Flow Meters Used in Municipal Water & Wastewater Applications

Flow Meters
Used in Municipal Water &

Wastewater Applications
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
Copyright 2008 by ISA, www.isa.org

Presented at ISA EXPO 2008, 14-16 October 2008, Reliant Center, Houston, Texas
Presenter
Jeff Smith Tampa, Florida

27-Years experience in Municipal & Industrial
Instrumentation and Process Controls
National Sales Manager Primary Flow Signal, Inc. - 2007
President Alpha Valve & Controls, Inc. - 1995-2007
Technical Sales Manager Badger Meter, Inc. - 19811995

Introduction
A flowmeter is an instrument used to measure volumetric or mass flow rate

of a liquid or a gas. Q = V x A for Volumetric Flow Rate
This seminar is an introduction of the fluid flowmeter technologies used

in water production and wastewater treatment applications. The session
includes a discussion on flow meters for monitoring the water cycle
including: raw water, water treatment plant processes, potable water
distribution, wastewater collection, wastewater treatment process control,
and plant effluent.
The most common principals for municipal water/wastewater flow metering

are: Differential Pressure Flowmeters, Velocity Inferential Flowmeters,
Area x Velocity Flowmeters, and Open-Channel Flowmeters.
Flowmeters Flow
metering basics will include an introduction to Orifice Plate, Venturi, Pitot
Tubes, Electromagnetic, Ultrasonic Doppler, Ultrasonic Transit-Time,
Thermal Mass, Weirs, Flumes, Weirs, and Area x Velocity.

Introduction
The Take Home Message
Selecting the right flowmeter technology for the application.
Defending your flowmeter calibrations and validations.
Old Wives Tales, Rules of Thumb, Marketing Mumbo Jumbo vs. Good
Engineering Practice.
Keywords
Flowmeter, Flow, Flowmeter selection, water treatment, wastewater
treatment, venturi flowmeter, magnetic flowmeter, Area x Velocity, Flumes

Velocity Profile
Well Developed
Evenly distributed

Magnetic Flowmeters
50+ Manufacturers to Choose From

Magnetic Flowmeters
Magnetic Flowmeters Theory of Operation
Field Coil
Flow Tube
Electrode
Electrically
Insulated
Lining
Conductive
Fluid
B
D
Flow
V
1
Es = BVD
C
Electrode
Wires
Liner insures that the induced

voltage is not short-circuited
by the pipe wall.
Es
Faradays Law of
Electromagnetic Induction
states that a conductor moving
in a magnetic field induces an
electrical voltage.
ES= the induced electrode voltage

Power to Coils
From mains or
dedicated
source
B = the magnetic field density
Converter
C = non-dimensional constant
V = liquid velocity
D = magmeter pipe diameter

Magnetic Flowmeters
Basic Requirements
CONDUCTIVITY:
This is the 1st parameter to consider in deciding whether or not to use a magnetic flowmeter . Liquid
conductivity must be greater than the minimum required by the meter manufacturer.
Full-Pipe Flow Does the meter remain fullAll The Time?

Process Compatibility of Materials
-Wetted Material : Liner / Electrodes / Grounding Rings
-Meter Body & Flanges
Line Pressure
Location & Orientation of the Flow Tube
Integral or Remote Signal Converter (Transmitter)
Signal Output Requirements
Field In-Situ Calibration Requirements
Magnetic Flowmeter
Flow Tube Orientation/Alignment
Electrodes should be oriented so they are not at the top
and bottom of the pipe in a horizontal or sloping
installation.
Correct !
Wrong !
10
Magnetic Flowmeter
Grounding
Bonds the meter body to
the process liquid.
Meter body must be in
electrical contact with the
liquid at each of its ends.
Conductive Pipe
Grounding Straps attached
between meter flanges and earth
ground.
Non-Conductive
or Lined Pipe
Grounding Rings create a
conductive path between the
meter body and the liquid.
Rule-of Thumb
Just specify and get
Grounding Rings
11
Magnetic Flowmeter
Electrode Fouling
Meter Failure due to electrode coating
Odor Control Additives
Ferrous iron solution added at lift stations to
precipitate dissolved sulfide and aid in
phosphorous and solids removal in wastewater

12
Magnetic Flowmeter
Submergence
General Purpose
Located High-and-Dry
Accidental Submergence
IP67 Temporary Submergence to 33 ft.
for 48 hours with potted terminal box.
Rule-of-Thumb
Always spec and get
IP67 or IP68
Continuous Submergence
Under Water up to 33-Ft (10m) Depth
(IP68, NEMA 6P)
Direct Bury
3ft (1m) to 16ft (5m) depth
(to top of sensor).
13
Magnetic Flowmeter
Laboratory Calibration
Magnetic Flowmeters are hydraulically

calibrated in the manufacturers Flow Lab
Each Magnetic Flowmeter is calibrated to
determine its unique Meter Factor
Standard 3-Point Calibration
For best accuracy,
the Flow Tube and
Signal Converter are
calibrated together
as a system.

