Verifying Flowmeter Accuracy

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Verifying Flowmeter Accuracy

By Greg Livelli September 26, 2010 No Comments Email / Print / Reprints / More Many factors can cause a flowmeter to lose calibration, including: buildup of deposits, minerals, oils, and solvents; wearing, breakage, or failure of internal mechanical parts; damaging impact; improper installation; and modified piping configurations. A flowmeter calibration, usually carried out by the manufacturer, adjusts the output of the meter to bring it back to a value within the specified accuracy tolerance. This article discusses the pros and cons of several calibration techniques. Calibration Relativity Flowmeter calibrations are not absolute operations. A calibration compares a flowmeter measurement relative to a standard. The comparison establishes a relationship between what the flowmeter measures and what the standard measures. The standard consists of a system of pumps, pipes, fluids, instrumentation, quantity reference measurement, calculations, and operators all combined to measure the quantity of fluid passing through the flowmeters in a unit of time. The relationship between the flowmeter under test and the standard must be expressed in a way that gives a meaningful expectation of how the flowmeter will perform in use. In practice, accuracy is the term that most users can relate to and that can usefully express an expectation and general specification. Accuracy is a qualitative term, and the number associated with it must be taken in the spirit of this concept. It indicates how close the flowmeter measurement agrees with the true measured flowrate. The standard must be able to reproduce the measurement that it claims to make with some degree of confidence. To this end, all the measurements in the system have to show traceability to higher-level measurements, and ultimately to national and international standards. Traceability must be through an unbroken chain of comparisons with stated uncertainties. The uncertainties of each calibration higher in the chain should be smaller at each step. Note, however, that providing or claiming traceability makes no statement regarding the quality or uncertainty of the final calibration; it only satisfies one aspect of the quality requirements for an accredited calibration. The uncertainty quoted for a calibration or a standard depends on a detailed examination of all the components of the system, the use of the system, and its history. The quote will specifically state which parameters underlie

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the uncertainty. This may be the quantity measured by the standard or the quantity passed through the flowmeter. This quoted uncertainty is not that of the calibration result. The resolution of the meter, influencing factors, and finally the repeatability and linearity of the calibration results must all be included to provide the uncertainty of the calibration. Why Bother? For one, manufacturers want to establish the quality of their management systems, as spelled out in ISO 9001 of the International Standards Organization (www.iso.org). Third-party auditors and regulators of this standard require documentation to verify the quality of these manufacturing management systems. Obviously a manufacturing process that depends on an accurate flowmeter for maintaining product quality will require documentation relating to its calibration. Often a flowmeter measures the amount of fluid transferred by pipeline from one company to another entity or division, sometimes known as fiscal metering. This is the case when you purchase gasoline. The flowmeter measurement determines the cost of the transfer and sometimes involves taxation. Flowmeter accuracy in these cases is obviously of paramount importance. Companies and governments will mandate the calibration frequencies to check on flowmeter accuracy. Another reason for flowmeter calibrations is better management of processes. With time, flowmeter performance may slowly degrade, negatively affecting quality and/or costs. Timely calibrations help management keep operating equipment functioning properly and efficiently. But what is a timely calibration? For most applications, users must examine the operating conditions and define their own calibration frequency. In other cases a third party or standard may mandate the calibration frequency. The idea is to determine a calibration interval that minimizes the risk of an incorrect meter reading that makes a significant impact on the process. Keeping a good history of past calibrations helps to spot trends for predicting when calibrations become necessary. Unfortunately, calibrating a flowmeter with good confidence in the result is usually costly and difficult. Practical calibration techniques do not exist, and many methods depend heavily on operator skill. Locating good testing points in the pipeline is usually difficult. And flowmeters experiencing high flowrates often cannot be calibrated. Calibrating In a Test Rig This technique requires removing the flowmeter and shipping it to a calibration facility having a test rig traceable to the National Institute of Standards and Technology (www.nist.gov). These facilities generally consist of a reservoir, pumps, meter runs, and weigh tanks. The system operates as a constant-flow facility. It uses timed collections of water to compute the average flow through the meter being calibrated. The relative expanded uncertainty for these facilities is between 0.2 percent and 0.5 percent. The calibration report typically includes an uncertainty value for the calibration factor of the flowmeter. Uncertainty depends on the reproducibility of the meter under test and the uncertainty of any instrumentation associated with the flowmeter output. A flow calibration often includes five different average flowrates and the standard flow made at each setpoint. Today, calibration in a test rig will typically run about $5,000 per meter. Drop Test or Volumetric Method Calibrations using this technique determine the amount of liquid collected in a tank within a certain time interval. The amount collected can be measured by weight or volume. The uncertainties tend to be large, typically 5 percent to 10 percent. For example, suppose the diameter of the tank is 10 feet +/- two inches, and the level changes three feet +/- one inch. The dimensional uncertainties compute to a difference of 7,040 to 7,500 gallons, or 6.1 percent. In addition, the tank may not have a perfectly circular cross section or exactly plumb walls. Undetected leaks will further degrade accuracy. The drop test diagram (Figure 1), typically involves volumes that are too large to be practical. Small uncertainties in the tank internal diameter or level can have a significant effect on calibration accuracy. Such tests are also time consuming. Ultrasonic Clamp-On Meters

