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Ins. Flow OTI
Ins. Flow OTI
Fundamental Training
Level 1 - Flow
Contents
Topics:
Slide No:
Why measure flow? 3 - 4
Flow terminology
5 - 18
Flowmeter selection 19 - 24
DP flowmeters 25 - 46
Velocity flowmeters 47 - 55
Mass flowmeters
56 - 61
Displacement meters 62
Rosemount flow products summary
Exercise 64 - 65
63
Level 1 - Flow
Safety
Uncontrolled flow rates may cause
temperature & pressure to reach dangerously high levels
turbines & other machinery to overspeed
tanks to spill
Custody Transfer
the measurement of fluid passing from a supplier to a customer
cash register of the system
example a local gas station measures how much gas being pumped into the
vehicle for billing
requires high measurement accuracy
Product Integrity
ensuring right amount of blended materials in for example processed food &
gasoline
Level 1 - Flow
Efficiency Indication
to determine efficiency of process by
measuring the amount of each input that has gone into the
product
comparing the above measurement to the amount of product
produced
Level 1 - Flow
Flow terminology
Flow Control Loop
FIC
FT
TT
Level 1 - Flow
Flow terminology
Fluid Properties
Liquids
Gases
Temperature = Density
Temperature = Density
Temperature = Density
Temperature = Density
Pressure = No change
Pressure = No change
Pressure = Density
Pressure = Density
Level 1 - Flow
Flow terminology
Fluid Properties
For Liquids,
Specific Gravity =
For Gases,
Specific Gravity =
Level 1 - Flow
Flow terminology
Fluid Properties
Absolute pressure
Absolute temperature
PV = nRT
Volume
Level 1 - Flow
Flow terminology
Fluid Properties
Viscosity
Measure of a fluids tendency to resist a shearing force, or to resist flow
A greater force is required to shear high viscosity fluids than low viscosity fluids (viscosity = shear stress/shear rate).
Viscosity normally decreases with an increase in temperature for a liquid, but increases with an increase in temperature for a gas
Area
Fluid
Thickness
Force
Fixed Plate
Level 1 - Flow
Flow terminology
Fluid Properties
10
Fluid Type
Clean Fluid
A fluid that is free from solid particles, e.g. clean water.
Dirty Fluid
A fluid containing solid particles, e.g. muddy water.
Slurry
A liquid with a suspension of fine solids, e.g. pulp and paper, or oatmeal.
Steam
Water vapour
Gas
Natural gas
Level 1 - Flow
Flow terminology
Fluid Properties
Flow Profile
11
Pipe Wall
Laminar Flow
Turbulent Flow
Transition Flow
Level 1 - Flow
Flow terminology
Fluid Properties
12
Laminar
0
4000
2000
Reynolds
Number
Turbulent
Transition
m/s
kg/m3
Rd = ( x v x D)/
Level 1 - Flow
Flow terminology
Fluid Properties
13
Example:
Flow conditions; Velocity = 0.5 m/s
density = 995.7kg/m
RD = V.d. /
Temperature = 25C
Viscosity
= 0.7 /= 1000
0.7cP kg/ms
Pipe ID = 60mm
= 42,673
i)
ii)
(a) Laminar
(b) Transitional
(c) Turbulent
Level 1 - Flow
Flow terminology
Fluid Properties
14
Pressure & Temperature changes inside process pipe determines which state
the steam is in
Saturated steam (all vapor)
Steam exactly at its saturation point (SP)
temperature & pressure at which liquid turns to vapor (as pressure increases, saturation
temperature increases)
Superheated steam
Steam when pressure drop below SP
Steam when temperature rise above SP
e.g. at 350 psia, saturation temperature for water is 222C.