14
Magnetic Flowmeter
Field Calibration
Validation / Verification
Electronic Calibration using a

Flow Simulator

15
Magnetic Flowmeter
Field Calibrations
Using a strap-on flowmeter to
calibrate your flowmeter is like
using a sundial to set your
Atomic Clock!!!
Clock

16
Magnetic Flowmeter
Field Calibrations

17
Magnetic Flowmeters
Common Causes of Mag Meter Faults & Failures
Entrained gas in liquid
Electrode Fouling (Grease/Chemicals)
Electrode Corrosion
Electrode Short-Circuit
Low Conductivity
Non-homogeneous
Liner Damage or Delamination
External Magnetic Fields
Water Intrusion into Meter Body (Coils/Signal Cable)
Partially-Filled Pipe (Entrapped Air)
18
Differential Pressure Flowmeters
Venturi Flow Meter

Orifice Plate
Flow Nozzle
Pitot Tube
Wedge
Oldest yet still most common

method to accurately measure
the flow of liquids and gases
Although sometimes called

archaic, dP flow measurement
is still among the most
trusted, precise and
defendable flow
measurement methods
employed by engineers and
end users today

19
Venturi Flowmeters
2006 Flowmeter User Study Results

By Jesse Yoder, Ph.D.
Flow Research published Worldwide Survey of Flowmeter
Users, 2nd Edition in January 2006.
44.5%
DP Flowmeters Still Dominate Installed Base

Users were asked in the survey how many flowmeters are in
use at their location, and what percentage of the total each
flowmeter type represents. The results are shown in Figure 1.
According to this figure, differential-pressure (DP)
flowmeters represent almost 45 percent of the total
flowmeters in use at end-user plants.

20
Venturi Flowmeter
A device consisting of a
Primary Element (venturi,
wedge, nozzle or orifice)
and a Secondary Device
(dP transmitter or gauge)
Commonly used to
measure the flow rates of
liquids, gases or steam
The Differential Pressure Generated is Proportional to

the Square of the Flow

21
Venturi Flowmeter
Typical Secondary Devices
Most common secondary devices

are differential pressure (dP)
Transmitters - Gauges - Manometers
22
Venturi Flowmeters
Full-Body
Pressure Vessel
Water Distribution
WTP Influent
Accuracy
0.5% Standard
0.25% Lab Calibrated
WWTP Effluent
180-Inch WTP Water Intake

23
Venturi Flowmeters
Full-Body
Rate-of-Flow
Controller System
Rate-of-Flow Controller
Water Treatment Plant Filter Gallery
WTP Filter Gallery

Modulating Butterfly Valve
Differential Pressure Transmitter
Manometer Verification System

24
Venturi Flowmeters
Full-Body
Sealed Metering
System
48-Inch Sealed System

Wastewater Treatment Plant Influent
WTP Influent
180-Inch WTP Water Intake
Calibration Ring

25
Venturi Flowmeters
Insert Style Venturi

26
Venturi Flowmeters
Insert Style Venturi

Clean Liquids & Gases
Accuracy
0.5% Standard
0.25% Lab Calibrated

27

Orifice Plates
Liquids / Gases / Steam
Accuracy:
+/- 1.0% (Calibrated)
+/- 2% to 5% (Uncalibrated)
Note: Accuracy under

conditions in which the
velocity profile within the pipe
is highly uniform.
Pressure Loss:
50 to 70% dP

28

Averaging Pitot Tubes
Clean Liquids / Gases / Steam
Accuracy:
+/- 0.5 to 1.0% (Calibrated)
+/- 5% (Uncalibrated)
Note: Accuracy under conditions in which the velocity
profile within the pipe is highly uniform.
Pressure Loss: 5 to 12% dP

29
Ultrasonic Transit-Time Flowmeters
Theory of Operation
Limitations
Velocity Profile Effects
Calibration

30

Permanently Installed
or Fixed for long-term
flow measurement
Windowed Spool
Strap-On Transit-Time

31

Portable Strap-On
Transit-Time
Flowmeter

32
Ultrasonic Doppler
Theory of Operation
Limitations
Calibration

33
Thermal Mass Flowmeters
Theory of Operation
The Rate of Heat Absorbed
by a Flow Stream is Directly
Proportional to its Mass Flow
Limitations
Calibration
Heated RTD
Reference Temperature RTD
Temperature Difference is related
to the Process Flow Rate

