water meter testing
TRANSCRIPT
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Water Meter Testing
APEC/APLMF Training Courses in Legal Metrology
September 23 – 26, 2008Hanoi, Vietnam
Asia-PacificLegal Metrology
Forum
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Definition
Water Meter Testing
“To ensure that the water meter is performing as designed and that it meets the necessary performance requirements put in place by the national legal metrology organization”
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Why Test Meters?
A water meter is subject to wear and deterioration and, over a period of time, loses its peak efficiency
Protect individual customer against over-registration
Protect customers (as a group) against inequity of under-registration and higher water rates
Protect water utility from revenue loss caused by under-registration
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Factors AffectingAccuracy
Turbidity of the water
Chemical build-up in the measuring chamber
Rates of flow
Total quantity metered
Age of meter
Type of meter installed
Poor installation practices
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Test Equipment
Test BenchSingle or multi-meter
Automated Test Controller
Comparative Standard (Test Method)
VolumetricGravimetricReference Meter
Water supplyFlow throughRe-circulating reservoir PumpGravity feed
Inlet valve
Flow disturbance devices
Quick-acting valve on discharge side
Flow regulating valve
Device for determining flow rate
Pressure gauge
Temperature gauge
High resolution test encoder
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Water MeterTest Facility
PTBBraunschweig, Germany
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Water Meter Test Station
General - Layout
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Single Meter Test Bench
One position only
Used primarily for large meters
Found in small meter shops
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Single Meter Test Bench
Large Meter Test BenchMARS Company
USA
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Single Meter Test Bench
Small Meter Test BenchCity of Brandon
Canada
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Single Meter Test Bench
testing large metersBadger Meter
USA
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Single Meter Test Bench
China
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Multi- Meter Test Bench
Advantage of testing more than one meter at the same time
Meters are mounted in-series and/or in parallel
Many different configurations, (stock or custom built)Ex:
2 rows (24 position) – small meters2 rows (3 position) -intermediate meters, (5 position) -small metersSingle row (5 position)
Caution about high pressure loss at Q3 or Q4
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Multi- Meter Test Bench
WRc-NSFWales, UK
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Multi- Meter Test Bench
MARS CompanyUSA
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Multi- Meter Test Bench
City of OttawaCanada
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Multi- Meter Test Bench
Coulter Meter ServiceIngersoll, Canada
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Multi- Meter Test Bench
Force TechnologyDenmark
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Multi- Meter Test Bench
OIML R 49-2
Neptune TGUSA
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Multi- Meter Test Bench
OIML R 49-2
Badger MeterUSA
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Automated Test Controller
Many test stations are Operator controlled
Reads meter and quantity of volume delivered
Determines and regulates flow rate
Observes and records pressure and temperature
Automated test controller (full or partial)
Reads meter
Determines quantity delivered
Monitor and controls flow
Monitors pressure and temperature
Calculates errors
Prints or stores test results
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Automated Test Controller
Gravimetric System Test Bench ConsoleMARS Company
USA
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Automated Test Controller
Test Bench ConsoleWRc-NSFWales, UK
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Automated Test Controller
Test Bench ConsoleForce Technology
Denmark
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Comparative StandardsTests Methods
VolumetricTest TankNarrow-neck Prover
Gravimetric
Master or Reference Meter
Displacement ProverPiston ProverPipe Prover
On-site or Portable Testing
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Volumetric – Test Tank
Older technology
Standing-start-and-finish method
Poor sensitivity if large diameter tank
Errors reading sight glass – meniscus
Careful to maintain proper drain times
Aware of effect of coefficient of expansion
Best use is for calibrating meter to zero error
Can be costly and difficult to re-certify
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Volumetric – Test Tank
Different size tanks for various test quantitiesBadger Meter
USA
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Volumetric – Test Tank
Sight GlassTwo readings - tanks are manifolded
Badger MeterUSA
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Volumetric – Test Tank
ScotiatechHalifax, Canada
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Narrow-Neck Prover
Older technology (aka: onion tank)
Standing-start-and-finish-method
Better sensitivity due to narrow-neck
Errors reading sight glass – meniscus
Careful to maintain proper drain times
Aware of effect of coefficient of expansion
Careful about spilling if meter is under-registering
Can be costly and difficult to re-certify
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Narrow-Neck Prover
City of HalifaxCanada
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Narrow-Neck Prover
Measurement Canada Certification StickerCity of Halifax
Canada
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Narrow-Neck Prover Test Station
Water CorporationAustralia
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Gravimetric
Operation
Usually standing-start-and-finish method
Uses a vessel and a highly accurate electronic scale or mass comparator