Steam at 350 psia & 278C includes 56C of super heat
Level 1 - Flow
Flow terminology
Pipe Geometry & Conditions
15
Qv
Qv
=
=
Flow terminology
Pipe Geometry & Conditions
16
asymmetrical profile
caused by elbows, valves and tees
eliminated by inserting appropriate length of straight pipes
swirl
caused by pumps, compressors, or two pipe elbows in different
planes
eliminated by inserting flow conditioners
Level 1 - Flow
Flow terminology
Engineering Units
17
Std
Nml
m3/s
- Standard Cubic feet per second
- Standard Cubic feet per minute
- Standard Cubic feet per hour
- Standard Cubic feet per day
- Standard Cubic meter per hour
- Standard Cubic meter per day
- Normal Cubic meter per hour
- Normal Cubic meter per day
Flow terminology
Engineering Units
Mass Flow Rate
Metric Unit Others
lbs/sec
lbs/min
lbs/hour
lbs/day
gram/sec
grams/min
grams/hour
kg/min
kg/hour
18
kg/s
- Pounds per second
- Pounds per minute
- Pounds per hour
- Pounds per day
- grams per second
- grams per minute
- grams per hour
- kilograms per minute
- kilogram per hour
Level 1 - Flow
Flowmeter selection
Specification
19
Accuracy
% of rate
uncertainty of flow proportional to flow rate
Rate of Flow
100 gpm
50 gpm
20 gpm
% of Rate Accuracy
2% of 100 gpm
2% of 50 gpm
2% of 20 gpm
Uncertainty Range
98-102 gpm
49-51 gpm
19.6-20.4 gpm
% of full scale
uncertainty of flow remains constant
Rate of Flow
100 gpm
50 gpm
20 gpm
% of Rate Accuracy
2% of 100 gpm
2% of 50 gpm
2% of 20 gpm
Uncertainty Range
98-102 gpm
49-51 gpm
19.6-20.4 gpm
Level 1 - Flow
Flowmeter selection
Specification
20
Rangeability (Turndown)
Meter maximum
maximum flow rate that a flowmeter is capable of reading
commonly used for magnetic, vortex and Coriolis meters
Application maximum
maximum flowrate that occurs in the process flow of a
particular application
commonly used for orifice plates, flow nozzles, and venturi
tubes
Repeatability
the ability of a flowmeter to produce the same
measurement each time it measures a flow
Level 1 - Flow
Flowmeter selection
Classes of Flowmeters
21
Flow Technologies
Mass
Volumetric
Head
Coriolis Meter
Thermal Meter
Positive
Velocity
Meter Displacement
Meter
DP Flow Target
Meter
Meter
Magnetic
Vortex
Ultrasonic
Turbine
Oval
Nutating disc
Gear
Gerotor
Annubar
Orifice
Venturi
Nozzle
Elbow Taps
Level 1 - Flow
Flowmeter selection
Classes of Flowmeters
22
. Displacement Meters
measure volume flow rate Qv directly by
repeatedly trapping a sample of the fluid.
total volume = sample volume * number of samples
High pressure loss
Level 1 - Flow
Flowmeter selection
Classes of Flowmeters
23
Velocity Meters
FLOW is measured inferentially by measuring
VELOCITY through a known AREA.
With this indirect method, the flow measured is the
volume flow rate, Qv. Stated in its simplest term
QV = A * v where
A:
v:
m3/s = m2 * m/s
A reliable flow measurement is dependent upon the correct
measurement of A and v.
Level 1 - Flow
Flowmeter selection
Classes of Flowmeters
24
Mass Meters
Infer the mass flow rate via the equation;
Qm = Qv * where,
Qm:
Qv :
:
Level 1 - Flow
DP flowmeter
DP Flow Equation
25
H.P.
L.P.
