NFOGM Workshop2015

Calibration, adjustment, fluid dependency and

long term stability of liquid ultrasonic meters

Presented by:

Andrew Soddy, FMC Technologies

NFOGM Workshop2015

Topics

• Ultrasonic meter calibration options

• Offsite laboratory calibration

• Dynamic Testing over Reynolds No. Range

• Using diagnostics verify offsite laboratory

calibration

NFOGM Workshop2015

Direct proving method

Conventional pipe prover

Small volume piston prover

Direct master meter proving method

MM and line meter proved on-site

Indirect master meter proving method

MM Proved at Off-Site (different flow and

conditions)

Meter proved off-site/lab calibration

(API 5.8)

Liquid flow meter calibration

Less uncertainty(smaller error band)

More uncertainty(larger error band)

NFOGM Workshop2015

Meter Proved Off-Site / Lab Verification (API 5.8)

API MPMS 5.8 Section 8.2.1: “In-situ proving is normally

preferred because it verifies the meter’s accuracy under actual

operating conditions. Operating conditions can affect a meter’s

accuracy and repeatability. In-situ proving at stable operating

conditions compensates for variations in performance caused

by flow rate, viscosity, density, temperature, pressure, as well

as flow conditions, piping configurations, and contaminants”

API MPMS 5.8 Section 8.2.2: “Laboratory proving is normally

not preferred because laboratory conditions may not duplicate

the piping and operating conditions. While there are more

measurement uncertainties associated with laboratory proving,

under certain conditions, it may provide the best alternative.”

NFOGM Workshop2015

Off site Laboratory Calibration

+

• When no site proving is available, lab proving (such as the one done

at the FMC FRTC) is the best alternative

• In this situation, an accurate meter over the entire operating (Re #)

range is key to providing good flow meter characterization

NFOGM Workshop2015

Calibration at the Flow Research and Test Center

Matching Flowing Conditions

Reynolds # testing is a simulation over the Reynolds Number

range determined from the field application parameters. It

provides a test range for ultrasonic flow meters based on the

concept

of dynamic similitude.

Dynamic Similitude, when performance at a given Reynolds

Number is the same with various combinations of flow rate and

viscosity.

Therefore meter performance on a test system can be validated

on a higher or lower viscosity and/or flow rate than the field

operating conditions.

NFOGM Workshop2015

Flow Profile at Equivalent Reynolds Numbers

NFOGM Workshop2015

Measured Velocity Profile Factor, Ultra 8c

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

100 1000 10000 100000 1000000

VP

C X

Re-Number

Re Number vs. Velocity Profile

Extra Heavy, 223 cSt - 12/18/2012

Brad Penn, 10 cSt - 12/18/2012

Hvy 36cSt, 36.6 cSt - 12/18/2012

Hvy 64cSt, 65.5 cSt - 12/18/2012

NFOGM Workshop2015

Ultra 8c measurement path design

• The Ultra 8c has eight

measurement paths and

sixteen transducers.

• Crossing measurement

paths in all 4 chordal

planes

• All measurement planes

are designed to maximize

cancellation of the effects

from cross flow and swirl.

tra c

PATHS 5 & 6

PATHS 7 & 8

PATH 5 PATH 6

PATH 7 PATH 8

NFOGM Workshop2015

• The Flow Research and

Test Center Lab located

in Erie PA can reproduce

the same Re No. range

as the actual field

operating conditions

• The limits are the

minimum fluid velocity &

flow rate in the meter and

its maximum flow rate

• Remote witnessing of all

testing is now possible

via web cams

Dynamic factory testing using dynamic similitude

NFOGM Workshop2015

Dynamic Test Range: Petroleum Products

Reynolds Number (Re No.)

Heavy

Crude Medium Crude

Refined Products

Light Crude

Heating Oil Diesel

2,000 50,000 1,000,000

K-F

ac

tor Gasoline

LPG

Average V

Max. V

Turbu ent or “P ug” F ow

(Re > 6,000)

Low ViscositiesMax. V

Average V

Higher Viscosities

Laminar Flow

(Re < 2,000)

Velocity

NFOGM Workshop2015

12 Inch Multi-path Meter Uncorrected

Testing Over an Extended Range

(Re# Range 1,000 to 672,746)

1555

1560

1565

1570

1575

1580

1585

1590

1595

1000 10000 100000 1000000

K-F

acto

r

Re Number

Test Data Uncorrected

Extra Heavy (220 cSt) Heavy (35 cSt) BradPenn (12 cSt) Light (2 cSt)

Overall Linearity ± 1.113%

Linearity over a 672:1 Dynamic Turndown

190 – 3,000 m3/h [1,200 – 19,000 bph]

NFOGM Workshop2015

12 Inch Multi-path Meter Corrected

Testing Over an Extended Range

(Re# Range 1,000 to 672,746)