Weigh the amount of water that has passed through the meter
Convert the weighed value to a volume based on the density of the measured water
Primary standard - test weights used to verify the accuracy of the weighing device
Advantages
Compensate for water temperature, pressure and gravitational effect
Relatively easy to recalibrate weighing device
Reduce operator error – easy to read indicator (no sight glass meniscus)
Easy to incorporate into fully automated system
Tank does not have to be drained between successive runs
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Gravimetric
City of BellvilleCanada
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Gravimetric
Badger MeterUSA
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Gravimetric
WRc-NSFWales, UK
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Gravimetric
WRc-NSFWales, UK
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Gravimetric
Load CellsBadger Meter
USA
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Gravimetric
Digital IndicatorWRc-NSFWales, UK
Digital IndicatorCity of Ottawa
Ottawa, Canada
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Gravimetric
Scale Inspection StickerBadger Meter
USA
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Gravimetric
Test WeightsWRc-NSFWales, UK
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Gravimetric
Hooks for Test WeightsBadger Meter
USA
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Master or Reference Meter
Operation
A highly accurate reference meter is placed in-series with the meter being tested
A volume of water is passed through both meters (usually standing-start-and-stop method)
The amount of volume displayed on both meter’s indicating devices are compared
Reference meters are periodically certified against a primary standard
FrequencyTimeVolumeCondition of water
Advantages
Flow through metering so no need to capture a volume of water.
Save spaceNo need for test tanksSaves time
Reduce operator error – easy to read indicator
Easy to incorporate into fully automated system reading
Disadvantages
Need to recalibrate meter regularly
Best if two reference meters are used in-line (3 way comparison)
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Master or Reference MeterTest Station
Water CorporationAustralia
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Master or Reference Meter
Large Meter Test Station200 mm (8”) Turbine Meter
Coulter Meter Service
Large Meter Test StationIn-take and Out-take lines
Coulter Meter Service
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Master or Reference Meter
Four ReferenceElectromagnetic Flowmeters
Coulter Meter Service
Digital IndicatorsElectromagnetic Flowmeters
Coulter Meter Service
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Master or Reference Meter
200 mm (8”) ReferenceElectromagnetic Flowmeter
(Fast Flow Tests)Coulter Meter Service
50 mm (2”) & 13 mm (1/2”) Reference Electromagnetic Flowmeter
(Intermediate and Slow Flow Tests)Coulter Meter Service
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Master or Reference Meter
Turbine Reference MetersNeptune Technology Group
USA
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Master or Reference Meter
Reference Mag Meter Remote DisplayBadger Meter
USA
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Master or Reference Meter
Test Scale Used with Reference Mag MeterBadger Meter
USA
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Displacement Provers
“Displacement provers operate on the principle of the repeatable displacement of a known volume of liquidfrom a calibrated section of pipe between two detectors.”
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Compact (Piston) Prover
o Flying-Start-and-Finish Method
o Utilizes a piston that travels through a measurement section
o Displaces a known volume of liquid
o Piston travel is detected with sensors
o Pulse interpolation allows for less than 10,000 pulses per pass
o Reliable proving with smaller volumes
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Compact (Piston) Prover
Brooks Compact Prover
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Compact (Piston) Prover
Brooks Compact Prover
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Compact (Piston) Prover
Brooks Compact Prover
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Compact (Piston) Prover
Brooks Compact Prover
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Compact (Piston) Prover
Brooks Compact ProverPTB
Germany
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Pipe Prover
Closed circuit system
Usually Flying-Start-and-Finish Method
Composed of a section of pipe of constant size
A displacer (ex. ball or sphere) passes a start and a stop detector
The volume between these two detectors is known (determined by water draw calibration)
Pulses received from the meter under test are counted while the displacer moves between the start and stop detectors
As the volume between these two detectors is known the pulses per litre of product can be deduced
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Pipe Prover
Badger MeterUSA
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On-site or Portable Testing
Operation
Customer meter is tested on-site
Standing-start-and-stop method
A portable reference meter is used (in-series)
Primary standard – reference meter is periodically certified with a traceable standard
Advantages
No need to remove meter for testing
No need for installing loaner meter or providing unmetered condition while regular meter is at test shop
Test may show meter errors due to installation – not seen at meter shop
Disadvantages
Large meters are not tested at Q3
Need an outlet for discharged water
Difficult to perform if no provisions have been made for on-site testing
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On-site or Portable Testing
Residential Meter TesterMARS Company
USA
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On-site or Portable Testing
MARS CompanyUSA
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On-site or Portable Testing
City of BellevilleCanada
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On-site or Portable Testing
ScotiaTechCanada
