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FLOWMETER
CALIBRATION
METHODOLOGY
AE M S L t d . , T h e E n e r g y C e n t r e , F i n n i m o r e In d u s t r i a l E s t a t e , O t t e r y S t . M a r y , D e v o n . E X1 1 1 NR
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K:\METHOD\methodflow1.doc
- CONT E NT S -
INTRODUCTION
THEORY
2.1
2.2
TEST APPARATUS
3.1
STANDARD EQUIPMENT
TAPPING ARRANGEMENTS
4.1
4.2
SUBMERSIBLE PUMPS
4.3
METHODOLOGY
5.1
CALIBRATION
5.2
TEST POINT
5.2.1 Power Monitoring
5.2.2 Connection Arrangement for 3 Phase Power Measurement
7
7
8
6.1
INTRODUCTION
6.2
6.3
DESCRIPTION OF PROCEDURES
10
6.4
12
APPENDICES
14
7.1
14
7.2
15
7.3
16
7.4
17
-2-
-3-
2 THEORY
A simplified form of the method is given as follows:
p =
W out
.
Win
Thus,
p =
Wout
=
W out + Losses
where,
& .c p .dT
Losses m
=
.
& .g.H
Wout
m
Therefore,
p =
1+
1
,
Losses
1+
Wout
1
.
c p .dT
g.H
Q=
Or,
Q=
Notation:
p
m
W
Q
H
dT
cp
Pgr
g
Pgr .m . p
.g.H
Pgr . m
.(g.H + c p .dT)
= pump efficiency
= motor efficiency
= work done
= volume flow rate
= head
= change in temperature
= specific heat capacity of fluid
= motor input power
= gravitational acceleration
= density of fluid
= mass flow rate
-4-
3 TEST APPARATUS
3.1 STANDARD EQUIPMENT
Photograph of Yatesmeter Equipment
-5-
4 TAPPING ARRANGEMENTS
All the tappings are fitted with gate valves, which will take BSP T-pieces. This is
illustrated in the Appendices, in section 7.1.
Tappings need to be positioned in different ways according to the pump arrangement.
-6-
5 METHODOLOGY
5.1 CALIBRATION
The probes and transducers can be installed while the pump is running. Once in place, a
calibration of the temperature probes is performed. This requires a minimum of 20
minutes running the pump at a constant speed.
For the first 10 minutes the suction temperature probe is put in the delivery pipework, and
the delivery temperature probe is put in the suction pipework. For the second ten minutes
the probes are reversed, subsequently, an offset is calculated by the Yatesmeter.
suction pressure
delivery pressure
pump efficiency
flow rate
suction head
delivery head
velocity head
pump head
motor efficiency
-7-
Method 2:
In the HV switch-room, a single revolution of the Ferraris wheel is timed
using a stop-watch. This is done at each test point, and the power is calculated each time.
Medium Voltage
On medium voltage systems monitoring equipment is attached the starter panel and a
data lead run from the power monitor to the Yatesmeter.
The power equipment consists of:
power monitor
earth/neutral connector.
Once the monitor is connected and the panel door closed there is usually no need to
access the starter panel again until the end of the test.
5.2.2 Connection Arrangement for 3 Phase Power Measurement
-8-
Operation
Time
(mins)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
30
5
5
10
30
15
5
15
5
15
5
5
30
30
3 hrs
-9-
Disruption
(mins)
0
5
5
10
0
15
5
15
5
15
5
5
30
0
2 hrs
The pump Efficiency monitor uses two temperature probes and two pressure
transducers to monitor and measure the pump efficiency in real time. The probes are
inserted into the pipework via the T-pieces, and the following information is recorded:
Station name
Flowmeter name
Motor power
Motor speed
-10-
-11-
Offset Error: the constant error throughout the range. It is expressed as a flow rate
(units MLD, m3/hr, l/s etc), and
Station Flow
Reference line
(grad.= 1)
Offset Error
Yatesflow
The diagram above shows a hypothetical flowmeter comparison. The red line represents
the reference line (i.e. Station Flow = Yatesflow) and the blue line shows the line drawn
through the test data. Therefore, using these results the range error may be calculated as
follows,
= (1 0.8)/1 100 %
range error
ER
= 20 %.
To calculate the actual flow through the flowmeter using the data collected, the following
method is used:
Using the form of a general linear equation, y = m x + c,
Let
m = (1 ER )
c = offset error (EO)
x = The actual flow rate (Q)
then
-12-
A comparison of meters will be made at zero flow. If the meter is not recording zero flow
when flow is stationary (i.e. The pump is off and isolated) then an adjustment is made.