1555

1560

1565

1570

1575

1580

1585

1590

1595

1000 10000 100000 1000000

K-F

acto

r

Re Number

Test Data with Correction Applied

Extra Heavy (220 cSt) Heavy (35 cSt) BradPenn (12 cSt) Light (2 cSt)

Overall Linearity ±0.139%

Linearity over a 672:1 Dynamic Turndown

190 - 3000 m3/h [1200 - 19000 bph]

NFOGM Workshop2015

High Flow (HF) Test System

1. Test run / Meter Under Test (MUT)

2. Pumps

3. Tank

4. Chiller

5. Master meter provers

6. Master prover

Flow range:

200 to 42,000 bph

(30 to 6,667 m3/h)

Viscosity range: 10 – 25 cSt

❶

❷

❸

❹

❺

❻

NFOGM Workshop2015

Multi-Viscosity (MV) Test System

1. Test run / Meter Under Test (MUT)

2. Pumps / drives

3. Tanks

4. Chiller

5. Master meter provers

6. Master prover

Flow range:

200 to 8,000 bph

(30 to 1,270 m3/h)

Viscosity range: 2 – 500 cSt

❶

❷

❸

❹

❺

❻

❸

❺

NFOGM Workshop2015

FMC Technologies Testing CapabilitiesF

low

Rate

, m

3/h

6,677

Viscosity, cSt

30

1.8 20

1,270

10310

Multi-Viscosity Loop

High

Flow

Loop

Maxi

mum

Flo

w, 10 m

/s

6” (715)

12” (3,021)

20” (6,670)Constant ReFlow Test Lines

NFOGM Workshop2015

Diagnostic Numerical Analysis

Process of Validating Installation Effects

1. Calibrate the meter on site A (Laboratory)

2. Record the conditions and meter diagnostics

3. Install the meter at site B

4. Compare site results – meter factors & diagnostics

– Meter factor differences are due to installation effects – less the uncertainty of the proving systems

– Meter diagnostics could define the installation conditions

NFOGM Workshop2015

Diagnostic Parameters – Flow Profile Parameters

Profile FlatnessAxial flow velocity of outer paths compared to the center paths.

Reynold’s number dependant. Deviation at similar conditions < 1.0%

Profile SymmetryVelocity of top paths compared to the bottom paths.

Installation dependant. Deviation at similar conditions < 2.0%

Swirl FlowAmount of transversal flow that is rotating in the pipe.

Installation dependant. Deviation at similar conditions < 2.0%

Cross FlowAmount of transversal flow that has two rotating vortexes

Installation dependant. Deviation at similar conditions < 2.0%

TurbulenceDescribes the stability of the flow measurements on each path.

Reynolds number dependant. Deviation at similar conditions < 1.0%

NFOGM Workshop2015

Diagnostic Analysis – Signal Parameters

Velocity of Sound (VOS)

Measured on each path to ensure correct measurement of

ultrasonic pulses. Density dependant.

Recording possible. Deviation < 1.5m/s

Gain

Indicates signal strength. Influenced by density, viscosity

and impurities.

Recording possible. Deviation < 200

Signal %Designates the signal quality. Should > 50%. Drop in

performance on similar conditions should be examined.

Signal to Noise Ratio

(S/N)

Measures the signal strength and noise. Should be > 20dB.

Drop in performance on similar conditions should be

examined.

NFOGM Workshop2015

Profile Flatness – Smith Erie and SPSE

80.00

82.00

84.00

86.00

88.00

90.00

92.00

94.00

96.00

98.00

100.00

10,000 100,000 1,000,000

Reynold Number

Pro

file

Fla

tne

ss

(%

)

Erie Profile - Red

SPSE Profile - Blue

Deviation < 1%; Actual 0.04% to 0.73%

Diagnostic Analysis – Inter laboratory Comparison

NFOGM Workshop2015

Symmetry, Swirl and Cross Flow

-10.00

-8.00

-6.00

-4.00

-2.00

0.00

2.00

4.00

6.00

8.00

10.00

Reynolds Number

%

Symmetry Erie

Swirl Erie

Crossflow Erie

Symmetry SPSE

Swir SPSE

Crossflow SPSE

100,000 200,000 300,000

Tolerance: < 2%

Diagnostic Analysis – Inter laboratory Comparison

NFOGM Workshop2015

Smith Erie & SPSE Calibration Data

154.0

154.5

155.0

155.5

156.0

156.5

157.0

157.5

158.0

158.5

159.0

159.5

160.0

0 2,500 5,000 7,500 10,000 12,500 15,000 17,500 20,000 22,500 25,000

Flow Rate (bph)

K-F

acto

r (p

/bb

l)

Erie 12 cSt data

SPSE 20 cSt data

Deviation < 0.02 to 0.17

Ultra6 Inter laboratory Comparison

NFOGM Workshop2015

Thank You