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What is Flow
The motion characteristic of fluids (liquids or gases) Tyes of Flow:
Laminar Flow Turbulant Flow
(RD < 2000) (RD > 4000)
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Flow Basics
Reynolds Number
V = Velocity D = Pipe Dia. = Viscosity = Density RD < 2000 is Laminar Flow > 4000 is Turbulent Flow
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Flow Depends on
Velocity of Fluid Friction of Fluid in contact with the pipe
Viscosity of fluid
Density of fluid ( In-turn Temperature for Fluid and Temperature & Pressure of the Gas)
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Operating data such as flow rate, pressure, temperature, density and viscosity. Application aspects, such as continuous/batch operation, pulsating flow, unidirectional or bi-directional flow, backflow risk, mechanical integrity, vibration and hydraulic noise.
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data regarding the operating environment of the instrument. This should include the following aspects: Accessibility and physical location in relation to equipment and piping.
3 ) Collect
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Mechanical integrity. Electrical safety and EMC requirements. Health, safety and environmental conditions.
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Requirements of the plant organisation regarding maintenance, data collection and retrieval, selfdiagnostic and documenting features, expertise and training etc.
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Authority requirements: Instruments, instrument systems and components for installation in certain areas, equivalent local regulations and certification requirements may apply.
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Orifice Plate
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Types of tapping
Flange tapping Corner tapping Vena contracta tapping Pipe tapping
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Orifices
General Technical Specifications : Design Pressure: For plates it is limited by readout device and pipe design only.
Design Temperature: Function of associated readout system, only when the differential pressure unit must operate at the elevated temperature. For integral orifice transmitter the standard range is -29 to 121 C.
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Materials of Const : There is no limitation on plate materials. Integral orifice transmitter wetted parts can be obtained in steel, stainless steel, Monel, nickel and Hastelloy.
Accuracy : 0.25 to 0.5% of actual flow. When a conventional d/p cell is used to detect the orifice differential, that will add a 0.1 to 0.3% of full scale error. The error contribution of smart d/p cells is only 0.1% of actual span. Rangeability 10:1
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Flange Tap
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Corner Tap
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Each orifice plate shall be provided with a tab that is clearly visible in the final installed position. Differential pressure transmitters for gas services should be mounted such that they are self draining
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Design Pressure ratings: Usually limited only by the readout evice or by pipe pressure Design Temperature Limited only by a readout device, if operation is at very low or high temperature.
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(1500 mm)
Fluids: Liquids, gases, and steam
Flow Range: Limited only by minimum and maximum beta (b) ratio and available pipe size range
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The point velocity of approach (VP) can be calculated by taking the square root of the difference between the total pressure (PT) and the static pressure (P) and multiplying that by the C/D ratio, where C is a dimensional constant and D is density: VP = C(PT - P)H /D
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Pitot Tube
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Pitot Tube
Pitot tubes utilize the principles captured in Bernoulli.s equation, to measure flow. Most pitot tubes actually consist of two tubes. One, the low pressure tube measures the static pressure in the pipe. The second, the high pressure tube is inserted in the pipe in such a way that the flowing fluid is stopped in the tube. The pressure in the high-pressure tube will be the static
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Disadvantage
The pressure differential is usually small and hard to measure. The differing flow velocities across the pipe make the accuracy dependent on the flow profile of the fluid and the position of the pitot in the pipe.
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Annubar
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Annubar
An annubar is very similar to a pitot tube. The difference is that there is more than one hole into the pressure measuring chambers. The pressure in the high-pressure chamber represents an average of the velocity across the pipe. Annubars are more accurate than pitots as they are not as positionsensitive or as sensitive to the velocity profile of the fluid.
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Problems
Erosion Particulate, suspended solids or debris in the piping will not only plug up the sensing lines, it will erode the sensing device. The orifice, by its design with a thin, sharp edge is most affected, but the flow nozzle and even venturi can also be damaged. As the material wears away, the differential pressure between the high and low sides of the sensor will drop and the flow readingwill decrease.
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Problems
Over ranging Damage to the D/P Cell pressures are usually much greater than the differential pressure and three valve manifolds must becorrectly used.
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Vapour Formation in the Throat D/P flow sensors operate on the relation between velocity and pressure. As gas requires less pressure to compress, there is a greater pressure differential across the D/P cell when the gas expands on the LP side of the sensor. The flow sensor will indicate a higher flow rate than there actually is. The turbulence created at the LP side of the sensor will also make the readingsomewhat unstable. A small amount of gas or vapour will make a large difference in the indicated flow rate.
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Problems
The opposite can occur if the vapour forms in the HP side of the sensor due to cavitation or gas pockets when the fluid approaches the boiling point. In such an instance there will be a fluctuating pressure drop across the D/P cell that will give an erroneously low (or even negative) D/P reading
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Problems
Plugged or Leaking Sensing Lines The instrument error will depend on where the plug/leak is: On the HP side a plugged or leaking sensing line will cause a lower reading. The reading will become irrational if the LP pressure equals or exceeds the HP sensing pressure. On the LP side a plugged or leaking sensing line will cause a higher reading.
