Abstract
A non-invasive thermal energy flow rate sensor based on a combination of transient heat flux and temperature measurements has been developed. A heat flux sensor and a thin-film thermocouple are covered by a thin-film electric heater and clamped onto the outer surface of a pipe. A one-dimensional transient thermal model is applied before and during activation of the external heater to provide estimates of the fluid heat transfer coefficient and thermal resistance. A parameter estimation code is used to estimate the unknown parameters by using the minimum root mean square error between the analytical and experimental sensor temperature values. The sensor was tested with two different fluids (water and diesel oil) and with two different pipe diameters (d=25.4mm and d=12.7mm). Experiments were completed over a range of Reynolds number from 2000 to 25,000 and a range of fluid temperature from 20 °C to 50 °C. Correlations for the fluid temperature and the fluid velocity were within ±0.13 K and ±5% of the direct measurements. The resulting non-invasive thermal energy flow rate sensor can be used to estimate a fluid velocity and a fluid temperature in heating and cooling pipe applications.