Non-Invasive Fuel Flow Meter
ORLEN Unipetrol RPA s.r.o.
Assignment and problem
ORLEN Unipetrol RPA commissioned a feasibility study for a specialised device to monitor fuel flow on railway tank wagons without modifying the tank. The demanding brief required almost six months of development and testing. The design also had to account for European standards and regulatory requirements for equipment intended for potentially explosive atmospheres.
Our solution
We examined several measurement approaches and designed custom electronics for an ultrasonic time-of-flight (TOF) method. We built a model of the tank outlet and an experimental measurement setup. Tests with water involved recording and analysing signals, comparing data processing methods and distinguishing flowing from stationary liquid. The study also covered data acquisition, wireless communication and integration with the customer's server.
Impact
The customer received evidence for the next development decision, including measurement results and technical requirements. Model tests showed a detectable difference between stationary and flowing water. They also revealed the influence of turbulence, so the study recommended further validation using actual fuels. The outcome was an assessment of the measurement principle and a defined path towards a device for use on tank wagons.
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