This adjustment is made by making the signal from the flowmeters converter unit equal 4
mA which corresponds to zero flow. The magnitude of this adjustment represents the
offset error.
The station is returned to normal operating conditions, and as stated previously, three
further test points are taken. These points give a linear representation of how the stations
flow varies with the reference flow (i.e. flow calculated by the Yatesmeter). Any remaining
error will be removed by adjusting the velocity range setting on the meter. This error is the
range error.
Below is a worked example of the calculation involved in finding the actual flow rate, given
the flow rate seen by the station flow meter. Using data from a tested flowmeter, the
following values have been calculated,
Offset error, EO
= -4.58 m3/hr
Range error, ER
= -0.99%
At open valve, the stations flowmeter recorded a flow, Ql = 144.6 m3/hr. Therefore, the
actual flow,
Q
This flow corresponds to the flow recorded by the Yatesmeter, at the same open valve
conditions.
-13-
7 APPENDICES
7.1 APPENDIX 1: TYPICAL TAPPING ARRANGEMENT
-14-
-15-
-16-
-17-
HAZARD
RISK
LEVEL
CONTROL
MEASURE
LEVEL
Working
Machinery
Entanglement
Crushing
Medium
Machinery Guards
Area Cordoned off
Low
Working below
1.2 metres
Flooded
chamber
Gas
High
Low
Working above
2 metres
Falling
Medium
Fixed ladder
Tower
Safety line
Low
Portable Tools
Electrocution
Medium
Tested 110V
equipment
Low
Noise
Chronic hearing
damage
High
Ear defenders
Low
Manual handling
Sprains, strains,
fractures etc.
Low
Trained personnel
Lifting aids
Low
General Working
Medium
Working practice
Personal safety
equipment
Low
Raw water;
sewage; oils;
greases;
additives
Ingestion
Internal damage
Illness
High
Protective clothing
Safe working
practice
Low
-18-
FOR
HAZARD
RISK
LEVEL
CONTROL
MEASURE
LEVEL
Working
Machinery
Entanglement
Crushing
Medium
Machinery Guards
Area Cordoned off
Low
Working below
1.2 metres
Flooded
chamber
Gas
High
Low
Working above
2 metres
Falling
Medium
Fixed ladder
Tower
Safety line
Low
Connecting
Power
monitoring equip
Electrocution
Medium
Safe working
practice; isolation;
insulated connectors
Low
Portable Tools
Electrocution
Medium
Tested 110V
equipment
Low
Noise
Chronic hearing
damage
High
Ear defenders
Low
Manual handling
Sprains, strains,
fractures etc.
Low
Trained personnel
Lifting aids
Low
General Working
Medium
Working practice
Personal safety
equipment
Low
-19-
PUMP PERFORMANCE
CERTIFICATE OF CONFORMITY
EXAMPLE
Client:
Flowmeter:
Meter Asset#:
Certificate#:
Date Tested:
Tested By:
FLOWMETER DETAILS
Manufacturer:
Device:
Type:
Serial #:
Output Signal:
Transducer:
Display:
Range:
Normal Flow:
% Scale of Flow:
Flowmeter Bore:
Zero Flow:
LCD
7 MLD
2.8 MLD
40%
200 mm
4.000 mA
Manufacturer:
Serial #
Certificate #:
Calibration Expires:
Dead weights
Budenburg
3094
2015
12/02/2004
Pressure Tester
Budenburg
24093
2015
12/02/2004
Yatesmeter
Flow Rate
Time
11:50 to 12:05
0:0 to 0:15
12:0 to 12:15
l/s
32.13
32.13
-0.60
12:05 to 12:20
12:22 to 12:37
12:45 to 13:00
32.25
26.89
21.13
COMMENTS:
Yatesmeter
Flow Rate
MLD
2.78
2.78
-0.05
Adjustment
2.79
2.32
1.83
Station
Signal
Calc'd
Offset Error
Station Flow
mA
9.01
9.01
4.00
Performed
10.35
9.34
8.19
MLD
2.19
2.19
2.78
2.34
1.83
Signed:
On Behalf of: Advanced Energy Monitoring Systems Ltd.
Issue #: 1
Registered in England Registration No. 1589111
-20-
Range Error
MLD
0.04
22.52
0.04
1.51
15
Pre Calibration
Post Calibration
Reference
14
13
12
4:47:42 PM
4:47:42 PM
11
4:47:42 PM
10
Station Flow
1
T/N: 5467
0
0
5
6
Yatesmeter Flow
-21-
10