Training - Flow
Training - Flow
Training - Flow
Flow
Level 1 - Flow
Contents
Topics: Why measure flow? Flow terminology Flowmeter selection DP flowmeters Velocity flowmeters Mass flowmeters Displacement meters Flow products summary Exercise Slide No: 3-4 5 - 18 19 - 24 25 - 46 47 - 55 56 - 61 62 63 64 - 65
Level 1 - Flow
Flow
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
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Level 1 - Flow
Flow
FT
TT
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Flow terminology
Fluid Properties
6
Density: (rho) = m/V = mass/volume Mass per unit volume at given operating conditions. Common units: kg/m3 or lb/ft3 Density of a liquid varies with temperature Density of a gas varies with temperature and pressure
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Flow
Level 1 - Flow
Flow terminology
Fluid Properties Gas Compressibility Factor: Z-factor Used to correct gas equations for real-gas effects. Accounts for the deviation from the ideal situation.
Absolute pressure Absolute temperature
8
PV = nRT
Volume Universal gas constant Molecular weight
For an ideal gas Z=1 and PV=nRT(Ideal Gas Law). The True Gas Law: PV=ZnRT Z & n Can be found in engineering tables. R is dependant on units chosen for P, T & V
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Flow
Force
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
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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
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Flow
11
Pipe Wall
Turbulent Flow
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Flow terminology
Fluid Properties Reynolds number defines the state of fluid flow Dimensionless number Indicates flow profile
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Laminar 0
Turbulent
m/s
kg/m3
Reynolds Number
Rd = ( x v x D)/
Flow
= =
i) ii)
Find the Reynolds number for the fluid. Identify the type of flow.
(a) (b) (c) Laminar Transitional 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
Flow
Qv
Qv
=
=
Flow terminology
Pipe Geometry & Conditions
16
Flow Profile Disturbance factors that cause flow profile to become irregular symmetrical profile
caused by reducers or expanders pipe sections eliminated by inserting appropriate length of straight pipes
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
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
Std Nml
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
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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
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Flow
Flowmeter selection
Specification Rangeability (Turndown) Meter maximum maximum flow rate that a flowmeter is capable of reading
commonly used for magnetic, vortex and Coriolis meters
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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
Flow
Flow Technologies
Mass
Coriolis Meter Thermal Meter
Volumetric
Positive Velocity Meter Displacement Meter Oval Nutating disc Gear Gerotor
Head
DP Flow Target Meter Meter
Flowmeter selection
Classes of Flowmeters
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. 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
Head Meters (DP Flow Meters) measures fluid flow indirectly by creating & measuring a differential pressure by means of a restriction to the fluid flow
Level 1 - Flow
Flow
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: cross-sectional area of the pipe fluid velocity
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 Mass Meters Infer the mass flow rate via the equation; Qm = Qv * where,
Q m: Qv : : the mass flow rate the volume flow rate fluid density
24
kg/s = m3/s * kg.m3 Consist of 2 devices; One device will measure fluid velocity The other device will measure fluid density
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Flow
H.P.
L.P.
QV= K
DP
Constant
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DP flowmeter
DP Flow Equation
Pressure Transmitter
FT
26
Flow Controller
FIC
Primary Element
FE
QV= K
DP
Outputs represent true flow only under specified conditions. Using constants in flow equations assumes a static flow environment. For DP flowmeter output to represent true flow, the following fluid properties must be constant: Fluid density Fluid viscosity,
Level 1 - Flow
Flow
QM= K
DP*(P/T)
Takes care of Density only
Partial Compensation
Mass Flow, QM
= = =
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DP flowmeter
DP Flow Equation Traditionally way of partially compensated DP mass flow has been accomplished using a system.
Pressure Transmitter (DP) FT Flow Computer FC FIC Flow Controller Control Valve
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QM= K
DP*(P/T)
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Flow
Cd
Actual_flow Theoretical_flow
Equations for calculating Cd are derived from experimental data. Cd is a function of beta ratio and Reynolds number, and is different for each primary element. (Beta ratio = restriction diam. / pipe diam.)
Y1 1
Cp Cv
=<1
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DP flowmeter
DP Flow Equation Discharge Coefficient vs. RD Cd
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RD
LIQUIDS
Flow
31
( 4 Flange Taps )
Beta Values are almost constant
Discharge Coefficient
0.6 0.59 0
4 5 10
5 1 10
5 1.5 10
5 3.5 10
5 4 10
5 4.5 10
5 5 10
DP flowmeter
DP Flow Equation Gas Expansion Factor vs. DP
1 Gas Expansion Factor Gas Expansion Factors 32
0.95
0.9
The higher the line pressure, the more constant Gas Expansion Factor for a variety of DP
0 20 40 60 80 100 120 140 160 180 200 220 240 260 Differential Pressure (inH2O)
0.85
Line Pressure
Flow
placed in the pipe to restrict the flow. Orifice, Venturi, nozzle, Pitot-static tube, elbow, and wedge. measures the differential pressure.
Using well-established conversion coefficients which depends on the type of head meter used and the diameter of the pipe, a measurement of the differential pressure may be translated into a volume rate. PRIMARY
Level 1 - Flow
Secondary -
SECONDARY
DP flowmeter
Orifice Plate
34
Simplest and least expensive. Constrict fluid flow to produce diff. pressure across the plate. Produce high pressure upstream and low pressure downstream. Flow proportional to square of the flow velocity. Greater overall pressure loss compared to other primary devices. Cost does not increase significantly with pipe size (advantage).
