Sensor tube with reduced coherent vortex shedding

BACKGROUND

p-0002This invention relates generally to fluid processing and related measurements. Specifically, the invention concerns a reduced vibration sensor tube for measuring a process parameter in a fluid flow. The sensor tube is configured to reduce coherent vortex shedding and reduce flow-induced vibrations. This lowers structural demands on the sensor tube, increases sensor and sensor tube service life, and improves signal quality by reducing vibration-induced noise.

p-0003Safe, accurate, and cost-effective fluid measurements are important to a wide range of industrial and scientific processes. Many of these applications require measurements using sensor tubes such thermowells, Pitot tubes and similar structures, which are positioned directly in a process flow stream in order to communicate a process parameter to a process sensor, in order to monitor the process parameter.

p-0004Process parameters are physical variables such as temperatures and pressures, which typically characterize a process fluid. Process sensors are used to sense or measure the process parameters by generating sensor signals as functions of the parameters. Typical sensors include thermocouples, resistance-temperature detectors, pressure transducers, flow sensors, PH sensors and other sensor devices configured to sense or characterize a wide range of process fluid parameters and other process variables.

p-0005In some applications, a sensor tube and a sensor make up a standalone sensor module. In other applications, the sensor module is combined with a mounting structure and a transmitter/connection head with a controller and input/output (I/O) interface, in a configuration typically referred to as a field device. Field devices typically perform additional signal processing and monitoring functions, generate higher-order outputs for communication with process measurement and control systems. In some configurations, field devices also perform process control functions. Representative sensor modules and field devices are available from a number of commercial inventors, including, for example, Rosemount Inc. of Chanhassen, Minn., a division of Emerson Process Management.

p-0006Because thermowells, Pitot tubes, and other sensor tube structures are situated directly in the process flow, they are subject to a number of stress factors including flow-induced vibrations. Flow-induced vibrations typically arise as a result of vortex shedding and other turbulent wake field effects, which generate periodically alternating forces on the sensor tube. These forces cause the tube to oscillate back and forth or vibrate, increasing mechanical stress and reducing service life for both the sensor tube and its associated sensor. Flow-induced vibrations are particularly problematic when they occur near a natural resonant frequency, producing forced resonant oscillations that can result in catastrophic failure. Even relatively small oscillations can also be an issue, particularly when combined with other stresses such as high drag forces or static pressure gradients, or with corrosion, fatigue, or erosion of the sensor tube structure.

p-0007Previously, the problem of sensor tube vibrations was addressed by increasing the strength of the sensor tube. This approach requires thicker tube walls or specialized construction, which increases cost, expands the devices' size and weight envelope, decreases sensitivity and increases response time. There is thus a need for flow-induced vibration reduction techniques that are not limited to mechanical strengthening, and are applicable to a range of different sensor tube configurations.

SUMMARY

p-0008This invention concerns a device for placement in a process flow. The device comprises a sensor tube with a flow-modifying element. The sensor tube is configured for placement in the process flow, and the flow-modifying element is formed on the sensor tube. The flow-modifying element is shaped to reduce flow-induced vibrations of the sensor tube, by reducing coherent vortex shedding in the process flow.

BRIEF DESCRIPTION OF THE DRAWINGS

p-0009<figref idrefs="DRAWINGS">FIG. 1A</figref> is a schematic top view of a flow conduit, illustrating vortex shedding by a prior-art sensor tube.

p-0010<figref idrefs="DRAWINGS">FIG. 1B</figref> is a perspective view of a vortex shedding body in a turbulent process flow.

p-0011<figref idrefs="DRAWINGS">FIG. 2</figref> is a side view of a field device with reduced coherent vortex-shedding.

p-0012<figref idrefs="DRAWINGS">FIG. 3</figref> is a side view of a sensor tube with a vibration-reducing element.

p-0013<figref idrefs="DRAWINGS">FIG. 3A</figref> is an enlarged view showing one embodiment of the vibration-reducing element in <figref idrefs="DRAWINGS">FIG. 3</figref>.

p-0014<figref idrefs="DRAWINGS">FIG. 3B</figref> is an enlarged view showing an alternate embodiment of the vibration-reducing element in <figref idrefs="DRAWINGS">FIG. 3</figref>.

p-0015<figref idrefs="DRAWINGS">FIG. 3C</figref> is an enlarged view showing a further alternate embodiment of the vibration-reducing element in <figref idrefs="DRAWINGS">FIG. 3</figref>.

p-0016<figref idrefs="DRAWINGS">FIG. 4</figref> is a side view of a vibration-reducing field device, illustrating an alternate mounting and sensor tube configuration.