QV= K
DP
Constant
Level 1 - Flow
DP flowmeter
DP Flow Equation
Pressure
Transmitter
26
Flow Controller
FIC
FT
DP volumetric
flow
Control
Valve
Primary
Element
FE
QV= K
DP
Level 1 - Flow
DP flowmeter
DP Flow Equation
27
QM= K
DP*(P/T)
Partial
Compensation
Takes care of
Density only
Mass Flow, QM
=
=
=
Level 1 - Flow
DP flowmeter
DP Flow Equation
28
Pressure
Transmitter PT
(AP)
Pressure
Transmitter
(DP)
FT
Flow Computer
FC
TT Temperature
Transmitter +
Sensor
FIC Flow
Controller
Control
Valve
Primary
FE
Element
QM= K
DP*(P/T)
Level 1 - Flow
DP flowmeter
DP Flow Equation
29
QM= N Cd E Y d2
DP*(P/T)
DP flowmeter
DP Flow Equation
30
DP*(P/T)
Cd
Actual_flow
Theoretical_flow
for Liquids:
Y1 1
Cp
Cv
=<1
Level 1 - Flow
DP flowmeter
DP Flow Equation
31
CONSTANT
102
103
LIQUIDS
104
105
RD
GASES
Level 1 - Flow
DP flowmeter
DP Flow Equation
32
0.66
( 4 Flange Taps )
Discharge Coefficient
0.65
0.64
0.63
0.62
0.61
0.6
0.59
0
4
5 10
Beta = .75
Beta = .6
Beta = .5
Beta = .4
Beta = .2
5
1 10
5
1.5 10
5
5
5
2 10
2.5 10
3 10
Pipe Reynolds Number
5
3.5 10
5
4 10
5
4.5 10
5
5 10
d/D =
Level 1 - Flow
DP flowmeter
DP Flow Equation
33
0.95
0.9
0.85
Line
Pressure
20
40
1000 psi
250 psi
100 psi
50 psi
20 psi
60
80
DP flowmeter
Components
34
Secondary -
SECONDARY
DP flowmeter
Orifice Plate
35
Level 1 - Flow
DP flowmeter
Venturi Tube
36
Cross
section
Area A1 Flow
P1 P2
Cross section
Area A2
Q (Actual) =
C x A1 x A2
( A12 - A22 )
2 x ( P1 -P2 )
Level 1 - Flow
DP flowmeter
Flow Nozzle
37
High Pressure
FLOW
D/2
Low Pressure
NOZZLE
Level 1 - Flow
DP flowmeter
Pitot Tube
38
Pf 2
Vf 1
Pf 1
V f 12
2 gc
Pf 2
Vf 1
2 gc Pf 2 Pf 1
DP flowmeter
Pitot Tube
39
Fluid Flow
DP flowmeter
Averaging Pitot Tube (Annubar)
High Pressure Tap
40
Sharp Edge
Blunt
Front
H.P.
L.P.
Blunt
Rear
Cross section
of Annubar
Fluid Flow
DP Flowmeter
Pitot Tube
41
Advantages:
Can be inserted through a small opening.
Can sample the velocity at many points.
Low pressure drop, non-obstrusive.
Disadvantages:
Pitot traverse requires a technician, and is time-consuming.
Pitot tube is fragile (not suited for industrial app.)
DP signal is low.
Accuracy depends on the velocity profile.
Easily plugged by foreign material in the fluid.
Level 1 - Flow
DP flowmeter
Wedge Flow Element
42
Level 1 - Flow
DP flowmeter
V-Cone
43
high accuracy
normally lab-calibrated
work equally well with short and long straight pipes
for customers who have limited room for straight
piping requirements
can be used with some dirty fluids
Level 1 - Flow
Head Meter
Rotameter
44
Variable-area flowmeters
float inside the tapered tube rises in response to fluid flow rate
pressure is higher at the bottom than the top of the tapered tube
float rests where the dp between upper & lower surfaces of the
float balances the weight of the float
flowrate read direct from scale or electronically
Level 1 - Flow
Head Meter
Target Meter
45
Level 1 - Flow
Head Meter
Target Meter
Advantages:
Low cost
Easily installed and/or
replaced
No moving parts
Suitable for most gases
or liquids
Available in a wide
range of sizes and
models
46
Disadvantages:
Square-root head/flow
relationship
High permanent
pressure loss
Low accuracy
Flow rage normal 4:1
Accuracy affected by
wear and/or damage of
the flow primary element
especially with corrosive
fluids.
