Ultrasonic Flow Metering Insertion & Clamp-on Types

Transcription

Ultrasonic Flow MeteringInsertion & Clamp-on Types(emphasis on Clamp-on UFM’s)Presenter : Izzy RiveraFlexim Americas Corporation

A Brief History – Significant Milestones 1955 – Doppler ultrasonic techniques were firstimplemented to detect valve heart motions 1963 – Tokyo Keiki first introduced Doppler Ultrasonicmeters to commercial markets 1970’s saw the release of more Doppler meters onto themarket, accelerating the pace of research in theindustrial field 1972 – Controlotron develops first clamp-on transit timemeters 1976 – Westinghouse LEFM; chordal transit time metersinstalled on Alaska Pipeline 1998 – AGA9 standard published for custody transfer ofnatural gas

Early Wetted UFM MeterInstalled 1976 – TransAlaska Pipeline

Early Clamp-on UFM MeterDopplerTransit-Time

UFM Market GrowthAccording to Flow Research the Ultrasonic flowmeter market is the fastest growingof any other flowmeter typePublished by Flow Control – Flow Research Study

Market Share – Wetted versus Clamp-on90%80%70%60%50%40%30%20%10%0%UFM WettedClamp-onLIQUID% in Units sold 2012 – Izzy’s best guessUFM WettedUFM GasGAS

Flexim 2011 Market Segments

UFM Transit Time StandardsLiquid Flow ASME MFC 5M - 1985 (general purpose) API 5.8 – 2005 (custody transfer, hydrocarbon liquids) OIML R117 (hydrocarbon liquids) ISO 12242 – 2012 (general purpose)Gas Flow AGA-9 1989 (custody transfer gas) ISO 17089-1 (custody transfer gas) ISO 17089-2 (clamp on gas allocation)

Attributes of Ultrasonic Flowmeters Bi-directional flow measurement Unlimited turndown Very good low flow sensitivity Dynamic zero High Accuracy0.15 - .25% custody transfer accuracy1-2% installed accuracy – Clamp-onHigher accuracy possible with calibration Aggressive liquids no problem – Clamp on High temperature capability – Clamp on No pressure drop Retrofit installation – Clamp on

Theory of Operation

Piezoelectric Crystal

Theory of OperationTransit Time - Wetted Transducer

Transit Time - Clamp onEmbedded RTD - temp compensation as per ASME MFC 5Mw Meter formulac tvl k 2 t F dic FluidAcoustic calibration factork c Q A kRevlc sin Snells Law:front panelAmultiplexerDpulseformingDSPdata processing,squence controlinterfacesccc sin sin sin Fluid mechanicalcalibration factorQ A kRevl

Shear Wave sound transmissionPipe wall penetrationMulti reflection

Lamb Wave principlePipe wall resonance

Doppler in Flow MeasurementDoppler meters use sound pulse reflection principle tomeasure liquid flow rate, solids or bubbles insuspension in the liquid reflect the sound back to thereceiving transducer. Assumption - Reflected particle external measurement of internal flowrepresentative of average flow

Digital Signal Processing1.0.750.50.250.Digital Signal .75 High random noisesuppression SNR measures amount ofrandom noise relative tofluid 60

Uncertainties of MeasurementMeter Formula tQ K Re A K 2t flError contributions:fluid mechanicsgeometryMeaurement uncertainty - Flexim1-2% -0.03ft/sNIST wet flow calibrated 1% of readingRepeatability 0.15% -0.03ft/sacousticselectronics andtime measurement

Volume flow of an ultrasonic flow meterQ A v A A Re vlRe vA d (Kinematic Viscosity)Laminar:K 0,75Turbulent:K 0,91 . 0,97Assumptions: undisturbed flow

Flow Profile effects –Diametral PathLaminar FlowTurbulent FlowRe 2700Re 6000 ( 10.000)

Re Compensation

Flow Profile effects –Chordal PathsChordal paths are strategically located to average the velocity profileLaminar FlowTurbulent FlowRe 2700Re 6000 ( 10.000)

Undeveloped Flow ProfilesCross FlowSwirl Flow

Other Profile effects Most flowmeters will be affected by the flow profile in a pipe Piping configuration, amount of straight run of pipe must be considered

Flow profile disturbanceBends, valves, elbows,diffusers, reducers,pumps etc. change theprofile of the flow.Certain distances to suchflow elements arenecessary for anundisturbed flow profile.