DETAILED DESCRIPTION

p-0017<figref idrefs="DRAWINGS">FIG. 1A</figref> is a schematic top view of flow conduit <b>10</b>, illustrating vortex shedding by prior-art sensor tube <b>11</b>A. In this particular example, sensor tube <b>11</b>A is a right circular cylinder (shown in cross section), which communicates a process parameter describing fluid <b>13</b> to sensor <b>12</b>.

p-0018As shown in <figref idrefs="DRAWINGS">FIG. 1A</figref>, sensor <b>12</b> is a thermocouple or resistance-temperature detector (RTD), located within sensor tube <b>11</b>A, adjacent an inside wall. In this embodiment, sensor <b>12</b> is in thermal communication with sensor tube <b>21</b>, and senses the temperature of a process fluid proximate the sensor tube by generating a sensor signal such as a voltage or a current, which is a function of the temperature as described above. In this embodiment sensor tube <b>11</b>A comprises a thermowell, which communicates or transmits the process fluid temperature to sensor <b>12</b> via thermal conduction. In other embodiments, such as Pitot tube embodiments, sensor <b>12</b> is located in a sensor housing adjacent to or external to sensor tube <b>11</b>A. In these embodiments, the sensor tube communicates or transmits the process fluid parameter to sensor <b>12</b> via pressure apertures, impulse tubing, flow tubes, or a combination of such elements.

p-0019Fluid <b>13</b> flows past sensor tube <b>11</b>A at bulk (or average) flow velocity V, creating downstream wake field <b>14</b>. For some velocities V, wake field <b>14</b> is a generalized turbulent wake field, without periodic structure. Over a wide range of flow velocities, however, sensor tube <b>11</b>A alternately sheds right-handed vortices <b>15</b>A (with counterclockwise rotation) and left-handed vortices <b>15</b>B (with clockwise rotation). When this behavior is exhibited, wake field <b>14</b> is typically known as a vortex trail or von Karman street.

p-0020Von Karman streets are a common feature of fluid flow. They are observed over many different size scales, from micro-fluidics to oceanography and global weather patterns. In the specific application of fluid processing, vortex streets are problematic because right-handed vortices <b>15</b>A and left-handed vortices <b>15</b>B carry alternating-sign momentum away from sensor tube <b>11</b>, resulting in flow-induced vibrations.

p-0021For some process conditions, the rate and strength of vortex shedding is substantially described as a function of bulk (average) flow velocity V, and the resulting sensor tube vibrations are described in terms of the first-order bending mode. In this model the sensor tube oscillates back and forth from its base, with amplitude as a function of the flow velocity. Vortex shedding is however a highly complex and nonlinear process, in which shear, turbulence and other non-uniform flow velocity components also play important roles. In more realistic approaches, moreover, higher-order oscillations must also be incorporated, as well as the effects of additional process parameters such as temperature, density and viscosity.

p-0022<figref idrefs="DRAWINGS">FIG. 1B</figref> is a perspective view of vortex-shedding body <b>11</b>B in a turbulent process flow. In this more detailed example, the axial flow velocity is a function of spanwise position y (measured perpendicularly from flow conduit <b>10</b>), and average flow velocity V is integrated across the process flow structure.

p-0023Turbulent process flow has both axial and non-axial components, however, which typically vary over a range of size and time scales. This distinguishes from the case of uniform flow, in which the velocity is axial and constant, and from shear or laminar flow, in which the velocity varies in spanwise direction y but the variation is relatively uniform, and remains axial. In turbulent flow, on the other hand, there are both axial and non-axial components, and these components vary not only in y but also in angular position.

p-0024Turbulent flow also exhibits a different spanwise profile than does laminar or shear flow. In turbulent flow the velocity rises rapidly from the conduit boundary, but peaks more gradually toward the center than in a laminar field. This makes the problem of process flow-induced vibrations significantly different from other, non-analogous applications such as car antennas, smokestacks and airplane wings, where the flow is relatively constant or is dominated by shear and other boundary effects.

p-0025In <figref idrefs="DRAWINGS">FIG. 1B</figref>, simple right circular cylinder flow tube <b>11</b>A of <figref idrefs="DRAWINGS">FIG. 1A</figref> is replaced by more generalized vortex-shedding body <b>11</b>B. Body <b>11</b>B is a representative vortex-shedding structure, illustrating various sensor tube features but not necessarily reflecting any particular design. Body <b>11</b>B is characterized by an oblong geometry with a roughly airfoil cross section. At the upper boundary of flow channel <b>10</b> (where y=0), body <b>11</b>B has width d, measured perpendicularly to y and across the axial flow direction, and length l, measured along the axial flow direction (along centerline C_L).