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Vortex
Gas, steam, clean liquids 0.5 to 12 in. (13 to 300 mm), also probes Liquids 1 to 33 ft/s (0.3 to 10 m/s)
Under Re of 8000 to 10,000, meters do not function at all; for best performance Re should exceed 20,000 in sizes under 4 in. (100 mm) and exceed 40,000 in sizes above 4 in.
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Rangeability:
Accuracy:
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Consist of multi-bladed rotor assembly suspended in fluid stream on free running bearing. Fluid impinging on rotor blade causes rotor to revolve Angular speed of rotation is directly proportional to volumetric flow rate Speed of rotation is monitored by magnetic pick-up
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Operating Temp.: -50 to 150C in standard and -200 to 450C in extended pickup designs.
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Accuracy: for
units. Rangeability: line-size viscosity. 7-Jan-13
Linearity is 0.25% of actual flow turbine meters larger than in. and 0.5% for smaller 10 : 1 unless limited by use of units or high process fluid
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Faradays Law: When a current carrying conductor is placed in a magnetic field, an emf (E) is induced in it. E = kBDV
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Design Temperature:
MOC Liners:
Electrodes:
Type of flow detected: Volumetric flow of conductive liquids, including slurries of corrosive or abrasive materials. Rangeability:
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30:1
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Velocity Ranges: 0 - 0.1 to 0 - 10 m/s Accuracy: 1% of full scale for AC excitation. 1% of actual flow for 10:1 range and 0.5% of actual flow for 2:1 or 5:1 range.
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Application Criteria
1) Conductivity of the liquid. 2) Effect of liquid operating temperature upon the threshold conductivity of the liquid.
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Avoid installation of electromagnetic flow meters close to large conducting surfaces such as metal supports. These large metal objects will interfere with the magnetic field of the flow meter and hence influence its accuracy and behaviour Liner material should be properly selected based on Service
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Electromagnetic flow meters shall be used for dirty and greasy fluids, untreated sewage and fluids containing solids where orifice plates cannot be used.
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Since most hydrocarbons have a very low conductivity, electromagnetic flow meters are mainly used in utility services and chemical plants.
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Advantage
Not affected by Physical Properties such as Pressure , temperature etc . No moving parts Short straight run requirement
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Limitations
Only Conductive liquids can be measured Limitation for use in high Temperature & pressure
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Positive displacement meters split the flow of liquid into separate known volumes based on physical dimension of meter & count them.
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Design Pressure: Up to 1500 PSIG (103.42 Bars) Design Temperature: MOC: Service: Range: 204 C
Bronze , Cast Iron , Aluminium , Steel , SS , Hastelloy , Monel. Clean liquid 0.01 GPM to 20000 GPM
Accuracy:
Rangeability:
0.1% to 2% of Flow
15:1
Advantage
High Accuracy
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Limitation
Sensitive to over-load Pressure Loss Pipe Blockage in case of Mechanical Failure
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Measures flow by measuring the time taken for ultrasonic energy to traverse a pipe section, both with & against the flow of liquid with in pipe.
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Ultrasonic energy is projected at angle trough pipe wall into liquid. Part of energy is reflected by bubbles or particles in liquid & returned to receiving crystal. Since reflectors are traveling at fluid velocity, the frequency of the reflected wave is shifted 68 according to Doppler principle.
B)
Reflection -Doppler frequency shift or multipulse time shift. (Note : A and B can be either wetted or clamp-on. Type A is more often wetted; type B is more often clamp-on. Clamp-on designs cannot be as easily used on concrete or lined metal pipe as on ordinary metal pipe.
Applications: A) Clean liquids with little or no solids or bubbles; gases. B) Slurries with solids (0.2 to 60% concentration, depending upon particle size), liquids that are aerated or contain bubbles, gases with sound reflecting particles; single phase turbulent clean liquid.
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Construction Materials:
Sizes:
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Ultrasonic flow meters shall be considered for use on large lines ( 18) and for large turn downs and where pressure drop is not permitted Only ultrasonic flow meters based on the time-of-flight method shall be used. Meters based on the Doppler principle are less accurate and is not advisable .
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Care shall be taken if an ultrasonic flow meter and a low noise control valve are installed in the same pipe. Certain high frequencies produced by a low noise control valve may interfere with the measuring signals of the ultrasonic flow meter. A special silencer may have to be installed between the meter and this type of control valve.
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Advantages
Can be used for very large diameters No pressure Loss Not dependent on Physical Properties
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Limitations
Average accuracy Dependent on flow-profile
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When fluid enters metering tube, the buoyant effect of the fluid lightens the float But it has greater density than the fluid & buoyant effect is sufficient to raise it. As there is small annular opening between float & metering tube, pressure drop across the float increases & raises the float to increase annular area. Float raises till upward hydraulic forces are balance by weight less the buoyant forces.
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Packing: The generally available elastomers are used and O-rings of commercially available materials; Teflon is also available.