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The user can install clamp-on ultrasonic transducers to the outside wall of a pipe and take measurements of flowrate to compare with readings of a flowmeter to be calibrated (Figure 2). These transit-time flowmeters measure the time difference between ultrasonic beams moving with and against the fluid flow. This time difference, combined with knowledge of the pipe''s internal diameter and the distance between the two ultrasonic transducers, permits a calculation of the volumetric flowrate through the pipe. The best Figure 1. In the drop test, calibration engineers determine the amount of liquid collected in a tank within a certain time interval.

Figure 2. Transit-time ultrasonic flowmeters measure the time difference between ultrasonic beams moving with and against the fluid flow. measurement accuracies possible with clamp-on ultrasonic flowmeters are 2 percent to 5 percent. But many other unknown factors generally result in lesser accuracies 5 percent to 10 percent. The three major sources of error include the pipe''s internal diameter, the flow velocity profile, and acoustic interference. Nonlaminar profile uncertainties, amounting to 1 percent to 10 percent of the measured flow value, can be corrected by determining the appropriate K factor from calibration at specific flow conditions, from empirical calculations, or by sampling a greater fraction of the cross-sectional flow area. Acoustic short-circuit interference can cause errors exceeding 7 percent if the signal/noise ratio is 10-to-one or less, or errors greater than 0.6 percent for signal/noise ratios below 100-to-one. Beam path changes caused by temperature, pressure, composition, or mechanical effects can be compensated for or eliminated by positioning each transducer with permanent mounting pads in a positive manner, by empirically calibrating the flowmeter at particular intervals of temperature, pressure, and composition, and by modifying the pipe interior. Errors relating to the pipe''s internal diameter can cause significant measurement errors. For example, if the pipe''s nominal ID is 78.85 inches, and the maximum ID is 81.79 inches, the difference produces a measurement uncertainty of 3.7 percent. To improve the calibration accuracy, install the ultrasonic transducers at a location that minimizes the discontinuities between the meter to be verified and the clamp-on meter. Discontinuities would include pipe fittings and open branches. To ensure a well-developed flow profile, the straight-pipe section upstream of the clamp-on meters should be at least 30 pipe diameters in length. Since uncertainty increases if the cross-sectional area calculation depends on single measurement of pipe diameter, you should average two perpendicular diameters. Insertion Probes Insertion probes, which measure fluid velocity at a point within a pipe''s cross-section, can check the performance of an installed full-bore meter. An insertion flowmeter (Figure 3), measures the fluid velocity at a point. It is unaware of surrounding flow velocities outside of the immediate location of the probe tip. The user or

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a secondary device must calculate the volumetric flowrate based on knowledge of the flow profile within the pipe. (For more information on flow profiles, see Part III of this series Flow Control, May 2007, page 14.) Measurement accuracy ranges from 2 percent to 5 percent. This technique works best for a fully developed flow profile at the measuring location, usually achieved by installing the probe after a long length of straight pipe. The proper straight length depends on the nature of the upstream disturbances to the flow. Attempting calibration in a location without a well-developed flow profile can lead to large errors. Figure 4 shows a fluid flow profile following an elbow fitting. An insertion probe tip sitting at a point one-quarter of the pipe diameter will measure a fluid velocity that is about 30 percent too high. To develop the flow profile, the engineer can make multiple velocity measurements across the pipe''s diameter a time-consuming operation. Other sources of inaccuracy with insertion probes include: errors in internal pipe diameter, crosssectional area, and pipe ovality; pulsating and Figure 4. An insertion probe inserted unstable one-quarter into the pipe having this flow flows; velocity profile will measure a fluid velocity varying that is about 30% too high. flowrates between point measurements while determining profiles; errors and uncertainties in associated instrumentation; and particulate material in the fluid.

Figure 3. Insertion probes, which measure fluid velocity at a point within a pipe''s cross section, can check the performance of an installed full-bore meter.

Tracer Methods Tracer techniques for calibrating flowrates include the transit-time and the dilution methods. Attainable measurement accuracies range from 2 percent to 5 percent. Using the transit-time method, engineers inject a pulse of tracer fluid into the main flow stream and measure the time taken for the tracer to pass between two detection points (Figure 5). Since the volume of the pipe between the detectors is known, they can determine the volumetric flowrate. Some disadvantages include: not suitable for sluggish or slow moving flows; difficulties in determining the volume between detectors; and often requires many measurements, which can be time consuming.