p-0026Body <b>11</b>B does not have a fixed cross section, but tapers in both length l and width d as a function of spanwise position y. This corresponds with a rapid increase in the average flow velocity from V₁to V₂at the outer boundary of flow conduit <b>10</b> (near y=0), and a more gradual increase to V₃and V₄toward the axis (along centerline C_L). In addition to the circular and airfoil cross sections shown in <figref idrefs="DRAWINGS">FIGS. 1A and 1B</figref>, sensor tubes also exhibit oval, oblong, rectangular, T-shaped and other geometries, in both tapered and non-tapered configurations. In the particular configuration of <figref idrefs="DRAWINGS">FIG. 1B</figref>, moreover, sensor tube/vortex-shedding body <b>11</b>B is cantilevered; that is, it is supported at only one boundary of the flow conduit (at the top in <figref idrefs="DRAWINGS">FIG. 1B</figref>, with y≈0). In other configurations, body <b>11</b>B is supported at both ends (see, e.g., <figref idrefs="DRAWINGS">FIG. 4</figref>).

p-0027The analysis of fluid flow around a vortex-shedding structure such as body <b>11</b>B typically begins with the Reynolds number (Re), a dimensionless parameter characterizing the ratio of inertial to viscous forces in the flow field. The Reynolds number is

p-0028<maths id="MATH-US-00001" num="00001"><math overflow="scroll"><mtable><mtr><mtd><mrow><mrow><mi>Re</mi><mo>=</mo><mfrac><mrow><mi>ρ</mi><mo></mo><mstyle><mspace width="0.3em" height="0.3ex" /></mstyle><mo></mo><mi>Vd</mi></mrow><mi>μ</mi></mfrac></mrow><mo>,</mo></mrow></mtd><mtd><mrow><mo>[</mo><mn>1</mn><mo>]</mo></mrow></mtd></mtr></mtable></math></maths>

p-0029where ρ is the fluid density, V is the average (or bulk) flow velocity, d is the width of the body in the flow, and μ is the absolute viscosity.

p-0030In the case of shear flow about a tapered flow tube, both V and d are functions of the perpendicular or spanwise position y. The vortex shedding frequency (f) is related to these quantities by a second dimensionless parameter known as the Strouhal number (St):

p-0031<maths id="MATH-US-00002" num="00002"><math overflow="scroll"><mtable><mtr><mtd><mrow><mi>St</mi><mo>=</mo><mrow><mfrac><mi>fd</mi><mi>V</mi></mfrac><mo>.</mo></mrow></mrow></mtd><mtd><mrow><mo>[</mo><mn>2</mn><mo>]</mo></mrow></mtd></mtr></mtable></math></maths>

p-0032Over a wide range of Reynolds numbers, vortex energy in the downstream wake field is dominated by large-scale wake instabilities, which in turn are characterized by a single, relatively constant low-frequency value for St. In this regime, EQ. 2 predicts that the vortex shedding frequency (f) is substantially linear with bulk (average axial) flow velocity V. Vortex amplitude is proportional to V², and is typically defined in units of pressure such that the amplitudes scale with forces on the shedding structure.

p-0033In the simplest approach to flow-induced vibration reduction, the shedding frequency is simply compared to the frequency of the first bending mode. The first bending mode is determined by the length and cross-sectional area of the sensor tube and the thickness and material properties of the tube wall (particularly, its Young's modulus). In this approach, flow-induced vibrations can in principle be limited by simply avoiding process configurations (i.e. flow rates) that result in coherent vortex shedding near the first bending mode frequency.

p-0034Unfortunately this model is too simplistic for actual process flow conditions, and does not reflect real-world fluid processing requirements. In particular, process measurement devices must accommodate required flow rates, not the other way around. Quantities like the Young's modulus also depend upon temperature and other process variables, which are not always subject to direct and independent control.

p-0035More to the point, in a more complete turbulent flow analysis the Strouhal number (St) is not constant, but instead exhibits an irregular stepwise behavior as a function of the ratio y/d. Thus <figref idrefs="DRAWINGS">FIG. 1A</figref> shows only one “layer” or spanwise slice of a highly complex wake field, in which detached vortices are not shed uniformly along the sensor tube but instead tend to organize into a series of cells as a function of y. Each cell exhibits a different shedding frequency and amplitude distribution (or energy spectrum), and each is capable of exciting different vibrational modes. The result is a broad-frequency vortex-shedding pattern that produces flow-induced vibrations over a wide range of flow velocities (alternatively, Reynolds and Strouhal numbers), and is not limited to a single resonant frequency but can affect almost any sensor tube geometry.

