Index

Paper 7.1
RELIABILITY AND INSTALLATION EFFECTS OF ULTRASONIC CUSTODY TRANSFER GAS FLOW METERS UNDER SPECIAL CONDITIONS

Volker Herrmann SICK|MAIHAK Toralf Dietz SICK|MAIHAK Matthias Wehmeier SICK|MAIHAK

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005

RELIABILITY AND INSTALLATION EFFECTS OF ULTRASONIC CUSTODY TRANSFER GAS FLOW METERS UNDER SPECIAL CONDITIONS
Volker Herrmann, Toralf Dietz and Matthias Wehmeier, SICK|MAIHAK

INTRODUCTION

Ultrasonic gas flow meters have been available commercially since the 1980s for a range of measuring tasks. Numerous developments have seen their application range increase enormously. Modern gas flow meters are more and more used in custody transfer applications. Even after more than 20 years of development, new advances are being made for ultrasonic gas flow meters and there is still room for improvement. Optimising the meter concept and analysing all the potential sources of errors are aimed at eliminating or minimising as many uncertainty factors as possible. Factors that result in significant measurement uncertainty must be identified and appropriate manufacturing technologies, procedures, and test strategies developed. A discussion on the uncertainty budget of the meter itself was presented in [2]. Taking into account the conclusions of this study, a reliable meter concept was developed, which ensures a high degree of accuracy and reproducibility. The typical field installation differs significantly from the test lab, leading to deviations and additional uncertainties for the ultrasonic gas flow meters. As is emphasised in a recent study [1] this is valid for different meter sizes and designs. The reason for this behaviour is based on the nature of the flowing fluid the fluid dynamics itself and the response of the meter on this special situation. A detailed knowledge of the velocity profiles in typical field installation and an improved understanding of the meter physics can help to further optimise the meter behaviour. This paper follows the recent study on uncertainty budget and manufacturing accuracy [2]. A modern measurement technique the particle image velocimetry (PIV) - is presented, which allows to measure the velocity profiles in the pipe independently, resulting in a complete representation of flow velocity pattern at each point of the pipe. The results of the PIVmethods where compared with the responses of an ultrasonic meter. Different installation configurations where tested with the PIV method. Using a modern disturbance plate [4] to produce the disturbed flow profiles was a time and effort saving fact. The results of these tests where implemented into the measurement algorithm of the flow meter FLOWSIC 600, leading to the fact, that the meter can detect and compensate installation effects to some certain extent. The practical meaning of this algorithm was checked on standard test procedures during the type approval at ambient conditions and on the high pressure test lab of Ruhrgas AG in Lintorf (Germany) with typical practical installation conditions. Inlet disturbances with only 5 D straight pipe where chosen as a worst case scenario, which is neither practical nor recommended by the manufacturer of the meter, but shows the response of the algorithm to unexpected and unusual flow disturbances. The benefit the user will gain from this (and future) investigations is mainly certainty: Certainty that the meter will behave like specified and that the number of unexpected installation effects will decrease. Another benefit is that it will be possible to gain a few points of a percent accuracy which counts to relevant numbers.

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005 2 FLOW PROFILE INDUCED MEASURING UNCERTAINTY OF ULTRASONIC GAS FLOW METERS

Gas flow meters rarely work under conditions comparable with those ideal situations in a calibration facility. To identify the sensitivity of the gas meter to flow profile conditions, tests have been carried out within pattern approvals for the gas meters. The deviation of the baseline under disturbed conditions should be within the allowable error range. Ultrasonic gas flow meters for custody transfer (fiscal applications) are before installation calibrated in a national recognised test facility. In the final result at least the average deviation over the measured range will be corrected by an adjust factor. The design of test facilities guarantees stable and approved flow profiles over the full measuring range. In practice the ultrasonic gas flow meter should possibly operate to a great extent independently of deviations from the calibration conditions. In order to respond as little as possible, on the flow profile conditions, the gas flow meter should be as tolerant as possible against deviations in the flow profile. 2.1 Flow Profiles And Standard Test Configurations

