GE Energy

Dresser Calibration Benches

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GE Energy continues to improve on gas metering and flow control equipment with innovative ideas and sophisticated technology and modular designs.
Introduction
GEs Energys Dresser Calibration Benches are designed for the testing and calibration of commonly used gas meters including diaphragm, rotary and turbine and some types of ultrasonic meter. The Dresser Calibration Benches can be operated manually, automatically and remotely (including active online support from GE energy and the Dutch Metrological Institute NMi upon request). The Dresser Calibration Benches employ innovative technology to deliver performance. range of the Calibration Bench is summarized as follows: CC1000: 0,5 - 1000 m3h. CC2000: 0,5 - 2000 m3/h. CC3000: 0,5 - 3000 m3/h. CC4000: 0,5 - 4000 m3/h. The application of Pulsation Free Rotary meters in-parallel is commonly used in advanced Calibration Systems all over the world. As shown in the image below, the primary high pressure reference meter (Trasys = Traceability System) of NMi is based on a parallel operation of five pulsation free rotary meters. The Dresser Calibration Benches can produce results with an overall uncertainty better than 0,25% with traceability to the NMi.

Operating Principle
The Dresser Calibration Bench uses a number of G650 Pulsation Free Rotary meters (RM-TWIN) and a G16 Rotary meter in parallel as master meters, to measure the volume passed through the Meter-Under-Test (MUT). With an approved range of 20 - 1000 m3/h for the G650 RM-TWINS each and 0,5 - 25 m3/h for the G16 rotary meter, the

Maintainable Metrology
The Dresser Calibration Bench incorporates technology that allows users to monitor and maintain system metrology. Our operating system checks metrology at a series of overlapping flow ranges during normal operation. The system also cross checks accuracy at the Master Meter and Meter under test or with a Dresser or NMi calibrated reference meter. Sufficient Overlap: The G16 and G650 have an overlapping range in which comparison with the Meter Under Test (MUT) must generate the same results. Continuous Cross Checking: During each test, the MUT can be compared with all the individual masters meters giving an indication about the ongoing performance and accuracy of the test bench. For less advanced, more traditional test benches not using parallel master meters, verification/validation is rather expensive and time consuming since a number of large size reference meters are needed to verify and validate the facility. In most cases, these reference meters are to be brought in from far away.
25 1000 TWIN Header/Damping Device 1000 1000 1000 1000 25 TWIN TWIN TWIN TWIN Header/Damping Device Flow Control

Verification using Local Transfer Module 0,5 - 1000 m3/h

MUT

Header/Damping Device 1000 1000 1000 1000 25 TWIN TWIN TWIN TWIN Header/Damping Device Flow Control

Continuous Comparison at 20 - 25 m3/h (overlap) Continuous Comparison by run switching

Reference package: When a reference package is used, consisting of a calibrated rotary meter G16, G160 Twin and a G650 turbine, each Dresser Calibration Bench can be checked/verified/validated, to meet metrology requirements. (Common practice is to verify the installation on a regular bases, unless the cross checking-as mentioned earlier-generates doubtful results.) This operation-just install the Reference meters and consider them as the MUT-can be done locally by the operator of the Calibration Center.

To report the traceability to recognized Notified Bodies (NB) such as NMi, a regular comparison with reference meters of the notified body is required. To reduce operational cost and maximize the availability of the Dresser Calibration Bench, NMi can verify the entire installation with a highly accurate reference meter consisting of a 10-points calibrated G16 a G160 TWIN and a G650 turbine. For more detailed information regarding verification and validation using a reference meter the NMi or the local GE representative can be contacted.
25 1000 TWIN Header/Damping Device 1000 1000 1000 1000 25 TWIN TWIN TWIN TWIN Header/Damping Device Flow Control

Verification using MNi Transfer Module 0,5 - 1000 m3/h

As standard feature, the Dresser Calibration Bench PC can be accessed via the internet. Through this access, GE Energy can remotely operate the Calibration Bench (with permission of the operator). The same modem and its functionality can be used to do remote verification and validation of the installation by NMi. Virtually and remotely a supervisor of NMi can control the Calibration Bench and make all the comparisons with the reference meter.

Transfer Master Unit

Reference RM-G16, G160 twin and G650 turbine in Box.