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Flow
Gradually narrows the diameter of pipe. Resultant drop in pressure is measured. Pressure recovers at the expanding section of the meter. For low pressure drop and high accuracy reading applications Widely used in large diameter pipes.
High Pressure Side
P1 P2
Q (Actual) =
C x A1 x A 2 x ( A12 - A22 )
2 x ( P1 -P2 )
Level 1 - Flow
DP flowmeter
Flow Nozzle
High velocity flow meter. Elliptical restriction of flow at nozzle opening. No outlet area for pressure recovery. For application where turbulence is high (Re > 50000) eg.,stream flow at high temperatures. Pressure drop falls betw. That of venturi tube and orifice plate (30-95%)
D D/2 36
High Pressure
Low Pressure
FLOW
D d
NOZZLE
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Flow
Pf 2
Pf 1
V f 12 2 gc
Pf 2
Vf 1 =
2 gc Pf 2 Pf 1
DP flowmeter
Pitot Tube
High (Impact) Pressure Tap Low (Static) Pressure Tap
38
Fluid Flow
One-point velocity measurement accuracy affected by changes in velocity profile tube must be moved back & forth in the flow stream for average measurement
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Flow
Blunt Rear
Fluid Flow
Include several measurement ports over the entire diameter of the pipeline more accurate flow measurement than the regular pitot tube
Level 1 - Flow
DP Flowmeter
Pitot Tube 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 timeconsuming. 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.
40
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Flow
Level 1 - Flow
DP flowmeter
V-Cone
42
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
Flow
Level 1 - Flow
Head Meter
Target Meter
44
A disc is centered in the pipe with surface positioned at right angle to the fluid flow. Force of the fluid acting against the target directly measures the fluid flow rate. Requires no external connections, seals or purge systems. Useful for dirty or corrosive fluids.
Level 1 - Flow
Flow
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
Faradays Law of electromagnetic Conductive induction. Process A voltage will be induced in a Medium conductor moving through a Lining magnetic field. Sensing E = kBDV
46
D
D
Electrodes
Field Coils
As the conductive process liquid moves through the field with average velocity V, the electrodes sense the induced voltage.
Level 1 - Flow
Flow
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
Consist of multi-blade rotors supported by bearings and enclosed in a pipe section. perpendicular to fluid flow. Fluid flow drives the rotor. Rotor Blades Rotor velocity is proportional to overall volume flow rate. Magnetic lines of flux created by a magnetic coil outside the meter.
48
Pickup Probe
FLOW
An alternating voltage is produced as each blades cuts the magnetic lines of flux. Each pulse represents a discrete volume of liquid.
Level 1 - Flow
Flow
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 von karman effect (vortex shedding)
As fluid pass a bluff body, it Sensor Force on separates and generates Sensor small eddies/vortices that are shed alternately along and FLOW behind each side of the bluff Vortex Pivoting body. Shedder Axis Force This vortices cause areas of fluctuating pressure that are Shedder Bar detected by a sensor. The frequency of vortex Shedder Bar generation is directly proportional to fluid velocity. FLOW
50
Vortices
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Flow
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)
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Velocity Meter
Ultrasonic Flowmeters uses sound waves to determine flow rates of fluids.
Transit-Time Method 2 piezoelectric transducers mounted opposing, to focus sound waves between them at 45 angle to the direction of flow within a pipe. In a simultaneous measurement in the opposite direction to fluid flow, a value (determined electronically) is linearly proportional to the flow rate.
Transmitter Upstream Transducer Receiver 52
FLOW
Downstream Transducer
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Flow
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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
54
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
Flow
Level 1 - Flow
Mass Meter
Coriolis Meter 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).
56
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Flow
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)
58
Disadvantages: Expensive Mounting is critical (no vibration) Heat-tracing is required in some applications
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Flow
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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
60
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
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Flow
Level 1 - Flow
Flow products
Summary Table
Meter Fluids Dirty Fluids No No Some Viscosity Pipe Size Maximum Maximum Pressure Pressure Temp. Loss 6000psig 6000psig Medium-High Medium-High Low 175C Very Low Low 200C 200C High* High 62
DP/Orifice MV/Orifice
Liquid,Gas,steam Liquid,Gas,steam
Level 1 - Flow
Flow
Exercise
1. Which of the following would generally provide the best turndown ? (A) DP - Orifice Plate (C) Magnetic Flowmeter (B) V.A.Meter (D) Turbine Meter
Which of the following directly measures mass flow rate, and which volume flow rate. Indicate M or V 2. Magnetic Flowmeter [ ] 3. Vortex Meter [ ] 4. Coriolis Meter [ ] 5. Non-compensated DP Flowmeter [ ] 6. Fully-compensated DP Flowmeter [ ]
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Level 1 - Flow
Exercise
7. The following flowmeters all create some pressure loss. Number them in order, beginning with that which create the least loss. (A) Venturi tube [ ] (B) Positive displacement meter [ ] (C) Magnetic flowmeter [ ] (D) Vortex Meter [ ] (E) Annubar [ ] (F) Orifice plate [ ]
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Level 1 - Flow