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Process Control
PIP PCEFL001
Flow Measurement Guidelines
Tables
Table 1 Selection of Flow Elements
Table 2 Flange Tap Orifice Meter Run Requirements
1. Introduction
1.1 Purpose
The purpose of this Practice is to provide guidance in the application of flow
meters.
1.2 Scope
This Practice provides recommendations for the selection of the meter, its general
applications, and its performance considerations. This guideline applies to devices
used to measure the flow of single phase, homogeneous liquids, vapors, and gases.
This Practice presents commonly accepted meter types but does not limit application
choices. Unique or special requirements may require consideration of other meter
types.
Specific custody transfer guidelines are not provided and are only mentioned with
reference to other industry practices.
2. References
Applicable considerations in the latest edition (or the edition indicated) of the
following industry standards may be referenced for additional information. Short
titles may be used herein when appropriate.
2.1 Process Industry Practices (PIP)
– PIP PCCFL001 - Flow Measurement Criteria
– PIP PCCGN002 - General Instrument Installation Criteria
2.2 Industry Codes and Standards
• American Gas Association
– AGA 7 - Measurement of Gas by Turbine Meters
• American National Standards Institute (ANSI) – ANSI-2530/API-14.3/AGA3/GPA-
8185 - Natural Gas Fluids Measurement
- Concentric, Square-Edged Orifice Meters
Part 1 General Equations and Uncertainty Guidelines
Part 2 Specification and Installation Requirements
Part 3 Natural Gas Applications
Part 4 Background, Development, Implementation Procedures and Subroutine
Documentation
• American Petroleum Institute (API)
– API RP 551 – Process Measurement Instrumentation
– API RP 554 – Process Instrument and Control
– API Manual Of Petroleum Measurement Standards (MPMS): Chapter 4 - Proving
Systems
4.2 Conventional Pipe Provers
4.3 Small Volume Provers
4.5 Master-Meter Provers
4.8 Operation of Proving Systems
Chapter 5 - Metering
5.2 Measurement of Liquid Hydrocarbons by Displacement Meters
5.3 Measurement of Liquid Hydrocarbons by Turbine Meters
Chapter 6 - Metering Assemblies
Chapter 12 - Calculation of Petroleum Quantities
12.2 Calculation of Liquid Petroleum Quantities Measured by Turbine or Displacement
Meters
Chapter 14 - Natural Gas Fluids Measurement
14.2 Compressibility Factors of Natural Gas and Other Related Hydrocarbon Gases
(AGA Report No. 8)
14.3 Concentric, Square-Edged Orifice Meters
14.4 Converting Mass of Natural Gas Liquids and Vapors to Equivalent Liquid
Volumes
14.5 Calculation of Gross Heating Value, Specific Gravity, and Compressibility of
Natural Gas Mixtures from Compositional Analysis
14.6 Continuous Density Measurement
14.7 Mass Measurement of Natural Gas Liquids
14.8 Liquefied Petroleum Gas Measurement
Chapter 21 - Flow Measurement Using Electronic Metering Systems
• American Society of Mechanical Engineers (ASME)
– ASME MFC-1M - Glossary of Terms Used in the Measurement of Fluid Flow in
Pipes
– ASME MFC-2M - Measurement Uncertainty for Fluid Flow in the Closed Conduits
– ASME MFC-3M - Measurement of Fluid Flow in Pipes Using Orifice, Nozzle, and
Venturi
– ASME MFC-4M - Measurement of Gas Flow by Turbine Meters
– ASME MFC-5M - Measurement of Liquid Flow in Closed Conduits Using
Transit-Time Ultrasonic Flow Meters
– ASME MFC-6M - Measurement of Fluid Flow in Pipes Using Vortex Flow Meters
– ASME MFC-7M - Measurement of Gas Flow by Means of Critical Flow Venturi
Nozzles
– ASME MFC-8M - Fluid Flow in Closed Conduits - Connections for Pressure Signal
Transmissions Between Primary and Secondary Devices – ASME
MFC-9M - Measurement of Liquid Flow in Closed Conduits by Weighing Method
– ASME MFC-10M - Method of Establishing Installation Effects on Flow Meters
– ASME MFC-11M - Measurement of Fluid Flow by Means of Coriolis Mass Flowmeters
– ASME MFC-14M - Measurement of Fluid Flows Using Small Bore Precision Orifice
Meters
[Note: For ½" to 1- ½" Orifice Meters and Integral Orifice]
– ASME MFC-16M - Measurement of Fluid Flow in Close Conduit by Means of
Electromagnetic Flowmeter
– ASME B16.5 - Pipe Flanges and Flanged Fittings
– ASME B16.36 - Orifice Flanges
– ASME PTC-6 - Performance Test Code, Steam Turbines
• International Organization for Standardization (ISO)
– ISO 5167-1 - Measurement of Fluid Flow by Means of Pressure Differential
Devices
• ISA, The International Society for Measurement and Control (ISA) –
ISA RP16.1,2,3 - Terminology, Dimensions and Safety Practices for
Indicating Variable Area Meters
– ISA RP16.4 - Nomenclature and Terminology for Extension Type Variable Area
Meters
– ISA RP16.5 - Installation, Operation, Maintenance Instructions for Glass Tube
Variable Area Meters
– ISA RP16.6 - Methods and Equipment for Calibration of Variable Area Meters
– ANSI/ISA RP31.1 - Specifications, Installations, and Calibration of Turbine
Flowmeters
2.3 Other References
– Miller, R.W., Flow Measurement Engineering Handbook
– ISA - Flow Measurement - Practical Guides for Measurement and Control,
Spitzer, D.W., Editor
– ASME - Fluid Meters, Their Theory and Application
3. General Considerations
4.2.1 Flow nozzles may be used in low viscosity, non-abrasive fluids at high
flow rates in which:
a. Lower head loss than an orifice plate is desired
b. A contoured element is needed for long service life where a sharp edge would
wear
4.2.2 Installation and removal of the nozzle should be considered in the piping
design. However in high pressure steam applications (greater than 1000 psig), the
flow nozzle should be welded directly into the pipe.