The flow profiles inside a pipe are influenced by many constructive piping elements (e.g. bends, double bends, T-pieces, reducers and expanders). The most common practical installations are simple 90 degree bends (elbows) and double bends (double elbows) either in or out of plane. Such elements create asymmetry of the axial velocity pattern and/or swirl movements, depending on the nature of the construction element. The gas flow meter should be tolerant against such disturbances of the profile. Therefor, its reaction on this is tested during pattern approval. These test configurations should produce swirl affected, asymmetric flow profiles and should represent extreme installation conditions. To ensure compatibility of the results a standard procedure is used. The International Organisation of Legal Metrology OIML defined therefore standard pipe configurations to perform perturbation tests within pattern approvals. Figure 1 shows the defined standard configurations for testing the disturbance sensitivity as described in OIML Recommendation R32 [5]. A double bend out of plane in a nominal pipe size smaller than the meter size is followed by a expander. This is the low level perturbation test configuration, but the flow profile distortion is heavier than just with a double-bend out of plane. For high level perturbation a half moon plate is installed between the two bends; this increases again the flow profile distortion. Both configurations create asymmetry and swirl in different degrees. As a result of these tests, a deviation from base line under undisturbed conditions is measured, which should mark the maximum of the expected deviations in practice and should define also the minimum length of the necessary undisturbed inlet and outlet lengths.

Fig. 1 Standard OIML test configurations

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005 Especially with testing of large diameters the spatial limits of the test facility will be easily reached. In order to carry out tests in an effective and flexible way, the German PTB (Physikalisch-Technische Bundesanstalt) in Braunschweig has developed perturbation plates. Figure 2 shows an example of the hole pattern of such a perturbation plate. The main idea is a perforated plate, like a flow conditioner, but the covered area is asymmetric to the pipe axis to induce asymmetries in the axial flow profile. Additionally holes are drilled under an angle to the pipe axis to induce swirl. The perturbation plates are scalable for various diameters. The plate can be placed between two flanges of a straight pipe in front of the meter for easy application. Investigations of the flow profiles generated by these plates, have shown that the perturbation level is a mix of the OIML low-level perturbation and a double bend out of plane. [3]

Fig. 2 - Example of hole pattern of a perturbation plate

2.2

Ultrasonic Meter Path Layout

All ultrasonic gas flow meters have arranged several measuring paths across the inner cross section of the meter to sample the velocity distribution of the flow profile. Figure 3 shows the path layout of the here investigated 4-path ultrasonic gas flow meter FLOWSIC 600 of SICKMAIHAK. The path layout consists of four parallel ultrasonic paths. All four paths are arranged in one plane, which has an angle of 60 to the meter body axis. The path levels are at 0.809R and 0.309R (R = radius).

v path 1 v path 2 v path 3 v path 4

Fig. 3 - Ultrasonic gas flow meter FLOWSIC 600 and its path layout

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005 For transmitting and receiving of the ultrasonic signals, the FLOWSIC 600 utilises new small size, high frequency transducers (figure 4). These transducers cause only negligible perturbations for the flow profile close to the wall of the meter body. Therefore the influence of the transducers can be neglected in this study.

Fig. 4 Ultrasonic transducers A special problem of all ultrasonic gas flow meters is their sensitivity to the orientation of the asymmetry in a disturbed flow profile. All path layouts are not symmetrically in a mathematical sense. Hence, a meter may show different results with a certain disturbance at different inlet lengths. The reason for this phenomenon is the length depending change of the asymmetry position in the grid of the paths and the resulting changes in path velocity pattern. These changes can be easily simulated in experiments by rotation of the perturbation plate instead of installing different pipe length. On the other hand, the independently determined path velocities offer the possibility to compensate for influences of swirl and asymmetry. Algorithms that determine the degree of asymmetry and the swirl strength using the path velocities can compensate for the measurement deviations produced by the disturbances. The implementation of such algorithms needs a full understanding of the local gas velocity distributions. To gain these information from the flowing gas a two dimensional velocity measurement method is necessary. A suitable method was found with the Particle Image Velocimetry (PIV). 3 3.1 PARTICLE IMAGE VELOCIMETRY (PIV) Basics

The Particle Image Velocimetry is a non intrusive method for the measurement of simultaneous two-dimensional velocity fields in one plane. The method is based on the tracing of particles that are transported with the movement of the flow, with algorithms of image processing. With a particle generator an adapted tracer is added to the flow and illuminated by a double pulse laser through light sheet optics. A special CCD camera provides two images of the measuring plane in a defined time distance, which will be divided in smaller portions for further processing, the so-called interrogation spots. For every spot a displacement of the particles from two successive images is calculated with help of crosscorrelation as shown in figure 5. This displacement, together with the time difference between the two exposures, results in the velocity components. The results of single spots are combined to a vector field for the whole measuring plane, which can be further processed depending on the purpose of the experiment.