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Sensor tube is driven by magnetic coil & it vibrates similar to tuning fork. Fluid flowing inside the tube pushes down the tube & fluid flowing outside tube pushes tube up words. This twisting characteristics is called Coriolis effect. As per Newton's second law of angular motion, amount of sensor twist is proportional to mass flow
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OPERATING PRINCIPLE
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Pressure Drop:
design
Operating Temp.: 73 to 204 C typical standard; 0 - 426 C high temperature MOC: Accuracy: Repeatability: Rangeability: SS, Hastelloy, Ti; 0.15 to 0.5% of rate 0.05 to 0.2% of rate 10:1 calibration range (typical)
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Advantages
1. The operation of the flowmeter is independent of Reynolds number, therefore, extremely viscous fluids can also be measured. 2. Coriolis flowmeters provide a direct mass flow measurement without the addition of external measurement instruments. 3. Coriolis flowmeters have outstanding accuracy. The base accuracy is usually on the order of 0.2%. In addition, the flowmeters are extremely linear over their entire flow range. 4. The rangeability of the flowmeters is usually on the order of 20:1 or greater. Coriolis flowmeters have been successfully applied at flow rates 100 times lower than their rated full scale flow rate.
5. A Coriolis flowmeter is capable of measuring mass flow rate, volumetric flow rate, fluid density and temperature - all from one instrument.
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Advantages
6. The operation of the flowmeter is independent of flow characteristics such as turbulence and flow profile. Therefore upstream and downstream straight run requirements and flow conditioning are not necessary. They can also be used in installations that have pulsating flow. 7. Coriolis flowmeters do not have internal obstructions which can be damaged or plugged by slurries or other type of particulate matter in the flow stream. Entrained gas or slugs of gas in the liquid will not damage the flowmeter. There are no moving parts which will wear out and require replacement. These design features reduce the need for routine maintenance. 8. The flowmeter can be configured to measure flow in either the forward or the reverse direction. In reverse flow there will still be a time or phase difference between the flow detector signals, but the relative difference between the two detector signals will be reversed.
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Limitations
1. Coriolis flowmeters are not available for large pipelines. The largest Coriolis flowmeter that is currently available has a maximum flow rating of 25,000 lb/min. (11,340 kg/min.) and is equipped with 6 inch (15 cms) flanges. When larger flow rates must be measured, two or more flowmeters mounted in parallel are required. Some flowmeter designs require extremely high fluid velocities in order to achieve a significant amount of time or phase difference between the flow detector signals. This can result is extremely high pressure drops across the flowmeter. Coriolis flowmeters are expensive. However, the cost of a Coriolis flowmeter is often comparable to (or below) the cost of a volumetric meter plus a densitometer used together to determine the mass flow rate. Coriolis flowmeters have difficulty measuring the flow rate of low pressure gas. Applications with pressure less than 150 psig. are marginal with the flowmeter designs that are currently available. Low pressure gases have low density and their mass flow rate is usually very low. In order to generate enough mass flow rate to provide sufficient Coriolis force to be measured, the gas velocity must be extremely high. This in turn may lead to prohibitively high pressure drops across the meter.
2.
3.
4.
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As Coriolis mass flow meters have no moving parts and in general do not require accessories like strainers, gas eliminators or flow straighteners, they should be used in preference to positive displacement meters and turbine meters.
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Heat is added to fluid stream with electric immersion heater. Power to heater equals heat transferred to fluid (Q) & is measured by wattm T1, T2 are thermocouple or RTD. Since we know measuring fluid we know Cp. By measuring T1, T2 & Q we can calculate flow rate-W. 88
Operating Principle
Inside the flow meter sensor head, a heated resistance thermometer (RTD) is electronically compared with an unheated RTD sensor. As a gas passes the heated RTD, heat is transferred from this sensor to the gas,and hence the RTD is cooled, thereby reducing the temperature difference between the two sensors. Heat transfer from the RTD to the process gas depends on the composition of the gas, hence the temperature difference between the two RTDs is a function of themass flow rate of the gas
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Application :
The thermal conductivity and the specific heat of the process fluid must be constant. These types of flowmeters are best suited for measurement of homogeneous gases and are not recommended for applications where the process fluid composition or moisture content are variable.
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Design Temperature :
Design Pressure
A)
B)
Pressure Drop
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Process Fluids
Flow Range
Accuracy
1% to 2% of full scale.
Rangeability MOC
: :
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ORIFICE FLOW NOZZLE PITOT TUBE VARIABLE AREA METER TURBINE VORTEX EMF
Clean liquids, gas, vapor Clean,dirty liquids Clean liquids, Gas, Steam Clean,dirty viscous liquids Clean, viscous liquids Clean,dirty liquids, Gas, steam Clean,dirty,viscous conductive liquids & slurries Clean, viscous liquids Clean,dirty,viscous liquids & slurries
4 to 1 4 to 1 4 to1 10 to 1 10 to 1 40 to 1 30 to 1
+/- 0.5 to 2 of FS +/- 1 to 2 of FS +/- 3 to 5 of FS +/- 1 to 10 of FS +/- 0. 25 of rate +/- 1 of rate +/- 0.5 % of rate +/- 1 to 3 of FS +/- 0.4 % of rate
ULTRASONIC MASSFLOW
10 to 1 10 to 1
None Low
15/5 None
None None
High High
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THANK YOU
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