Flow ConditionersTube Bundle: Used typicallyfor turbines and orifice metersCPA Plate: Used forUFM Gas and beginningto replace tube bundletype

AGA-9 Gas Standard requires metering section

Inflow requirementsmethods of compensation for flow profile deviationsCompensation of profiledistortions:Cross flow compensation: Reflect mode or Two beam reflect mode Two beam Direct moderVFlow vectorUnsymmetry offlow profile

Mounting ConfigurationsDirect MountReflect MountDual Beam

Profile Compensation through multiple chordsWetted UFM’s Typically Chordal TypeMostly seen in Gas Applications

UFMUtilized primarily for viscousliquids

Profile EffectDiametral Paths yeilding perfect flow symmetry

Dual Channel meter on 48” Pipe30deg Elbow

No Conditioner 5d after 30o elbow

2 Channel on Orifice meter runTube Bundle Flow Conditioner

Downstream of tube bundle (less than 10d)Results show either profile or dimensional effect

Encana Test2 Orifice Meters at Fiscal point Anadarko & Encana – Flexim meter installed next to Encana meter

Profile effected by product changeProfile condition of Liquid TypeDieselJet Fuel

Summary of profile effects Diametral systems – profile effects are minimizedthrough mounting and multiple beams Chordal systems – profile effects are minimized byaligning the paths to mathematically achieve averagevelocity For highest accuracy flow profile conditioners arerecommended

UFM Types

Wetted Meters - GasDaniels – 4 PathJunior SonicSick - 4 pathSick - 4 4Elster American Meter 6 path

Wetted UFM arriving at the CEESI Cal Lab

Wetted Meters - LiquidsHydrocarbon MetersCameron 2,4,8 pathKrohne 3,5 pathFMC Technologies 4,6 path

Wetted Meters - LiquidsWater and General Purpose MetersSiemens (Danfoss)Kamstrup BTU MetersMaster MeterBroad BTU Meters

Wetted Meters - SteamGE – saturated and superheatedKrohne – superheated

Clamp-On Meters – Gas and LiquidPermaLok mounting FleximEx Housing Siemens (Controlotron) GE (Panametrics) E&HNema 4x (also C1D2) DynasonicsFlexim - Class 1 Div 2 PortableEx Stainless Steel

Where’s the Grease?No more maintenance associated with dry-out of coupling greasePermanent Couplant PadsCoupling Pad external measurement of internal flow

FLEXIM'sPermaLokTrackMountSystem external measurement of internal flow

Ultrasonic Metering DiagnosticsA window to the process

Signal Waveforms

Data Set

Diagnostic Statistics and Quality Indicators

ic Velocity (m/sec)Sound Velocity used for Fluid IdentitySonic Velocities of Some Fluids (@ 0300200100

Special HPI Variables A number of new variables that are unique to the HPImeter are available to the user:– SonicID: Temperature corrected speed of sound of the liquid.This variable allows the meter to know which liquid is beingsensed for Multi-Liquid systems.– DBC (density @ base conditions), S.G. (specific gravity) and APIgravity: These are all expressions of the same basic parameter(mass per unit volume of the liquid being sensed).– VCF & VCP: Temperature and Pressure Volume correctionfactors used to publish standard volumetric rate and totals.– Liquid: If enabled, the meter publishes which of a series ofliquids is currently being sensed based on SonicID.

Special HPI Variables VSC: Computed Liquid Viscosity based on currentlysensed liquid and measured temperature. Normalized Volumetric Flowrate and Totals ( and -)– These are derived by multiplying the actual rate and totals by thetemperature and pressure volume correction factors. The volumecorrection factors are computed in accordance with industrystandard algorithms such as TP-25, ASTM1250 and D4311.– The meter ‘knows’ which algorithm to apply since it knows theliquid currently being sensed by means of its SonicID variable.

Concentration MeasurementNaOH

Concentration MeasurementH2SO4 between temperatures 60 180 F

Duke Energy – Feedwater Downcomers

Aeration Diagnostic

Lab Calibrations of Clamp-onCEESI Calibration Lab - Iowa

Gas Accuracy Testing on Multiple Pipe Sizes external measurement of internal flow

3rd party calibration results

ATMOS builds a 24” SpoolCalibrated at CEESI Iowa

CEESI Calibration 8/2012

DELFT Calibration LabCustomer Acceptance Testing external measurement of internal flow

DELFT Calibration ResultsDelft Calibration Lab 3/16/2006FLEXIM 7407 2 Beam with M2N7 TransducersAverage of 3 runs at each rate2.001.50As found 1st runAs Found 2nd run1.00As Left% -2.000246810Velocity Ft/sec12141618 external measurement of internal flow

1963 – Tokyo Keiki first introduced Doppler Ultrasonic meters to commercial markets 1970’s saw the release of more Doppler meters onto the market, accelerating the pace of research in the industrial field 1972 – Controlotron develops first clamp-on transit time meter