Fig. 5 - Example for interrogation spots taken from a double image with resulting spatial correlation

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005 3.2 PIV - Measurements On The Perturbation Plate Generated Flow Profile

In connection with these test programs PIV measurements were carried out in air under ambient pressure 10D after the perturbation plate for the above-referenced path levels of a four-path FLOWSIC 600 with size DN200 (8-inch). Two perturbation plates were used with clockwise and counter-clockwise swirl. To test the response of the meter relative to the disturbed flow profile, the plates were rotated in 30 degrees steps. The PIV layout is sketched in figure 6.

CCD-Camera

Tracer particels

pipe Measuring section

Laser

Gas flow

Fig. 6 - Picture of PIV test setup The essential advantage of the PIV-method is that, because of the two-dimensional nature, the axial and tangential velocity (the latter one does not contribute to the total flow) can be determined directly. From the measuring values of the ultrasonic gas flow meter these single components can generally not be derived, since they are connected by the path angle. This PIV measurement can help to better understand how swirl and asymmetry are projected in the path velocities. With this knowledge an algorithm should be developed, which allows for a correction of the measuring deviations caused by the disturbed flow using only the path velocities. As an example for a PIV result in figure 7 average fields of axial and tangential velocity for the path level 2 are presented as grey scale diagrams. Drawn is here the trace of the acoustic measuring path, along which in a further step of processing the path velocities are integrated. The integration of the local velocities is performed in the virtual region, which is the direct connection between the two transducer membranes (between the two dotted lines).
transducer position

Fig. 7 - Average velocity patterns 10D after disturber plate 2, orientation 60

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005 For a better understanding we will first have a look at the distorted axial velocity profiles as shown in figure 8. Compared with an undisturbed pipe flow under the same conditions, one realises immediately the distinctly flatter and especially at the inner paths levels (2 and 3) clearly tilted curves. Further on, the velocity ratio of the paths has considerably changed compared to an undisturbed situation. Both effects, even without the swirl influence still further investigated, have the consequence of clear recognisable measurement deviations.

6 5 4 vx [m/s] 3 2 1 0

path level 1 path level 2 path level 3 path level 4

20

40

60

80 100 y [mm]

120

140

160

180

Fig. 8 - Average profile of axial velocity 10D after disturber plate 2, orientation 60 3.3 The Numerical Calculation Of The Path Velocities

For both perturbation plates and all measured orientations the axial and tangential components of the path velocities were calculated by integration of the velocity fields along the acoustic measurement paths. From these together with the path angles, synthetic path velocities v path were derived.

6 5 4 3 2 1 0

530m3/ h

perturbation plate 1 orientation 60o

path 1 path 2 path 3 path 4

6 5 4 3 2 1 0

530m3/ h

perturbation plate 2 orientation 60o

path 1 path 2 path 3 path 4

v [m/s]

Vax

Vtan

"Vpath"

v [m/s]

Vax

Vtan

"Vpath"

6 5 4 3 2 1 0

530m3/ h

perturbation plate 1 orientation 150o

path 1 path 2 path 3 path 4

6 5 4 3 2 1 0

530m3/ h

perturbation plate 2 orientation 150o

path 1 path 2 path 3 path 4

v [m/s]

Vax

Vtan

"Vpath"

v [m/s]

Vax

Vtan

"Vpath"

Fig. 9 - Composition of path velocities at the axial and tangential components from the PIV measurement

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005 Figure 9 represents examples for this, with especially extreme behaviour, as block diagrams. First of all it is clear that the two perturbation plates at same orientation show similar profile The tangential contribution from these deformation (vax), but opposed swirl (vtan). disturbances can reach until 15% of the axial velocities on the outer paths. But is also noticeable at the inner paths. The distribution of the tangential velocities on the single paths shows asymmetry. Furthermore it is striking that the path velocities differ considerably from the axial components, which determine the flow. Here lies the essential reason for the measurement deviations of ultrasonic gas flow meters in disturbed flow profiles. From the complete data set, collected with the perturbation plates, an optimal correction algorithm was developed based only on the path velocities. The operation of this algorithm was tested, as described in the following sections, with the OIML standard disturbances as well as with more practically relevant installation conditions. 4 4.1 PRACTICAL TEST WITH DISTURBED FLOW PROFILES Verification With OIML Standard Configurations At Ambient Test Conditions