Level 1 - Flow
Velocity Meter
Magnetic Flowmeter
47
Electrodes
Field Coils
Magnetic Field B
(Constant Strength)
Velocity Meter
Magnetic Flowmeter
Advantages:
Obstructionless flow
Unaffected by viscosity,
pressure, temperature and
density
Good accuracy
No RD constraints
Suitable for slurries and
corrosive, nonlubricating, or
abrasive liquids
Wide rangeability (30:1)
48
Disadvantages:
Liquid must be
electrically conductive
Not suitable for gases
Can be expensive,
particularly in small
sizes
Must be installed so that
the meter is always full
Level 1 - Flow
Velocity Meter
Turbine Meter
49
Pickup Probe
FLOW
Level 1 - Flow
Velocity Meter
Turbine Meter
Advantages:
High accuracy
Rangeability 10:1
Very good repeatability
Low pressure drops
Can be used on high
viscosity fluids (but with
lower turndowns)
50
Disadvantages:
Moving parts subject to wear
Can be damaged by
overspeeding
High temperature,
overspeeding, corrosion,
abrasion and pressure transient
can shorten bearing life
Rather expensive
Filtration required in dirty fluids
Level 1 - Flow
Velocity Meter
Vortex Flowmeter
51
Sensor
FLOW
Vortex
Shedder
Force
Shedder Bar
FLOW
Vortices
Level 1 - Flow
Velocity Meter
Vortex Flowmeter
Advantages:
Good accuracy
Usually wide flow range
Used with liquids, gases
and steam
Minimal maintenance (no
moving parts)
Good linearity over the
working range
52
Disadvantages:
Not suitable for abrasive or
dirty fluids
Straight upstream pipe
required equal to 30 times
pipe diameter or longer
Limited by low velocity (RD
< 10,000)
Level 1 - Flow
Velocity Meter
Ultrasonic Flowmeters
53
Receiver
FLOW
Downstream Transducer
Level 1 - Flow
Velocity Meter
54
Ultrasonic Flowmeters
uses sound waves to determine flow rates of fluids.
Level 1 - Flow
Velocity Meter
Ultrasonic Flowmeters
Advantages:
Non-intrusive,
obstructionless
Wide rangeability (10:1)
Easy to install (especially
for clamp-on version)
Cost virtually
independent of pipe size
The flow measurement is
bi-directional
55
Disadvantages:
Maximum temperature 150C
Particular fluid conditions are
required (TOF-type: clean
liquids; Doppler-type: particles
or impurities in the stream)
Not very high accuracy (about
2%)
Doppler flowmeter clamp-on
type requires a pipe of
homogeneous material
(cement or fibreglass linings
must be avoided)
Level 1 - Flow
Mass Meter
Coriolis Meter
56
Operating Principle
Level 1 - Flow
Mass Meter
Coriolis Meter
57
Coriolis Effect
Fluid flowing through the upward moving tube, pushes
downward against the tube.
Fluid flowing out through the downward moving tube,
pushes upward against the tube.
The combination of upward and downward resistive forces
causes the sensor tube to twist (coriolis effect).
Level 1 - Flow
Mass Meter
Coriolis Meter
58
Signal Transmission
The amount the tube twist is proportional to the mass flow
rate of the fluid flowing through it.
Electromagnetic sensors located at each side of the tube
measures the respective velocity of the vibrating tube at
these points.
The sensor sends this information to the transmitter which
gives an output signal directly proportional to mass flow
rate.
Level 1 - Flow
Mass Meter
Coriolis Meter
Advantages:
High accuracy: 0.25%
Relatively low pressure
drops
Suitable for liquid and
gas flow
Easy to install
Flow range (10:1)
59
Disadvantages:
Expensive
Mounting is critical (no
vibration)
Heat-tracing is required
in some applications
Level 1 - Flow
Mass Meter
Thermal Meter
60
Level 1 - Flow
Mass Meter
Thermal Meter
Advantages:
No moving parts
Suitable for large size
pipe (insertion type)
Good rangeability (50:1)
Accuracy: 1% FS
Low permanent pressure
losses
61
Disadvantages:
Meter sensitive to fluid heat
conductivity, viscosity, and
specific heat
Mostly gas service (only rare
liquid service)
Specific heat of the fluid
must be known and constant
i.e. the gas must have a
constant composition
Proper operation requires no
heat losses due to
conductive exchanges
though the pipe walls
Level 1 - Flow
Displacement flowmeter
Oval Gear Meter
62
Level 1 - Flow
63
Meter
Fluids
Dirty
Fluids
Viscosity
DP/Orifice
Liquid,Gas,steam
No
6000psig
Medium-High
MV/Orifice
Liquid,Gas,steam
No
6000psig
Medium-High
Some
Low
MV/Annubar Liquid,Gas,steam
Pipe
Size
Magmeter
Any
Vortex
Liquid,Gas,steam
Some
1400psig
Coriolis
All
Yes
Any
4000psig
200C
High*
Turbine
Liquid,Gas,steam
No
6000psig
200C
High
0.5 - 6in
1400psig
Low
175C
Very Low
Low
Level 1 - Flow
Exercise
64
Level 1 - Flow
Exercise
65
Level 1 - Flow