p-0036A full understanding of flow-induced vibrations thus requires a detailed analysis of turbulent process flow and sensor tube geometry, including multiple shedding frequencies, higher-order oscillation modes, and (particularly near bends or elbows in the flow conduit) the effects of swirl on the flow field. The result is a multi-dimensional parameter space characterized by a rich variety of vortex-shedding solutions and corresponding modes of oscillation, in which even sophisticated computer models may insufficiently describe the resulting flow-induced vibrations

p-0037Because the problem is complex, solutions from non-analogous fields such as aircraft wings, smokestacks and car antennas cannot simply be scaled to process flow devices. Instead, the problem must be approached from the unique perspective of each particular sensor tube configuration, and must account not only for bulk and shear flow but also higher-order components of the turbulent flow field. A full solution must also be applicable over a wide range of flow velocities, and should address the effects of other fluid parameters including density, viscosity, pressure and temperature.

p-0038<figref idrefs="DRAWINGS">FIG. 2</figref> is a side view of field device <b>20</b> with reduced coherent vortex shedding. Field device <b>20</b> comprises sensor tube <b>21</b>, vibration-reducing element <b>22</b> and sensor <b>23</b>. Sensor <b>23</b> is shown in phantom, as are the portions of vibration-reducing element <b>22</b> on the back side of sensor tube <b>21</b>. In the particular embodiment of <figref idrefs="DRAWINGS">FIG. 2</figref>, field device <b>20</b> also comprises compression fitting <b>24</b>, union <b>25</b>, seal <b>26</b>, nipple <b>27</b> and transmitter/connection head <b>28</b>.

p-0039As shown in <figref idrefs="DRAWINGS">FIG. 2</figref>, sensor <b>23</b> is a thermal sensor positioned within sensor tube <b>21</b>, adjacent tube wall <b>29</b>. In this configuration, sensor tube <b>21</b> is a thermowell, which protects sensor <b>23</b> and communicates a process parameter (a fluid temperature) to sensor <b>23</b> via conduction through tube wall <b>29</b>. In alternate embodiments sensor <b>23</b> is not located within tube wall <b>29</b>, and sensor tube <b>21</b> communicates the fluid property to sensor <b>23</b> via pressure apertures or another form of fluid connection (see, e.g., <figref idrefs="DRAWINGS">FIG. 4</figref>, below).

p-0040In general embodiments, sensor <b>23</b> represents one or more of a temperature sensor for sensing a process temperature, a pressure sensor for sensing or characterizing a process pressure, a flow sensor for sensing or characterizing a process flow rate, a PH sensor for characterizing a PH, or another sensor device for sensing another process parameter. In some of these embodiments, sensor <b>23</b> is a primary sensor and field device <b>20</b> also comprises a secondary sensor for characterizing a secondary process parameter, such as a temperature compensation sensor for characterizing a compensation temperature.

p-0041Compression fitting <b>24</b>, union <b>25</b>, seal <b>26</b>, and nipple <b>27</b> are representative of a general-purpose sensor tube/sensor probe mounting assembly and support structure, and transmitter/connection head <b>28</b> is representative of a generalized transmitter housing with generalized controller and I/O interface components. These elements vary from embodiment to embodiment, and are not present in all embodiments. A wide variety of representative configurations with these and other features are available from Rosemount Inc. and other commercial vendors.

p-0042Field device <b>20</b> monitors a process parameter associated with the process fluid proximate sensor tube <b>21</b>. Sensor tube <b>21</b> communicates the process parameter (or fluid parameter) to sensor <b>23</b> via thermal conduction, a flow connection such as a flow tube, a pressure connection such as a pressure aperture or Pitot tube aperture, or analogous means.

p-0043Process sensor <b>23</b> comprises a primary sensor element or other sensor device positioned for communication with sensor tube <b>21</b>. In some embodiments, including thermowell embodiments, sensor <b>23</b> comprises a thermal sensor, and is positioned in thermal communication with the sensor tube. In these embodiments sensor <b>23</b> is typically located inside sensor tube <b>23</b>, positioned proximate or adjacent to an inside wall of the sensor tube.

p-0044In other embodiments, including Pitot embodiments, sensor <b>23</b> is positioned for pressure or flow communication with sensor tube <b>21</b>. In these embodiments, sensor <b>23</b> comprises a Pitot sensor, and is positioned in direct communication with sensor tube <b>21</b>, via Pitot apertures or pressure apertures in the sensor tube. Alternatively, the Pitot sensor is positioned in remote communication with sensor tube <b>21</b>, by means of impulse tubing or other fluid connection to sensor tube <b>21</b>.