Pulsation Free Dresser Rotary Meter (RM TWIN) as Master

The Dresser RM-TWIN series of pulsation free rotary meters are using two sets of impellers instead of the traditional single set. The two sets of impellers are fixed at an angle of 45 degrees in respect to each other. In terms of flow passing the meter, it means that the two sine waves generated by each set of impellers will be opposite and thus eliminate each other. The result is a unique non-pulsating device suitable for installing in line with turbine meters (MUT). NOTE: The accuracy of turbine meters is affected by pulsation and thus a proper calibration can only be carried out with comparison to a non-pulsating master meter. The Dresser RM-TWIN has a large turn down ratio and can reproduce within 0.05% within the range of 20 - 1000 m3/h.

Hardware
The Dresser Calibration Bench is suitable to calibrate diaphragm, rotary, turbine meters and some ultra sonic meters. The individual Master Meters are each connected by headers (one to the blower and one to the MUT). The inside of the wall of the header connected to the MUT is lined with a special damping material, to eliminate resonances generated by a rotary meters as MUT. To protect the Master Meters against possible dirt particles from the MUT, a filter is installed. The flow through the filters is upwards, so dirt and particles do not collect in the filter.

In the outlet section of the MUT as well as each Master Meter, a temperature sensor is installed to correct the flow according to the law of Boyle-GayLussac. To eliminate influences of pressure fluctuations, the pressure at the MUT and the Master Meter is compared to a dP-cell instead. Barometer pressure is measured and applied in the error calculations. To minimize the effect of temperature and pressure changes, each second the data is retrieved from the sensors and averaged in the error calculations. The Dresser Calibration Benches are fitted with an automatic leakage control using compressed air, to pressurize the piping in between the MUT and the Master Meters. During the leakage testing, the variations in pressure are monitored. In each Master Meter Run two butterfly (block) valves guarantee leak tightness. A small leakage will cause additional errors especially when the flow rate is low. The use of two such block valves is in accordance with the PTB guidelines for test benches. A part of the required outlet section of the turbine meter as MUT has been integrated into the header. All the smaller size connection flanges including the required straight outlet section of the turbine meter as MUT are connected to this basic flange connection. These connection spool pieces are optional and have to be customer specified at order or can be made locally (a set of drawings is part of the scope of supply). Each connection spool piece has been fitted with a temperature tapping. Rotary meters as MUT will generate pulsations, except for pulsation free designs like the Dresser Series RM-TWIN. The pulsation forms a longitudinal wave in the adjacent piping and can affect the

accuracy of the calibration. To reduce the effect of the longitudinal wave a damping device is installed. The volume and the internal shape of this damping device (header) eliminate the effect of the pulsation. To reduce the effect of pulsation at the inlet of the rotary meter (MUT) it is essential that the meter is tested with an open inlet. In this case, the entire test room is used as damping device. The Calibration Bench blower, able to reach a dP of 80 mbar over a large flow range is sucking the air through the Master Meters and MUT. The dP of 80 mbar enables serial testing of meters. To reduce electrical energy dissipation, the flow rate is adjusted by means of frequency control. The controller is placed in a electric cabinet sized for flow rates, less than 1000 m3/h, two pneumatically activated valves (6 butterfly and 1 1/2 plug) as shown on figure 11, are used. During testing the air flow controls the frequency and the position of the valves are fixed to provide a steady flow.

Human Machine Interface (HMI)

During test set-up the operator is guided by the HMI (Human Machine Interface) software, and can select from a menu of predefined meters and test runs. Once test set-up is complete the Dresser Calibration Bench will run through each test, automatically changing flow rates for each test, processing and storing relevant test data. When the test is complete the operator can print a detailed report. The Dresser Calibration Bench software runs on a dedicated PC, and includes several security levels.The HMI consists of:

PC with test bench software including backup of relevant data 20 screen monitor Mouse and keyboard

Advanced Electronic
The Dresser Calibration Bench uses an advanced time-measurement to determine the passed volume through the MUT and the Master Meters. This timemeasurement reduces the time for testing the MUT and provides increased daily throughput of the calibration bench. All sensors are connected to an industrial PLC, this PLC measures and calculates the time and all relevant data such as temperature and pressure It switches all mechanical devices such as the valves. The PLC is connected with the PC. Through the PC one can arrange the settings of the operational parameters for the test bench itself and the MUT (such as the sequence or type of the test run) and the reporting, displaying, evaluation and validation of the results.