Without a priori knowledge of the present disturbed flow situations device characteristics were obtained for the following situations:

ideal flow condition (20D straight upstream pipe) OIML Low-level disturbance, 10D upstream OIML High-Level disturbance, 10D upstream Single bend (90), 10D upstream, in two positions (12 oclock and 9 oclock)

The test of the characteristics in a disturbed configuration was carried out according to the OIML directive at relative flow values of 10%, 25%, 40%, 70% and 100% of Qmax. For better understanding the following results are represented based on the initial characteristics (ideal flow condition). The presented deviation was calculated as follows:

Devi = Edisturbed ,i Ebase,i

Figure 11 shows the response of the FLOWSIC 600 on the disturbances according to OIML R32 at ambient test conditions. The algorithm shows the general ability to compensate for the swirl and asymmetry induced flow measurement deviations. For the Low-level disturbance the deviations can be kept in a bandwidth of less than 0.35%.

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005
1,0
air @ pamb, Tamb

0,5

Deviation [%]

0,0

-0,5
Low-level left Low-level right

-1,0 0 20 40 60 80 100 120

Q / Qmax [%]
Fig. 11 Test result FLOWSIC 600 (DN 200, Qmax 2500 m/h), OIML standard configurations 10D upstream at ambient conditions The results of the high-level disturbance tests have left the error band of 0.5%. For such heavy distorted situations it is recommended to condition the disturbed flow with a flow conditioner. Therefore additional test series with an upstream installed flow conditioner were done. The flow conditioner was placed at 2D upstream of the meter. If using a preferred flow conditioner, the necessary upstream pipe length could be reduced to 5D upstream of the disturbance. In this configuration also the very heavy distorted flow situations of the high-level disturbance, which is caused by the half moon plate, can be kept in a bandwidth of 0.35%. Furthermore, the use of a flow conditioner flattened also the error curves.
1,0
air @ pamb, Tamb

0,5

Deviation [%]

0,0

-0,5
Low-level left High-level left Low-level right High-level right

-1,0 0 20 40 60 80 100 120

Q / Qmax [%]
Fig. 12 Test result FLOWSIC 600 (DN 200, Qmax 2500 m/h), OIML standard configurations 5D upstream at ambient conditions

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005 A single 90-bend was used to test the algorithm in a more common situation. The bend was rotated by 90 to check this flow situation in two different relations for the path layout.
1,0
air @ pamb, Tamb

0,5

Deviation [%]

0,0

-0,5

single elbow 9 o'clock single elbow 12 o'clock

-1,0 0 20 40 60 80 100 120

Q / Qmax [%]
Fig. 13 Test result FLOWSIC 600 (DN 200, Qmax 2500 m/h), single 90-bend in two orientations 10D upstream at ambient conditions The FWME of the meter deviations during the different tests was calculated and is summarised for a general overview as shown in the next picture.
1,0 10D 0,5 avg. deviation [%] 5D with FC avg. deviation [%] 10D 0,5 1,0

0,0

0,0

-0,5

-0,5

-1,0 Low-level right Low-level left High-level left High-level right

-1,0 single elbow 9 o'clock single elbow 12 o'clock

Fig. 14 FWME presentation of all tested configurations at ambient conditions

4.2

Verification With Typical Installation Elements At High Pressure Conditions

Because the OIML standard pipe configuration does normally not exist in real world applications, the question arises of course how well the compensation works for other, practically relevant installation elements, like single bends, u-bends and double bends. Also until now all measurements were carried out with atmospheric air, on one meter size. How will the compensation relate in another Reynolds-domain, determined by high pressure natural gas as test medium and different meter diameter? For this purpose extensive test series will be reported from the test rig of Ruhrgas AG in Lintorf, Germany. These results will be presented in the following section. The used meter size was a DN 300 (12 inch), four-path meter FLOWSIC 600. The tests were carried out with high pressure natural gas at 10 bar. Figure 15 and Figure 16 show two of the tested configurations. The U-bend was build from two 90-bends. The double bend out of plane has used the same elements. For every test a Zanker-type flow conditioner was 9

4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005 installed 10D upstream of the disturbance element to produce repeatable conditions for the disturbance tests.