p-0045Sensor element <b>23</b> senses the fluid parameter in a fluid flow proximate sensor tube <b>21</b>, and generates a sensor signal such as a voltage, a current or a digital sensor signal, which is a functional representation of the parameter. In embodiments that include transmitter/connection head <b>28</b>, field device <b>20</b> also generates an output representative of the sensor signal for communication with a process control system. In some of these embodiments field device <b>20</b> also receives a process input, and performs process control functions.

p-0046Sensor tube <b>1</b> is configured for positioning in a process conduit or for other forms of placement in a process flow. When sensor tube <b>21</b> is exposed to the process flow, it is subject to flow-induced vibrations as described above. These vibrations cause mechanical stress on sensor tube <b>21</b>, sensor <b>23</b>, and other components of field device <b>20</b>. This reduces sensor and sensor tube service life, either due to the vibrations themselves, or a combination of flow-induced vibrations and high static drag forces, large differential pressures, erosion, corrosion, or fatigue. A range of potential failure modes result, from localized cracks and leaks to electrical shorts, broken wires or cracked mandrels in an RTD or other sensor, and even catastrophic failure of sensor tube <b>21</b> or sensor <b>23</b>.

p-0047Flow-modifying element <b>22</b> is shaped to reduce coherent vortex shedding by sensor tube <b>21</b>, and to reduce the resulting flow-induced vibrations. In particular, flow-modifying (or vibration-reducing) element <b>22</b> reduces coherent vortex shedding by modifying flow at the boundary layer, controlling the point of detachment in order to alter the amplitude distribution and shedding frequency of vortices in the wake field. This decreases the energy available for resonant excitation of sensor tube <b>21</b>, increasing service life and reliability for both sensor tube <b>21</b> and sensor <b>23</b>. In some embodiments, flow-modifying element <b>22</b> also expands the operational ranges of sensor tube <b>21</b> and sensor <b>23</b>, and reduces signal noise generated by sensor <b>23</b>, by reducing mechanical, thermodynamic or electronic noise effects associated with flow-induced vibrations.

p-0048Field devices with a lower level of flow-induced vibrations provide greater flexibility in the design of sensor tube <b>21</b>, particularly in applications where required response times make increased wall thickness an unacceptable solution. This facilitates efforts to reduce costs and lower the overall weight and size envelope, while increasing sensitivity and reliability.

p-0049<figref idrefs="DRAWINGS">FIG. 3</figref> is a side view of sensor tube <b>21</b> with vibration-reducing/flow-modifying element <b>22</b>. In this particular embodiment, element <b>22</b> winds around sensor tube <b>21</b> in a spiral path along tube wall <b>29</b>.

p-0050In some embodiments, the spiral path is characterized by a helical or truncated helicoid function. A helicoid is a minimal surface defined in the x-z plane as a function of spanwise position y:

p-0051<br /><i>x=r </i>cos(<i>ay</i>);  [3A]

p-0052<br /><i>z=r </i>sin(<i>ay</i>).  [3B]

p-0053The axis of the helicoid lies in they direction. The constant a determines the twist rate or “pitch” of the helicoid, as a function of rotational angle θ=ay. For a=0, for example, there is no twist and rotational angle θ is always zero. Thus z=0 everywhere, and the helicoid is just the (untwisted) x-y plane. As a varies from 0, the plane is continuously twisted (homeomorphed) into a spiral or “Archimedes screw” shape, in which a>0 describes a right-handed spiral (a structure with right-handed helicity) about the y axis and a<0 describes a left-handed spiral (a structure with left-handed helicity) about they axis.

p-0054Measuring angles in radians, the pitch (the distance between twists, per unit length along y) is p=2λ/a. If angles are measured in degrees rather than radians, the pitch is 360°/a. In some embodiments pitch p is relatively small, such that vibration-reducing element <b>22</b> winds two or more times around sensor tube <b>21</b>, as shown in <figref idrefs="DRAWINGS">FIG. 3</figref>. In other embodiments pitch p is relatively large, such that vibration-reducing element <b>22</b> winds fewer than two times. In further embodiments pitch p varies as a function of spanwise position y, winding more tightly in some regions of sensor tube <b>21</b>, and less tightly in other regions.

p-0055In various embodiments element <b>22</b> extends along substantially the entire length of sensor tube <b>21</b>, as shown in <figref idrefs="DRAWINGS">FIG. 3</figref>, or along part of the length. In these latter embodiments, element <b>22</b> typically winds around tip region <b>31</b>, which is the region most distant from the mounting structure (as represented by compression fitting <b>24</b>). In some cases, however, element <b>22</b> winds around the region near the mounting structure, or around an intermediate region.

p-0056Alternatively, element <b>22</b> comprises a number of discrete or discontinuous helical structures, such as notches, grooves, protrusions or regions of different surface finish, which are separated by regions in which the structure is absent. In these embodiments element <b>22</b> is formed as at least one set of structures, where each individual structure in the set is formed or shaped along part of a helical or spiral path, and the set of structures together defines the helical or spiral path.

