1. Introduction
With the rapid development of the world’s industry, the demand for energy in various countries is continuously increasing. As a high-quality and efficient primary energy source, natural gas has become the first choice for industrial energy consumption in various countries [
1]. Natural gas is a type of gaseous hydrocarbon produced by microbial decomposition after long-term accumulation of paleontological remains in the ground. Therefore, the distribution of natural gas reserves in the world is related to geographical location [
2]. Countries with developed industries but small natural gas reserves need to trade natural gas with countries with rich natural gas reserves [
3]. Today, natural gas trade plays an important role in international trade, promoting global economic integration.
Fair trade is a key premise of international trade. In the international trade of natural gas, the accuracy of large flow measurement is particularly important not only for economic interests, but also to maintain the stable operation of the international trade of natural gas. At present, ultrasonic flowmeters are widely used in natural gas large flow measurement. Its measurement principle is to use the different propagation speeds of ultrasonic waves in different fluid flow velocities. The manufacturing cost has nothing to do with the diameter of the pipeline, especially in large diameter, large flow measurement, has the advantages of convenient installation and use. However, there is a high demand for measurements in noisy environments. If the pipeline scales or the measurement environment has noise, the measurement accuracy will be severely affected [
4]. Therefore, in the international trade of natural gas, a new type of flowmeter with high precision and strong resistance to external interference is urgently needed.
With the development of computers and image processing technology, the particle image velocimetry (PIV) technique has become an important method to test the microscopic flow characteristics of flow fields [
5,
6]. Xiaolong et al. used PIV testing technology to analyze the internal flow field and pressure pulsation in the bladeless region of a pump turbine [
7], Moneib et al. studied the near-field spray characterization of an overflow return atomizer using a PIV laser [
8], Seon and Jin used PIV technology to study the effect of buoyancy on mixed convection in vertical channels [
9], and Gangfu et al. used PIV technology to measure the velocity field in the rotating boundary layer [
10]. The above studies were all based on PIV technology, and all achieved good results.
The principle of PIV testing is that the flow field at the transparent pipe is irradiated at a high frequency by a laser connected to a synchronizer and computer to capture tracer particles in the flow field, and the velocity information of the flow field is obtained by taking a series of displacement photos of particles in the flow field with a high frequency camera [
11,
12,
13]. In this type of experiment, it is necessary to form a complete set of equipment placed around the transparent pipes, which can then be measured. This method possesses the advantages of convenient installation and simple operation because it is based on tracer particles of the pulsed laser refractive reaction flow field characteristics, making it less sensitive to outside interference; furthermore, the accuracy of PIV testing of the flow field has been thoroughly experimentally validated [
14,
15,
16]. Therefore, the application of PIV technology in large flow metering of natural gas has the advantages of convenient installation and use, strong anti-noise ability and long service life.
The addition of tracer particles is a key step in PIV testing. At the intersection of the particle injection flow field and test flow field, a flow field disturbance will inevitably be generated, and under the action of shear force, the disturbance will gradually weaken and disappear along the flow direction. In a PIV flowmeter, the distance from the confluence of the flow field to the disappearance of the flow field disturbance is called the disturbance distance. If the PIV flowmeter is installed within the disturbance distance, it will cause a large metering error, so the disturbance distance must be taken into account in the application of PIV flow timing. The particle distribution outside the disturbance distance also affects the accuracy of the PIV flowmeter. Therefore, it is necessary to study the disturbance distance and particle distribution of PIV flowmeters.
In this paper, a large flow DN100 natural gas pipeline is taken as the research object, and the disturbance distance caused by different particle injection modes in the PIV flowmeter is analyzed through numerical calculation. The injection mode with the smallest disturbance distance is obtained, and the injection mode is optimized by combining numerical calculation and testing. The measurement results of a PIV flowmeter with an optimized structure were compared with those of an ultrasonic flowmeter to verify the feasibility of the PIV flowmeter with an optimized structure. This study provides a theoretical reference for the development of PIV flowmeters.
2. Materials and Methods
When using a PIV flowmeter, the injection fluid and the fluid in the main pipeline of natural gas flow in their respective pipelines, resulting in the generation of fluid collision and disturbance at the intersection. The entire process should follow the mass conservation and momentum conservation equations [
17]:
where
is the fluid density,
is the viscous shear stress of the fluid, and
is the volumetric force on the fluid. Tracer particles are injected into the natural gas pipeline by the particle injector using differential pressure and are fully mixed with the natural gas. Owing to the action of gaseous natural gas, the virtual mass force, pressure gradient force, drag force, and buoyancy force should be taken into account in the movement of tracer particles in the flow field [
18]:
where
is the grain quality,
is the acceleration of a single particle,
is the drag coefficient,
is the fluid velocity,
is the particle velocity,
is the gravitational acceleration, and
is the fictitious quality factor.
At the confluence of the flow fields, the fluid flow state is extremely unstable, and the turbulence intensity is an important parameter to characterize the microscopic pulsation characteristics of the flow field. The symbol
I is used to represent the intensity of turbulence:
When exploring the flow characteristics of the flow field in the pipeline, turbulence intensity is an important standard. When the turbulence intensity is small, the flow field tends to be stable [
19,
20,
21].
The above Equations (1)–(7) is integrated through the numerical simulation software FLUENT, and we use FLUENT to simulate the flow field of natural gas pipeline in this paper.