Fig. 15 U-bend

Fig. 16 Double bend out of plane

The main investigation focus was on the double bend out of plane. This test configuration generates asymmetry and swirl. Different relations between the flow profile and the ultrasonic path layout was tested, by rotating the meter in 90 steps clockwise. The reproducibility of the test configurations were proven by comparison with the results of a former test (curve 0 03/2003). The graphs show again the deviation of the meter from the meter response under ideal flow condition (baseline at 55D straight inlet pipe).
1,0
natural gas 10bar(g)

0,5

deviation [%]

0,0

-0,5

0 180 0 03/2004

90 270

-1,0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

flow rate [m/h]

Fig. 17 - Test results FLOWSIC 600, DN 300 (12 inch), double bend out of plane 10D upstream at high pressure gas, HDV Lintorf, Germany The algorithm works in the same satisfying way, no matter which meter size or Reynolds domain. The deviation remains in a error band of 0.35%. To double check that the algorithm is not optimised for the 10D distance, the whole test was repeated with 5D upstream inlet pipe between the meter and the double bend.

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4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005
1,0
natural gas 10bar(g)

0,5

deviation [%]

0,0

-0,5
0 180 90 270

-1,0 0 500 1000 1500 2000 2500 3000

0 03/2004

3500

4000

4500

5000

flow rate [m/h]

Fig. 18 - Test results FLOWSIC 600, DN 300 (12 inch), double bend out of plane 5D upstream at high pressure gas, HDV Lintorf, Germany Also under these more severe situation the deviation remains in a error band of 0.5%. Finally also the test results are shown for a single bend at 20, 10 and 5 diameter distances and for a ubend at 10 and 5 diameter distances.
1,0
natural gas 10bar(g)

0,5

deviation [%]

0,0

-0,5
90-bend 5D U-bend 5D 90-bend 10D U-bend 10D 90-bend 20D

-1,0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

flow rate [m/h]

Fig. 19 - Test results FLOWSIC 600, DN 300 (12 inch), single bend and u-bend on different upstream distances, at high pressure gas, HDV Lintorf, Germany

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4th International South East Asia Hydrocarbon Flow Measurement Workshop 9 - 11 March 2005 To summarise all test results, again the flow weighted mean errors (FWME) of the tests are calculated and shown together in the next picture.
FWME of meter deviation, test double bend out of plane
1,0 5D

FWME of the 90-bend and U-bend tests

1,0 avg. deviation [%] 0,5 0,0 -0,5 -1,0 90-bend 5D 90-bend 5D 90 turn 90-bend 10D 90-bend 20D U-bend 5D U-bend 10D

avg. deviation [%]

0,5

10D

0,0

-0,5

-1,0 0 90 180 270 meter orientation

Fig. 20 - FWME presentation of all tested configurations, HDV Lintorf Germany 5 CONCLUSION

The investigations show that it is possible to gain a better understanding of the fluid dynamics and the resulting meter behaviour. The FLOWSIC 600 has the ability to work well in typical field configuration, if taking into account the installation recommendations. Furthermore, if using the preferred flow conditioner, only 5D upstream inlet length can be used. The fact, that ultrasonic gas flow meters have become really mature over the last years does not mean that there is no room for improvements left. Substantial efforts in research will improve quality standards for the future even more and most important will reduce the overall uncertainty picture of ultrasonic meters. 6 NOTATION resulting deviation of the meter error in disturbed flow situation error in ideal flow condition test flow rate 10, 25, 40, 70, 100% Q/Qmax tangential velocity component axial velocity component

Dev Edisturbed ,i

Ebase,i i vtan vax

7 [1]

REFERENCES Delenne, Mouton, Pritchard, Huppertz, Ciok, van den Heuvel, Folkestad, Vieth, Lezuan, Marini, Evaluation of Flow Conditioners Ultrasonic Gas flow meters combinations, North Sea Flow Measurement Workshop, October, 2004 Herrmann, Ehrlich, Dietz, MANUFACTURING ACCURACY A KEY FACTOR FOR OVERALL PERFORMANCE ON AN ULTRASONIC GAS FLOW METER, 3rd International SE Asia Hydrocarbon Flow Measurement Workshop, March 2004 Pereira, Mickan, Kramer, Dopheide, von Lavante, INVESTIGATION OF FLOW CONDITIONING IN PIPES, FLOWMEKO 2002 Dr. Rainer Kramer, Physikalisch-Technische Bundesanstalt, Braunschweig, Special aspects concerning the type approval of ultrasonic gas flow meters used for legal metrology applications, Gas Berlin 2003, OIML Recommendation R32, Rotary piston gas flow meters and turbine gas meters, Annex A, 1989

[2]

[3] [4]

[5]

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