p-0057In EQS. 3A and 3B, each value of r defines a helix about the z axis, and the helicoid is the union of these helices. Alternatively, the helicoid is defined as a ruled surface formed by drawing a semi-infinite line from the origin out along the x axis, then rotating the line in the x-z plane as a function of y. In this interpretation, each point on the line sweeps out a helix, and the entire line sweeps out the helicoid.

p-0058For the ideal helicoid, radius r runs from 0 (at the y axis) toward +∞, so that the helicoid extends toward ±∞ in both x and z (that is, the helicoid is unbounded). To create a physical vibration-reducing element, the helicoid is truncated at a first radius r₁, corresponding to wall <b>29</b> of sensor tube <b>21</b>, and a second radius r₂, with finite width w=|r₂−r₁|.

p-0059Because the ideal helicoid of EQS. 3A and 3B is generated as a homeomorph of the x-z plane, it is also infinitely thin. Again, this is non-physical. For actual vibration-reducing/flow-modifying elements <b>22</b>, the truncated helicoid defines only a “backbone” or template for the spiral path of the vibration-reducing structure, along which each individual element <b>22</b> is formed with a finite thickness that extends above or below the helicoid (see <figref idrefs="DRAWINGS">FIGS. 3A-3C</figref>).

p-0060For sensor tubes <b>21</b> comprising right circular cylinders, first (inner) radius r₁and second (outer) radius r₂are typically fixed as shown in <figref idrefs="DRAWINGS">FIG. 3</figref>. For tapered sensor tubes, the inner and outer radii are typically functions of spanwise position y. For sensor tubes with more general cross sections, the radii are also functions of angular position θ; that is, first radius r₁maps out the cross section of sensor tube <b>21</b> along tube wall <b>29</b>, and second radius r₂maps out the width w of vibration-reducing element <b>22</b> with respect to tube wall <b>29</b>. In further embodiments, pitch p and width w each vary independently with spanwise position y, and/or with rotational angle θ.

p-0061Under appropriate flow conditions, boundary layers along sensor tube <b>21</b> separate, and the sensor tube sheds detached vortices. When one vortex is shed at the same time that another (opposite-handed) vortex forms on the other side of the sensor tube, the vortices begin to alternate and coherent shedding results. Coherent vortex shedding generates a von Karman street or vortex trail, and results in flow-induced vibrations as described above.

p-0062Vibration-reducing/flow-modifying element <b>22</b> is formed by considering the range of process parameters that describe the flow field, and mapping the pitch, thickness and width of element <b>22</b> to the particular geometry of sensor tube <b>21</b> such that coherent vortex shedding is disrupted. In particular, element <b>22</b> controls the detachment point to prevent periodic shedding of alternating vortices on opposites sides of the sensor tube. This reduces coherent vortex shedding, and modifies the energy spectrum (amplitude distribution) and frequency spectrum of vortices in the downstream wake field. Note that flow-modifying element <b>22</b> does not necessarily reduce the total energy shed in the form of vortices, but it does reduce the total energy available for exciting oscillations of sensor tube <b>21</b>.

p-0063More specifically, flow-modifying element <b>22</b> disrupts vortex shedding by altering the boundary layer flow, encouraging separation at prescribed points determined by the geometry of sensor tube <b>21</b> and element <b>22</b>, rather than by an unmodified sensor tube structure as in previous designs. Typically, element <b>22</b> follows a spiral or helical path, as shown in <figref idrefs="DRAWINGS">FIG. 3</figref>, which further reduces coherent vortex shedding by encouraging detachment at locations that are not oppositely located on different sides of sensor tube <b>21</b>. In some embodiments, element <b>22</b> also encourages detachment at intervals that are aperiodic, or otherwise do not correspond to resonant frequencies (natural modes) of sensor tube <b>21</b>.

p-0064Because many contributions to coherent vortex shedding are non-linear (and thus not typically intuitive or scalable), the most effective vibration-reducing structures vary from embodiment to embodiment. Each different flow-modifying element <b>22</b> thus varies in pitch, width, thickness, and other geometrical features. These features cannot be predicted by or scaled from non-analogous fields that do not exhibit the same probe and conduit geometries, and do not have the same turbulent process fluid flow characteristics.