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For the dilution method (Figure 6), engineers use a tracer fluid that is detectable in low Figure 5. Transit-time tracer calibrations measure the time the injected tracer fluid passes between two detectors. concentrations and inject it into the flow at a known rate. They then sample the mainstream flow downstream of the injection point, far enough to allow homogeneous mixing. The downstream detector measures the tracer fluid concentration. Since the tracer fluid flowrate q is comparatively small, they can derive the main flowrate Q via the equation: Q = q/C, where C is the measured tracer concentration. The primary source of error occurs in accurately determining the tracer concentration. Additionally, the technique also requires many measurements and can be quite time consuming. Hydraulic Model Testing For some piping flow situations, engineers may find it difficult to calibrate the flow measurement system using either the dilution or volumetric tracer technique. For example, they may be unable to reproduce the full operating flow range in the system. In some cases, testing would potentially result in a release of an unacceptable contaminant loading to the environment. (For example, test flowrates may be limited by seasonal downstream receiving water restrictions.) If the site handles only emergency overflows, testing may be ruled out by water quality limitations. For these situations, engineers may be able to construct a hydraulic model of the flow system and then run calibration tests on the model under laboratory conditions. They would design the hydraulic model based on the principle of hydraulic similitude. With this approach, the model represents a geometric reduction of the actual flow measurement system. The model is scaled down via a fixed ratio between the model and actual flow system for all homogeneous lengths, velocities, and forces involved in motion. Engineers should pick a scale factor that provides model flows as close as practical to actual flows. Of course the model must be consistent with pumping capacity available at the testing facility. The hydraulic model should be constructed based on field-measured dimensions that are confirmed before construction. Common construction materials for a hydraulic model are wood and steel. In laboratory testing facilities, flowrate through the model is usually determined by applying the volumetric tracer method. Measurement accuracy ranges from 10 percent to 15 percent. A detailed description of hydraulic similitude and hydraulic model studies may be found in Hwang (1981) and Streeter and Wylie (1985) [1, 2]. Reference Meter in Series Another way to verify the calibration of a flowmeter is to install two or more in a single pipeline (Figure 7). In this case, one meter verifies another. For example, one flowmeter may be used as the pay meter and the other as a check meter. The pay meter serves for billing purposes and the check meter ensures that the pay meter is still within calibration. The meters are checked against one another on a regular basis. Good practice calls for proving the pay meter on an annual basis. Figure 6. In the dilution tracer calibration technique, the fluid flowrate is a function of the tracer injection rate and its downstream concentration.

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To minimize discrepancies, the meter readings must be taken at the same time every reporting period. If possible, it is best to record the inventory readings from both meters simultaneously. The longer the reporting period, the smaller the errors associated with recording the inventory readings will be. Measurement accuracies for reference meters in series typically range from 0.5 percent to 1 percent. Obviously having two flowmeters in series for a single Figure 7. In the case of the reference meter in measurement can be quite expensive and is often not series, one flowmeter verifies another. practical. Calibration Applied: CalMaster Magmeter Verification In the case of electromagnetic flowmeters, ABB Instrumentation (www.abb.com) offers a verification system that can check calibration of ABB''s Magmaster flowmeters without access to the pipe or the sensing electrodes. Called the CalMaster system, it permits in-place verification and certification of the magmeter to ensure that it remains within its specified calibration. When connected to a MagMaster transmitter and a personal computer (Figure 8), the portable CalMaster system performs a complex series of tests over the course of 20 minutes. It compares key flowmeter parameters to those measured by the factory at the time of meter manufacture. The tests evaluate the status of the complete system, including the sensor coils, electrodes, cables, and transmitter. Figure 8. The CalMaster verification system from ABB Instrumentation compares key The flowmeter will require servicing only when it fails the magmeter parameters to those measured by calibration check. the factory at the time of meter manufacture. The CalMaster system also serves as a diagnostic and condition-monitoring tool. It automatically stores all the measured values and calibration information in its own database files for each meter. It maintains a calibration history log, making it easy to undertake long-term trend analysis. Trends can give early warning of possible system failure, enabling the maintenance engineer to anticipate problems and take remedial action in advance. This is the fourth article in a five-part series on flowmeter technology. Part V will appear in the August issue. Greg Livelli is a senior product manager for ABB Instrumentation, based in Warminster, Pa. He has more than 15 years experience in the design and marketing of flowmetering equipment. Mr. Livelli earned an MBA from Regis University and a bachelors degree in Mechanical Engineering from New Jersey Institute of Technology. Mr. Livelli can be reached at greg.livelli@us.abb.com or 215 674-6641. www.abb.com References 1. Hwang, N.C. 1981. Fundamentals of Hydraulic Engineering Systems. Prentice-Hall Series in Environmental Sciences. 2. Streeter, V.L., E.B. Wylie. 1985. Fluid Mechanics. Eighth Edition. McGraw-Hill. Email
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