 156 may have a
thickness 164 (e.g., a radial thickness that is solid and devoid of
the additive structure 72). In some embodiments, the thicknesses
162, 164 may be between approximately 1 to 10, 2 to 9, 3 to 8, or 4
to 7 millimeters (mm). With reference to FIG. 8, the additive
structure 72 may be square or rectangular and formed with a
plurality of bars or rods 180 that define a cuboid space 182. The
bars or rods 180 may have a length 184 that is between 1 to 10, 2
to 8, or 3 to 5 mm, and a width 186 that is between 1 to 6, 1 to 4,
or 1 to 3 mm. The reduction in weight of the rotor 44 may enable a
more rapid response to changes in flow rates through the flowmeter
system 10. In other words, the rotor 44 may change its rotational
speed or inertia more quickly because of the reduction in weight. A
more rapid response to changing flow rates may enable more accurate
measurements of fluid flow by reducing the lag that may occur
between changes in the flow rate and the corresponding change in
the rotational speed of the rotor 44.
[0039] FIG. 9 is a cross-sectional view of the rotor 44. As
illustrated, the blades 46 may also include the additive structure
72. The additive structure 72 may be provided between opposing
sidewalls 200 and 202 of the blades 46. In the illustrated
embodiment, the additive structure 72 defines a square and/or
rectangular lattice structure. However, and as explained above, the
additive structure 72 may have any variety of cross-sectional
shapes, such as squares, triangles, rectangles (e.g., non-square),
diamonds, pentagons, octagons, or circles. In some embodiments, the
additive structure 72 may be in all of the blades 46 or subset of
the blades 46 (e.g., 1, 2, 3, 4, 5).
[0040] The additive structure 72 may reduce the weight of the
blades 46 and therefore the overall weight of the rotor 44 (e.g.,
by 10, 20, 30, 40, 50 percent or more), while maintaining adequate
strength. For example, the sidewalls 200 and 202 may have a
thickness devoid of the additive structure 72. In some embodiments,
the thicknesses of the sidewalls 200 and 202 may be between
approximately 1 to 5, 1 to 4, 1 to 3 mm. The reduction in weight of
the rotor 44 may enable a more rapid response to changes in flow
rates through the flowmeter system 10. In other words, the rotor 44
may change its rotational speed or inertia more quickly because of
the reduction in weight. A more rapid response to changes in flow
rates may enable more accurate measurements of fluid flow.
[0041] As illustrated, the additive structure 72 may extend along
the entire length of the blade 46 or partially along the length of
the blade 46. For example, the additive structure 72 may extend
from blade tips 204 to the outer wall 154 of the rotor hub 150. In
some embodiments, the additive structure 72 in the blades 46 may
couple to the additive structure 72 in the rotor hub 150. In still
other embodiments, the additive structure 72 in the blades 46 may
extend from the blade tips 204 to the additive structure 72 in the
rotor hub 150.
[0042] FIG. 10 is a perspective view of one side of a vane (e.g.,
56, 58) that may be used in the flowmeter system 10 of FIG. 1.
During the discussion below, the vane illustrated in FIG. 10 will
be referred to as vane 56. However, it should be understood that
the discussion below is equally applicable to the vane 58 as well
as other components of the flowmeter system 10. As illustrated,
vane 56 includes the vane hub or body 60 and fins 68 that couple to
the vane body 60. The vane body 60 defines an aperture 220 that
receives an end 54 of the shaft 48. In some embodiments, the vane
body 60 may define a first portion 222 that couples to the fins 68
and a second portion 224 that defines the aperture 220 and couples
to the shaft 48.
[0043] In some embodiments, the second portion 224 may define an
outer wall 226 (e.g., solid wall, radially-outer annular wall,
cylindrical wall) and an inner wall 228 (e.g., solid wall,
radially-inner annular wall, cylindrical wall). The inner wall 228
defines the aperture 220 (e.g., bore or aperture) in the second
portion 224. As illustrated, the vane body 60 includes the additive
structure 72. For example, the additive structure 72 may be
provided between the outer wall 226 and the inner wall 228. In the
illustrated embodiment, the additive structure 72 defines a square
and/or rectangular lattice structure. However, and as explained
above, the additive structure 72 may have any variety of
cross-sectional shapes, such as squares, triangles, rectangles
(e.g., non-square), diamonds, pentagons, octagons, or circles.