p-0065<figref idrefs="DRAWINGS">FIG. 3A</figref> is an enlarged view showing one embodiment of vibration-reducing/flow-modifying element <b>22</b>, in the region of <figref idrefs="DRAWINGS">FIG. 3</figref> indicated by arrow A,B,C. In this embodiment, element <b>22</b> is a ridge, protrusion or other raised structure that follows a spiral path to form a helix or helicoid on outside wall <b>29</b> of sensor tube <b>21</b>. Element <b>22</b> has a first radius at the sensor tube wall, and a second radius at width w from the first radius. Element <b>22</b> also has thickness t, which is defined about the idealized (thin) helicoid of EQS. 3A and 3B.

p-0066In the configuration of <figref idrefs="DRAWINGS">FIG. 3A</figref>, vibration-reducing/flow modifying element <b>22</b> has a sharp leading edge defined by thickness t less than width w (that is, t<w). In other embodiments, thickness t is comparable to width w (t≈w), or, alternatively, element <b>22</b> has a blunt leading edge defined by thickness t greater than width w (t>w).

p-0067In further embodiments, the vibration reducing element comprises a number of helical or spiral structures. In some of these embodiments, the structures have generally similar physical characteristics, as described, for example, in <figref idrefs="DRAWINGS">FIGS. 3A</figref>, <b>3</b>B and <b>3</b>C. In these embodiments, the structures are generally parallel and laterally spaced, and element <b>22</b> is characterized by an overall helicity that is either right-handed or left-handed, but not both. In other embodiments, the structures have different physical characteristics, such as different thicknesses, widths, pitches or helicities. In some of these embodiments, element <b>22</b> is characterized by both right-handed and left-handed helicities.

p-0068For embodiments in which element <b>22</b> comprises a number of different structures, the structures are sometimes discontinuous, as described above, in order to avoid physical intersections between structures or sets of structures with different physical characteristics. Specifically, for embodiments that include both right-handed and left-handed spiral structures, the structures are sometimes discontinuous at points where the right-handed and left-handed spiral paths cross.

p-0069<figref idrefs="DRAWINGS">FIG. 3B</figref> is an enlarged view showing an alternate embodiment of vibration-reducing/flow modifying element <b>22</b>, in the region of <figref idrefs="DRAWINGS">FIG. 3</figref> indicated by arrow A,B,C. In this embodiment, width w and thickness t are substantially equal (w≈t), as determined by a diameter of element <b>22</b>.

p-0070In one method of manufacturing this embodiment, element <b>22</b> is formed from a deformable cylinder or wire-shaped structure with a substantially circular cross section. This structure is spiral wound around sensor tube <b>21</b> to form helical element <b>22</b>, and attached to the sensor tube by means of welding or other mechanical technique.

p-0071The embodiment of <figref idrefs="DRAWINGS">FIG. 3B</figref> has manufacturing advantages, but does not have as sharp a leading edge as the embodiment of <figref idrefs="DRAWINGS">FIG. 3A</figref>. As a result, the wake field is more or less turbulent than in other embodiments. The advantage of reduced flow-induced vibrations is nonetheless retained, because element <b>22</b> still disrupts the process of coherent vortex shedding.

p-0072<figref idrefs="DRAWINGS">FIG. 3C</figref> is an enlarged view showing a further alternate embodiment of vibration-reducing/flow modifying element <b>22</b>, in the region of <figref idrefs="DRAWINGS">FIG. 3</figref> indicated by arrow A,B,C. In this embodiment, element <b>22</b> is formed as a spiral groove (equivalently, a trough, channel or other depression) in sensor tube <b>21</b>, which follows a spiral, helical or helicoid path along tube wall <b>29</b>. Thickness t is measured in a perpendicular direction, and width w corresponds to a depth, measured from first (outer) radius at the outer surface of tube wall <b>29</b>, and second (inner) radius at the bottom or deepest part of the groove.

p-0073The grooved embodiment of <figref idrefs="DRAWINGS">FIG. 3C</figref> is typically formed by milling or similar machining process, but can also be formed by molding or casting element <b>22</b> as a unitary structure with sensor tube <b>21</b>. The groove profile is variously arcuate or semicircular (as shown in <figref idrefs="DRAWINGS">FIG. 3C</figref>), or substantially rectangular or v-shaped, or has another form. In some of these embodiments, the groove is formed as a slot or a notch that is cut, machined, molded, or otherwise shaped into a side of sensor tube <b>21</b>, along wall <b>29</b>.

p-0074The depth of the groove in <figref idrefs="DRAWINGS">FIG. 3C</figref> is typically limited by structural considerations, including the thickness of tube wall <b>29</b>. Alternatively, the vibration-reducing element is formed by milling or machining tube wall <b>29</b> to fashion a surface finish, such as a rough surface finish, in a helical or spiral pattern, rather than actually forming a groove or other structure in the tube wall. In these embodiments, the variation in surface finish controls the detachment point by altering laminar flow rates and other flow features proximate the surface, rather than via larger-scale structures such as a helical groove or raised spiral structure (a spiral or helical protrusion).