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On-site or Portable Testing
City of WindsorCanada
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On-site or Portable Testing
MARS CompanyUSA
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Water Supply
Flow Through
Water is only used once, discharged to sewer
Supplied by pump or gravity feed
Expensive if water is treated or purchased from independent sources
Waste - environmentally unfriendly
Difficult to control temperature
Re-circulation
Closed system
Tanks is used to store water used for test (above or below ground)
Pump circulates water
Water temperature can be controlled (heaters & chillers)
Water has to be monitored for contamination
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Water Supply
Pump Supplied
Pump is used to supply water to test bench
Allows for varying test pressures (variable speed pump)
Can be expensive if high energy costs
Gravity Feed
Water is stored in tower or tank that is above the test station
Pressure will be dependent on distance of the drop
Allows for constant head pressure
Not good if need for varying test pressures
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Re-circulation Tanks
6,000 litre tankCoulter Meter Service
Canada
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Re-circulation Tanks
Tanks and ChillerWRc-NSFWales, UK
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Water Supply- Pump Supplied
Badger MeterUSA
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Water Supply- Gravity Feed
National Research CouncilOttawa, Canada
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Water Supply- Gravity Feed
National Research CouncilOttawa, Canada
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Flow Disturbance Devices
Introduce flow disturbances upstream of meter
Ex. (ISO 4064 Part 3, Annex B)
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Flow RateDetermining Device
Rotameter
In-line meter
Stop watch
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Rotameter
“A device used to measure fluid flow, in which a float rises in a tapered vertical tube to a height dependent on the rate of flow through the tube”
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Rotameter
City of KitchenerCanada
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Rotameter
City of BellevilleCanada
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In-line Meter
Badger MeterUSA
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In-line Meter
WRc-NSFWales, UK
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Pressure Gauge
Badger MeterUSA
City of WindsorCanada
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Pressure Gauge
NeptuneTGUSA
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Pressure Gauge
WRc-NSFWales, UK
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Temperature Gauge
Neptune TGUSA
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Temperature Gauge
PTBGermany
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High Resolution Test Encoder
Device which replaces mechanical indicating device during testing
Provides a high number of output pulses
When used with high resolution test equipment allows for a relatively small amount of test volume
Result is faster test times
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High Resolution Test Encoder
Neptune TGUSA
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High Resolution Test Encoder
Calibration & CertificationNeptune TG
USA
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High Resolution Test Encoder
Badger MeterUSA
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High Resolution Test Encoder
Badger MeterUSA
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High Resolution Test Encoder
Badger MeterUSA
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Standing-Start-and-Finish Method
The meter is read when the registration is stationary
Flow is established by opening a valve
The flow rate is determined
The flow rate is adjusted (if required)
The minimum test quantity is delivered
Flow is stopped by closing a valve
The meter is read when the registration is stationary
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Standing-Start-and-Finish Method
Ensure that only 1/50 of the (by volume) run takes place at start up and shut-down.
If there is any doubt with target flow rates or start-up and shut-down times:
To increase the volume of the testTo increase the duration of the test
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Flying-Start-and-Finish Method
The measurement is carried out when flow conditions have stabilized
A switch diverts the flow into a test standard at the beginning of the measurement and diverts it away at the end
The meter is read whilst in motion (pulse output)
The reading of the meter is synchronized with the movement of the flow switch.
The uncertainty introduced by the flow switching will be considered negligible if the time involved is less than 1/50 of the total time of the test.
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Flying-Start-and-Finish Method
PTB Test FacilityBraunschweig, Germany
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Flying-Start-and-Finish Method
WRc-NSFWales, UK
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Major Factors Affecting Measurement Errors
Variations and Uncertainty in Measuring:
Supply Pressure
Flowrate
Temperature
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Supply Pressure
Shall be maintained at a constant value
Considerations for small meters at test flowrates ≤ 0.1 Q3Gravity feed (constant head)Pressurized tankVariable speed pump
During test shall not vary more than 10 %
The maximum uncertainty (k = 2) in the measurement of pressure shall be 5 % of the measured value
Pressure at the entrance to the meter shall not exceed the maximum admissible pressure for the meter
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Flow Rate
Shall be maintained constant throughout the test at the chosen value
The relative variation in the flowrate during each test (not including starting and stopping) shall not exceed:
± 2.5 % from Q1 to Q2 (not inclusive)± 5.0 % from Q2 (inclusive) to Q4.