[0044] As illustrated, a width 230 (e.g., diameter) of the vane
body 60 changes between opposing ends 232 and 234 of the vane 56.
In some embodiments, the size of the additive structure 72 within
the second portion 224 may progressive decrease in size the greater
the distance from the end 234. By progressively decreasing in size,
the additive structure 72 enables uniform or substantially uniform
thicknesses 236 and 238 of the respective outer and inner walls 226
and 228. This uniformity may maintain adequate strength and
rigidity of the vane body 60 to support the rotor 44 during
operation of the flowmeter system 10.
[0045] The first portion 222 may also include additive structure 72
that reduces the weight of vane 56 while also maintaining adequate
strength. In some embodiments, the vane 56 may include an outer
wall 240 between the additive structure 72 and the fins 68. This
outer wall 240 may also have a uniform or substantially uniform
thickness 242 to maintain adequate strength and rigidity of the
fins 68 with respect to the vane body 60 as the diameter of the
vane body 60 changes between the first and second ends 232,
234.
[0046] The fins 68 may also include additive structure 72 between
opposing sidewalls 244 and 246. In the illustrated embodiment, the
additive structure 72 defines a square and/or rectangular lattice
structure. However, and as explained above, the additive structure
72 may have any variety of cross-sectional shapes, such as squares,
triangles, rectangles (e.g., non-square), diamonds, pentagons,
octagons, or circles. In some embodiments, the additive structure
72 may be in all of the blades 46 or subset of the blades 46 (e.g.,
1, 2, 3, 4, 5).
[0047] The additive structure 72 may reduce the weight of the fins
68 and therefore the overall weight of the rotor 44 (e.g., by 10,
20, 30, 40, 50 percent or more), while maintaining adequate
strength. For example, the sidewalls 244 and 246 may have a
thickness devoid of the additive structure 72. In some embodiments,
the thicknesses of the sidewalls 244 and 246 may be between
approximately 1 to 5, 1 to 4, 1 to 3 mm.
[0048] As illustrated, the additive structure 72 may extend along
the entire width of the fin 68 or partially along the width of the
fin 68. In some embodiments, the additive structure 72 in the fins
68 may couple to the additive structure 72 in the vane body 60. In
still other embodiments, the additive structure 72 in the fins 68
may extend from the tips 248 to the additive structure 72 in the
rotor hub 150. The additive structure 72 may also extend along an
entire length 250 of the fins 68 or a portion of the length
250.
[0049] FIG. 11 is a perspective cross-sectional view of the vane
56. As illustrated, walls may completely enclose the additive
structure 72 in the fins 68. FIG. 11 also illustrates that one or
more of the fins 68 may include one or more sections 270 of solid
material between sections 272 of additive structure 72. These solid
sections of material 270 may increase the overall strength and
rigidity of the fins 68 while also enabling an overall reduction in
the weight of the vane 56 and therefore the flowmeter system
10.
[0050] FIG. 12 is a flow diagram of a method 300 that may be used
to manufacture the flowmeter system 10. The method 300 includes
steps for constructing the flowmeter system 10 using an additive
manufacturing process (e.g., 3-D printing, such as laser metal
deposition). The method 300 may be performed by an additive
manufacturing system, which may include a controller (e.g.,
electronic controller), a processor, a memory device, a user
interface, and/or an energy source.
[0051] The method 300 includes defining a particular configuration
or shape for the flowmeter system 10 (e.g., flowmeter body 12,
flange 14, flange 16, connector 18, rotor 44, vane 56, vane 58), in
step 302. The configuration may be a computer-generated
three-dimensional representation of the flowmeter system 10 and may
be programmed by an operator into an additive manufacturing system
by using a specialized or general purpose computer having the
processor, for example. The defined configuration may have any of
the shapes and features described above.
[0052] In step 304, feedstock (e.g., a metal powder or wire) is
deposited into a chamber, such as a vacuum chamber. Any of a
variety of materials may used in any suitable combination,
including those described in more detail below. In step 306, an
energy source, such a laser or electron beam, is applied to the
deposited feedstock to melt or otherwise consolidate the feedstock.