p-0075Thus the different embodiments described here are not typically suitable to the same sensor tube geometries and process flow conditions. Each is configured for a particular sensor tube geometry, and for particular process fluid flow conditions. The results are nonetheless analogous, in that coherent vortex shedding is reduced, the frequency and energy spectra (amplitude distribution) of vortices are altered in the downfield wake, and the energy available for flow-induced vibrations is reduced.

p-0076<figref idrefs="DRAWINGS">FIG. 4</figref> is a side view of reduced coherent vortex-shedding field device <b>40</b>, illustrating an alternate mounting and sensor tube configuration. In this embodiment sensor tube <b>21</b> is an averaging Pitot tube and field device <b>40</b> comprises an averaging Pitot tube sensor assembly.

p-0077The Pitot sensor assembly comprises sensor tube/Pitot tube <b>21</b> with apertures <b>41</b> and vibration-reducing/flow-modifying element <b>22</b>. Pitot tube <b>21</b> is a representative device, encompassing averaging and non-averaging Pitot tubes and Pitot probes, and is positioned within flow conduit <b>10</b> to measure a process fluid flow in a direction that is primarily in or out of the plane of the figure.

p-0078In the particular configuration of <figref idrefs="DRAWINGS">FIG. 4</figref>, field device <b>40</b> also comprises mounting flange assembly <b>42</b>, which is connected to sensor flange <b>43</b> via studs <b>44</b> and nuts <b>45</b>, and transmitter/connection head <b>28</b>. These elements are merely representative, and vary from embodiment to embodiment as described above with respect to compression fitting <b>24</b>, union <b>25</b>, seal <b>26</b>, and nipple <b>27</b> of <figref idrefs="DRAWINGS">FIG. 2</figref>. In some embodiments, for example, opposite-end support <b>47</b> is provided to support tip region <b>46</b> of sensor tube <b>21</b> against conduit <b>10</b>. In other embodiments, sensor tube <b>21</b> exhibits a cantilevered mounting structure, which is supported only at mounting flange assembly <b>42</b>, and element <b>22</b> sufficiently reduces flow-induced vibrations to eliminate the need for opposite-side support <b>47</b>. In further embodiments the mounting structure is absent, and only sensor tube <b>21</b> and a sensor are provided.

p-0079Apertures <b>41</b> are pressure apertures or Pitot ports, which transmit a process parameter that is a pressure (or average pressure) to a primary sensor. The primary Pitot sensor (not shown) is positioned for communication with Pitot tube/sensor tube <b>21</b>. Specifically, the Pitot sensor is in pressure communication with sensor tube <b>21</b> via one or more of apertures <b>41</b>. In some embodiments the Pitot sensor is positioned adjacent sensor tube <b>21</b>, and in other embodiments the Pitot sensor is positioned remotely, and communicates with sensor tube <b>21</b> via impulse tubing or other means, as described above.

p-0080In general, vibration-reducing/flow-modifying element <b>22</b> is configurable to the particular geometry of sensor tube <b>21</b>, such that coherent vortex shedding is disrupted and flow-induced vibrations are reduced. The thermowell embodiment of <figref idrefs="DRAWINGS">FIG. 2</figref> and the Pitot tube embodiment of <figref idrefs="DRAWINGS">FIG. 4</figref> are illustrative of a wide range of such geometries, including right circular cylinders and geometries with oval, oblong, wedge-shaped, airfoil-shaped or T-shaped cross sections, and both tapered and non-tapered configurations.

p-0081<figref idrefs="DRAWINGS">FIGS. 2-4</figref> are similarly representative of a wide range of sensor tube and vibration-reducing element configurations. In particular, some sensor tubes <b>21</b> are closed to fluid flow, particularly in thermowell embodiments, and some sensor tubes are open to fluid flow, particularly in Pitot tube embodiments.

p-0082Closed-flow geometries are typically sealed, while open-flow geometries variously exhibit apertures <b>41</b> along the span, as shown in <figref idrefs="DRAWINGS">FIG. 4</figref>, at tip region <b>46</b>, or both. Apertures <b>41</b> exhibit a number of forms, including slots, as shown in <figref idrefs="DRAWINGS">FIG. 4</figref>, circular apertures, oval apertures and other geometries. The particular configuration depends, for example, upon whether the sensor tube in question is a Pitot tube or an averaging Pitot tube, or another, more generalized sensor tube for a flow meter, integrated flow controller, PH sensor, or another general-purpose fluid processing measurement and control device.

p-0083Although the present invention has been described with reference to preferred embodiments, the terminology used is for the purposes of description, not limitation. Workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.