The principle of PIV flow measurement is that the laser emitted by a pulsed laser source is used to form a sheet light source in the measurement area through a sheet light lens. The tracer particles, which are fully mixed with natural gas, pass through the light area. The flow characteristics are captured by a CCD camera, the particle velocity vector is calculated by the built-in PIV algorithm, and the particle velocity is replaced by the flow field velocity.
In the measurement section of a DN100 natural gas pipeline, the axial change of the flow field velocity can be ignored because the axial distance is short and there is no flow stopper inside the pipeline. The radial distribution of the flow velocity is similar to that of circular straight pipe, which gradually decreases from the axial center along the radial direction. We take a certain axial section of the measuring section and calculate the flow rate through the section by method of the ring integral.
The principle of the loop integral is as follows: In the internal PIV algorithm DPIV, the calculation area (Line A) is automatically divided into equal distances, divided into several small areas, and defined as the query area. As shown in
Figure 1. The average velocity of the tracer particles in the query area is used to replace the flow velocity of the query area. We define V
N as the speed of query area N, V
N+1 as the speed of query area N + 1, R
N as the distance from query area N to the center of the pipeline, and R
N+1 as the distance from query area N + 1 to the center of the pipeline. Query area N is adjacent to query area N + 1, and R
N+1 > R
N. We define the area of a ring with an inner diameter R
N and an outer diameter R
N+1 as S
N. The product of S
N and V
N is the flow rate through the annular region. The flow through each annular area is the sum of the flow through that section.
In order to explore the influence of particle injection modes on the disturbance distance, in this study, we perform numerical calculation regarding a single pipe injection, multi-pipe injection, and L pipe injection, and compare the disturbance distance. The model is shown in
Figure 2. The diameter of the main pipe is 100 mm, and the total length of the main pipe is 5000 mm. The vertical intersection of the flow field causes backflow. In order to prevent the flow from flowing out of the control body under the action of backflow, ensure the full development of the main flow field, and increase the stability of the calculation, the filling pipe is placed 800 mm away from the inlet of the main pipe.
In the PIV flowmeter, when the diameter of the filling pipe is too large, the high pressure resistance of the pipe is affected; when the diameter is too small, the particles are blocked, resulting in particles that do not mix well with the natural gas fluid. Therefore, in this study, the diameter of the filling pipe is 6 mm.
After being pressurized by the particle emitter, the tracer particles are transported to the vertical section of the filling pipe through a hose, then enter the main flow field and fully mix with the main flow field. If the vertical pipeline length is short, the flow pattern of the injection flow field cannot be fully developed; if the vertical pipeline length is long, it wastes processing materials and impairs the connection between the hose and the vertical pipeline. After the field investigation of the natural gas large flow measuring station, the optimal vertical length was determined to be 200 mm. The horizontal pipe length (Lx) of the L-type filling is 80 mm (see
Figure 3).
The grid model draws the structural grid using ICEM, and the grid independence test shows that when the grid number of the three schemes reaches 4,933,259, the speed of the monitoring points changes only minimally with an increase in the grid number.
The numerical calculation is carried out with fluent 18.2, and the axial direction of the main pipe is x direction. The inlet is set as a mass inlet, the fluid medium is methane, the density is the ideal gas density, the operating pressure is 2 MPa, the operating temperature is 20 °C, the difference between the injection pressure and the main pressure is 0.5 MPa, the particle model is a droplet model, the particle size is 10 µm, and the mass flow is 1 × 10−20 kg/s. The particles are affected by the drag force, buoyancy force, pressure gradient force, and virtual mass force in the flow field. Since there is a large pressure gradient in the calculation, the realizable K-ε turbulence model have been used. The wall has a reflection effect on particles, and the reflection angle is 45°.
4. Discussion
In this study, the method of adding tracer particles in a PIV flowmeter was investigated by combining numerical calculations and experiments. The disturbance distance of the flow field caused by the confluence of the flow field was compared with that of single pipe injection, multi-pipe injection, and L pipe injection of tracer particles, and the relationship between disturbance distance and flow rate was obtained. At a flow rate of 600 m3/h, the disturbance distance of single pipe filling, multi-pipe filling, and L pipe filling was 10, 12 and 8 times the pipe diameter, respectively. In comparison, the disturbance distance caused by L pipe filling was the shortest, hence the L pipe filling mode was preferred during the test.
However, the relative error between the measurement results of the PIV and ultrasonic flowmeters was larger than 6% when the L tube is filled. By observing the test process and data, it was found that the non-uniform distribution of particles was the main cause of the measurement error.
The relationship between the particle distribution, flow rate, and injection pressure was studied using numerical calculations. It was found that the flow rate is inversely proportional to the particle distribution area, and the injection pressure is positively proportional to the particle distribution area.
However, the desired effect was not achieved by improving the working conditions. To this end, the structure of the L pipe was optimized. By shortening the intersection distance between the injection flow field and the main flow field, the radial velocity of the particles at the outlet of the injection pipe was increased such that the particles were fully mixed with the natural gas in the main flow field, and the measurement requirements of the PIV flowmeter were met. The optimized structure did not increase the disturbance distance of the flow field, and the peak turbulence intensity at the intersection of the flow fields decreased from 13.4% to 8%.
The optimized structure was used to measure the flow rate of 100 m3/h to 600 m3/h in six different conditions. In each condition, the maximum relative error of the PIV and ultrasonic flowmeter was about 2%, and the measurement deviation was significantly improved. However, in the natural gas large flow measurement, the manifold structure also has a certain influence on the measurement results of the PIV flowmeter. This study was based on the ideal state of natural gas flow field flow and did not consider the manifold structure on the measurement results; this will be considered in future work.