The flowrate value is the actual volume passed during the test divided by the time.
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Temperature
During a test, the temperature of the water shall not change by more than 5 ºC
The maximum uncertainty in the measurement of temperature shall not exceed 1 ºC
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Uncertainty of Measurement
The uncertainty of this measurement, is influenced by a number of general factors:
Measurement uncertainty of the test standard or test equipment
Any variations between the volume seen by the meter and that seen by the test standard or test equipment
Testing process errors (stability metering conditions, meter cyclic effect, error of the measured metering conditions , etc)
Meter output resolution
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Minimum Test Quantity
“The minimum quantity of water that must pass through the meter to ensure that there is a high level of confidence that the results of the test are accurate”
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Minimum Test QuantityCalculations
Assume that the combined measurement uncertainty of the first three factors (Uref) = 0.125%.
For testing of water meters, two readings are taken (start of test run and end of test run)
the uncertainty due to the resolution of the indicating device (e) is based on a triangular distribution of ± e (GUM).
U res = e /√6 = .41e
Ures (%) = .41e * 100 / TQ , (TQ - test quantity)
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Minimum Test QuantityCalculations (cont:)
The uncertainty of the measured meter error (Umeter) is calculated using this formula:
(Umeter error %)2 = (Ures %) 2 + (Uref %) 2
Ratio between the meter MPE (maximum permissible error) and the expanded meter error measurement uncertainty (k) = 2, OIML recommends:
Type Approval: 5:1Initial Verification: 3:1
2 * Umeter error (%) ≤ MPE/5 (ex. Type Approval)
Umeter error (%) = MPE/10 (ex. Type Approval)
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Minimum Test QuantityCalculations (cont:)
With the equations shown, the minimum test quantity can be calculated using this formula:
TQ min = 0.41 e ÷ √ ( (MPE/10) 2 - (.125) 2 )
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Minimum Test QuantityExample # 1
Meter resolution (e) = 1 litre (0.001 m3)Flow Rate = Q3MPE = ± 2 %K=2Type Approval Testing: 5 to 1 Ratio
TQ min = 0.41 e ÷ √ ( (MPE/10) 2 - (.125) 2 )
TQ min = 0.41 x 1 ÷ √ ( (2/10)2 - (.125) 2 )
TQ min = 262.61 litre
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Minimum Test QuantityExample # 2
Meter resolution (e) = 1 litre (0.001 m3)Flow Rate = 1.1 Q1MPE = ± 5 %K=2Type Approval Testing: 5 to 1 Ratio
TQ min = 0.41 e ÷ √ ( (MPE/10) 2 - (.125) 2 )
TQ min = 0.41 x 1 ÷ √ ( (5/10)2 - (.125) 2 )
TQ min = 84.68 litre
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Minimum Test QuantityExample # 3
Meter resolution (e) = 1 litre (0.001 m3)Flow Rate = 0.9 Q3MPE = ± 2 %K=2Initial Verification: 3 to 1 Ratio
TQ min = 0.41 e ÷ √ ( (MPE/6) 2 - (.125) 2 )
TQ min = 0.41 x 1 ÷ √ ( (2/6)2 - (.125) 2 )
TQ min = 132.68 litre
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Minimum Test QuantityExample # 4
Meter resolution (e) = 1 litre (0.001 m3)Flow Rate = 1.1 Q1MPE = ± 5 %K=2Initial Verification: 3 to 1 Ratio
TQ min = 0.41 e ÷ √ ( (MPE/6) 2 - (.125) 2 )
TQ min = 0.41 x 1 ÷ √ ( (5/6)2 - (.125) 2 )
TQ min = 49.76 litre
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Minimum Test QuantitySummary Table
Example Inspection Type
MeterResolution
(Litre)
FlowRate
MPE K=Value
UncertaintyRatio
TQ Min(Litre)
#1 TypeApproval
1 litre 0.9 Q3 ± 2 % 2 5 : 1 263
# 2 TypeApproval
1 litre 1.1 Q1 ± 5 % 2 5 : 1 85
# 3 InitialVerification
1 litre 0.9 Q3 ± 2 % 2 3 : 1 133
# 4 InitialVerification
1 litre 1.1 Q1 ± 5 % 2 3 : 1 50
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Water Meter Testing
Questions or Comments