As shown at block 208, a consolidated layer having a
cross-sectional shape corresponding to the configuration defined in
step 302 is formed. The processor or operator may determine whether
the flowmeter system 10 is incomplete or complete, in step 310. If
the part is incomplete, then steps 304 and 306 are repeated to
produce layers of consolidated feedstock having cross-sectional
shapes corresponding to the defined confirmation or model until
construction of the flowmeter system 10 is complete. Thus, the
energy source is applied to melt or otherwise consolidate each
newly deposited portion of the feedstock until the final product is
complete and the flowmeter system 10 having the defined
configuration is produced, as shown in step 312.
[0053] The flowmeter system 10 constructed at step 312 via the
method 300 may be devoid of welds or welded bonds. The flowmeter
system 10 constructed at step 312 via the method 300 may be used in
a mineral extraction system or a pipe system without further
processing (e.g., without subsequent machining, smoothing, or heat
and pressure treatments, such as hot isostatic pressing) of the
flowmeter body assembly. However, in some embodiments, the
flowmeter system 10 constructed at step 312 may be machined (e.g.,
to smooth or to shape various surfaces or to add threaded
surfaces). Additionally or alternatively, in some embodiments, the
flowmeter system 10 may be compacted via a heat and pressure
treatment, such as a hot isostatic pressing process. In such cases,
the flowmeter system 10 may be positioned within a canister. The
flowmeter system 10 produced via the method 300 may have
characteristics (e.g., density and/or porosity) that enable the
flowmeter system 10 to maintain its shape during the hot isostatic
pressing process. The canister may be sealed and vacuumed, and heat
and/or pressure is applied to the flowmeter system 10 within the
canister via a heat source and/or a pressure source (e.g., an
autoclave furnace) to compact the flowmeter system 10 (e.g.,
further reduce porosity of the flowmeter system 10). In certain
embodiments, the temperature applied to the flowmeter system 10
within the canister may be approximately 1050 to 1100 degrees
Celsius, and the hydrostatic pressure within the canister may be
approximately 400 to 450 MPa. However, any suitable temperature
and/or pressure may be utilized to compact the flowmeter system
10.
[0054] Constructing components of the flowmeter system 10 via the
method 300 may enable the components to be manufactured efficiently
and/or on-site at the location where the components will be
utilized. For example, the components may be manufactured via the
method 300 via the additive manufacturing system on an offshore rig
of a subsea mineral extraction system.
[0055] The flowmeter system 10 disclosed herein may have a reduced
weight, while maintaining adequate structural integrity when used
in mineral-extraction systems or pipe systems. For example, the
flowmeter system 10 may demonstrate stress and plastic strain below
allowable limits, thereby providing protection against failures,
such as cracks and plastic collapse. The components the flowmeter
system 10 may be formed from any of a variety of materials. For
example, some or all of the portions of the flowmeter system 10 may
be formed from a nickel-based alloy (e.g., Inconel 718) or a
stainless steel material (e.g., martensitic precipitation hardened
stainless steel, such as 17-4 PH). In some embodiments, some or all
of the portions of the flowmeter system 10 may be devoid of any
other materials (e.g., the portions only include a nickel-based
alloy or a stainless steel material). It should be appreciated that
different portions of the flowmeter system 10 may be formed from
different materials (e.g., the additive structure 72 may be formed
from a different material than the outer wall 104 and/or the inner
wall 106 of the flanges 14, 16). In some embodiments, the flowmeter
system 10 may be formed from a material having a yield strength of
between approximately 700 and 1000 Newtons per square millimeter
(N/mm.sup.2) at room temperature.
[0056] While the disclosure may be susceptible to various
modifications and alternative forms, specific embodiments have been
shown by way of example in the drawings and have been described in
detail herein. However, it should be understood that the disclosure
is not intended to be limited to the particular forms disclosed.
Rather, the disclosure is to cover all modifications, equivalents,
and alternatives falling within the spirit and scope of the
disclosure as defined by the following appended claims. It should
be appreciated that any of the features illustrated in FIGS. 1-15
or disclosed herein may be combined in any combination.
[0057] The techniques presented and claimed herein are referenced
and applied to material objects and concrete examples of a
practical nature that demonstrably improve the present technical
field and, as such, are not abstract, intangible or purely
theoretical. Further, if any claims appended to the end of this
specification contain one or more elements designated as "means for
[perform]ing [a function] . . . " or "step for [perform]ing [a
function] . . . ", it is intended that such elements are to be
interpreted under 35 U.S.C. 112(f). However, for any claims
containing elements designated in any other manner, it is intended
that such elements are not to be interpreted under 35 U.S.C.
112(f).
* * * * *