Technical Data Master Meters Sensors

Rotary Meter RM G16 Range: 0,5 - 25 m3/h

Repeatability: better than 0.05% Construction: single set impeller concept 2 HF with Reference Disc

Rotary Meter RM-TWIN G650 Range: 20 - 1000 m3/h

Repeatability: better than 0.05 % Construction: Pulsation Free TWIN 2 HF with Reference Disc

XP Platform HMI
Software Features:

Temperature Sensor Range: 0 - 40C

Repeatability: better than 0.05C 4 wire PT100

System based on MS Windows** XP Professional Test program for turbine-and rotary gas meters Menu-controlled user guidance Graphical process display Screen output of all process data Automatic storage of all meter data on hard disk Measuring data protocol on screen and printer Ergonomic menus with extended tree structure Special User Guidance Menu Complex User-Rights-Management. Rights can be defined for each user (Different user classes like operator, administrator, metrological authorities, management, etc.) All parameters can be set in the program (depending on user rights) Different meters and preferred test sequence can be defined, copied and implemented Parameters for test sequences can be change during running the test Integrated Tool List & Label for complex protocol definitions, an unlimited number of protocols (e.g. different languages) can be defined Basic statistics features of all tested meters Remote Control Software Input masks with extended plausibility checks Integrated database for all parameters and results Integrated diagnostics for test bench functions

dP Sensor

Range: 0 - 50 mbar Repeatability: better than 0.1 mbar

Absolute Pressure Sensor Range: 900 - 1100 mbar

Repeatability: better than 1 mbar

Technical Data iMCC

Skid and headers Steel, RAL painted

Outlet Header inside isolated (damping)

Valves Type: Butterfly (Block and Bleed)

Size: 6 (150 mm) Actuator: Double Acting Pneumatic Minimum Pressure: 5 bar

Filters Wire Mesh 150 micron

Stainless steel

Blower/Frequency Control: Blower: Rotamill, maximum differential pressure 80 mbar, power consumption approx. 15 KW

Frequency converter: SEW Movidrive Rittal Cabinet (W=800)

Blower/Frequency Control Blower: maximum differential pressure 80 mbar, power consumption approx. 15 KW

Frequency converter

** Registered trademark of Microsoft Corporation.

Control Valves Plug Valve: Electronically/Pneumatically actuated

Technical Data PC Keyboard, Mouse (English Version)

Butterfly Valve: Electronically/Pneumatically actuated

Windows XP Prof. (English Version) Remote-Control Software

Technical Data Dresser Calibration Bench Electronics Electric Cabinet

Power Consumption: approx. 2KW

CC1000 Master RM Master RM-Twin G650 Total Range (m /h)

3

CC2000 1 2 0,5 - 2000 <0,25% 2000 80

CC3000 1 3 0,5 - 3000 <0,25% 3000 80

CC4000 1 4 0.5 - 4000 <0,25% 4000 80

1 1 0,5 - 1000 <0,25% 1000 80

Overall Uncertainty Blower Capacity (m3/h) Differential Pressure (mbar) MUT Pulse Connections Simultaneous High Frequency Low Frequency Outlet Connection Outlet Size

2x 1 ANSI 150 DIN PN 16 8 (200)

2x 1 ANSI 150 DIN PN 16 8 (200)

2x 1 ANSI 150 DIN PN 16 8 (200)

2x 1 ANSI 150 DIN PN 16 12 (200)

Dimensions (up to basic connection flange) Width (mm) Depth (mm) 1500 Height (mm) MUT (max) Diaphragm Rotary Rotary (pulsation free) Turbine Maximum Size Serial Testing Available Options Serial Testing dp MUT (PTB) Reference Matter

2000

2000 1250 1500 G160/6 G400/6 G650/8 G1600/8 G1000 Yes Yes Yes

2000

G160/6 G400/6 G650/8 G650/8 G250 Yes Yes Yes

G160/6 G400/6 G650/8 G1000/8 G1000 Yes Yes Yes

G160/6 G400/6 G650/8 G2500/12 G1000 Yes Yes Yes

GE Energy Dresser Meters & Instruments 16240 Port Northwest Dr., Suite 100 Houston, TX 77041 P: 832.590.2303 F: 832.590.2494 7051HS Vasserveld The Netherlands P: +31 (0) 31527 1100 F: +31 (0) 31527 1105 Visit us online at: www.ge.com/energy 2011 General Electric Company All Rights Reserved

TS: Calibration Bench 9.11