34
Open-Channel Flowmeters
Theory of Operation
Structure of Known Dimensions allows Flow
Rate to be Measured as a Function of
Depth of Flow through the Structure
Head Class Flowmeters

Conduits that have a Free Fluid Surface
Flumes & Weirs
Flow rate is a function of depth of flow
through the structure
Limitations
Calibration

35
Open-Channel Flowmeters - Flumes

H-Flume
Palmer
Palmer Bowlus-Flume
Bowlus-Flume
Parshall Flume

36
Open-Channel Flowmeters - Weirs
V-Notch Weir
Rectangular Weir
Cipoletti Weir

37
Open-Channel Flowmeters
V-Notch Weir

38
Area x Velocity Flowmeters
Theory of Operation
Q = VxA
Limitations
Calibration
Portable AxV Flowmeter

39
Portable
Area x Velocity
Flowmeter

40
Radar
Area x Velocity
Flowmeter

41
Pulsed Doppler
Area x Velocity
Flowmeter
Theory of Operation
Measures the Horizontal
Distribution of the Velocity
Profile across the Channel
Velocity Profiling
Side-Channel Mounting

42
Flowmeters
Turbine
Propeller
Nutating Disk
Insertion Mag
Variable-Area (Rotameter)
Insertion Paddle
43
Flowmeters
Selection Criteria
Initial Cost: Purchase Price / Installation Cost

Ease of Installation
Maintenance Cost / Cost of Ownership / Serviceability
Accuracy / Repeatability / Rangeability
Service Life
Local Support / Factory Support
Defendability
Rules-of-Thumb
Rule #1: Dont Rely on Rules-of-Thumb
Rule #2: Apply the Best Solution First

44
Flow Meters
Used in Municipal Water &
Wastewater Applications
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits


Flow Meters Used in Municipal Water &amp; Wastewater Applications

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Flow Meters

Used in Municipal Water &

Copyright 2008 by ISA, www.isa.org

Jeff Smith Tampa, Florida

Copyright 2008 by ISA, www.isa.org

A flowmeter is an instrument used to measure volumetric or mass flow rate

This seminar is an introduction of the fluid flowmeter technologies used

The most common principals for municipal water/wastewater flow metering

Copyright 2008 by ISA, www.isa.org

Copyright 2008 by ISA, www.isa.org

Copyright 2008 by ISA, www.isa.org

Copyright 2008 by ISA, www.isa.org

Liner insures that the induced

ES= the induced electrode voltage

B = the magnetic field density

Copyright 2008 by ISA, www.isa.org

Full-Pipe Flow Does the meter remain fullAll The Time?

Copyright 2008 by ISA, www.isa.org

Magnetic Flowmeters are hydraulically

Copyright 2008 by ISA, www.isa.org

Electronic Calibration using a

Copyright 2008 by ISA, www.isa.org

Copyright 2008 by ISA, www.isa.org

Copyright 2008 by ISA, www.isa.org

Differential Pressure Flowmeters

Venturi Flow Meter

Oldest yet still most common

Although sometimes called

Copyright 2008 by ISA, www.isa.org

2006 Flowmeter User Study Results

DP Flowmeters Still Dominate Installed Base

Copyright 2008 by ISA, www.isa.org

The Differential Pressure Generated is Proportional to

Copyright 2008 by ISA, www.isa.org

Typical Secondary Devices

Most common secondary devices

180-Inch WTP Water Intake

Copyright 2008 by ISA, www.isa.org

WTP Filter Gallery

Copyright 2008 by ISA, www.isa.org

48-Inch Sealed System

Copyright 2008 by ISA, www.isa.org

Insert Style Venturi

Copyright 2008 by ISA, www.isa.org

Insert Style Venturi

Copyright 2008 by ISA, www.isa.org

Differential Pressure Flowmeters

Liquids / Gases / Steam

Note: Accuracy under

Copyright 2008 by ISA, www.isa.org

Differential Pressure Flowmeters

Pressure Loss: 5 to 12% dP

Copyright 2008 by ISA, www.isa.org

Ultrasonic Transit-Time Flowmeters

Copyright 2008 by ISA, www.isa.org

Ultrasonic Transit-Time Flowmeters

Copyright 2008 by ISA, www.isa.org

Ultrasonic Transit-Time Flowmeters

Copyright 2008 by ISA, www.isa.org

Velocity Profile Effects

Copyright 2008 by ISA, www.isa.org

Thermal Mass Flowmeters

Copyright 2008 by ISA, www.isa.org

Head Class Flowmeters

Flow Meters Used in Municipal Water & Wastewater Applications

Flow Meters Used in Municipal Water & Wastewater Applications