4.2.3 Orifice plate upstream and downstream piping criteria should apply to a flow
nozzle as it is a flow profile sensitive device.
4.3 Venturi (Classical and Proprietary Designs)
Advantages:
• Very low permanent pressure loss
• Good for fluid flows with entrained solids
• Upstream run length is less than for orifice meters Limitations:
• Expensive in larger sizes
• Big and heavy in larger sizes
• Because a venturi is fabricated, quality of workmanship varies. Inspection is
generally desirable before shipment and required before installation.
• Limited data set for coefficient and upstream straight pipe requirements
• Higher measurement uncertainty at pipe Reynolds numbers less than 100,000
4.3.1 A venturi may be used in low viscosity, non-abrasive fluids at high
flow rates where only a small pressure drop or permanent head loss is allowed.
4.3.2 Process conditions which can tolerate only a relatively small amount of
unrecovered losses of developed differential pressure may require a
proprietary low loss venturi tube. In some cases one of the proprietary design
meters may provide lower installation cost.
4.3.3 For high accuracy applications, the venturi should be flow
calibrated.
4.4 Averaging Pitot Elements
Advantages:
• Low cost
• Low permanent pressure loss
• Negligible flow obstruction
• May be installed using hot taps
• Shorter upstream and downstream piping requirements than for orifice
Limitations:
• Very low differential pressures developed, so signal may be noisy
• Impulse lines must be kept to minimum length due to low DPs involved
• Must be precisely aligned in pipe
• Turndown limited due to low differential pressure
• Subject to plugging or fouling
• Subject to vibration induced fatigue failure if maximum velocity limit is
exceeded
4.4.1 An averaging pitot tube may be an alternative to an orifice plate where
lower head loss is needed, lower cost is desired and less accuracy is acceptable.
4.4.2 Averaging pitot tubes are subject to plugging and should be limited to
clean process liquids and gases.
4.4.3 Depending on velocity profile characteristics, averaging pitot tubes
are more accurate than pitot tubes.
4.4.4 Maximum expected fluid velocity should be considered in the design to avoid
exceeding manufacturer’s recommended limits.
4.4.5 In large line sizes, where long traverse lengths may be encountered,
opposite side support should be provided or heavier walled elements used.
4.4.6 Since most designs of averaging pitot type devices only average flow
over a single plane of the full cross-section of the conduit, the flow profile
distortions can have an adverse effect on measurement accuracy.
4.4.7 If a failed pitot tube could enter and damage downstream rotating
equipment, another element type should be considered. If a pitot tube is used,
opposite side support should be considered.
4.5 Integral Orifice
Advantages:
• Good for very low flows
• Other meters may be more expensive or unavailable in small sizes Limitations:
• Subject to plugging
• May be less accurate unless flow calibrated
4.5.1 When low flow rates dictate a meter tube less than 2 inch, an integral
orifice assembly may be used.
4.5.2 Integral orifices and honed pre-fabricated meter tubes can be designed
in sizes that meter comparable flow rates. Selection between the two should be
based on cost (both hardware and installation), metallurgy requirements,
transmitter mounting options, on-line servicing requirements and metering accuracy
needs.
4.5.3 Integral orifices are available in two types of configurations. One
design type routes the process flow through one or both chambers of the
differential pressure transmitter. The other design is much like a standard orifice
flange except the transmitter connection is machined (like a manifold flange) so
the transmitter can be mounted directly up against the orifice assembly.
4.5.4 If the meter needs to be serviced while the process is on-line,
isolation valves must be installed. Process line block and bypass valves are
required for servicing the flow-through design while on-line. For an adjacent
transmitter design, root valves (or a flange by flange manifold) allow servicing
the transmitter. If the expected on-line servicing includes checking a small bore
for plugging, then the block and bypass arrangement are required for either
integral orifice design.
Comment: Even small leakage through a meter bypass will result in significant flow
measurement errors of small integral orifices. Ensure the bypass valve is capable
of zero leakage.
4.5.5 The fluid should be of low viscosity and contain no solids when small
bores are dictated. This may require a strainer installed upstream of the meter run
and be located beyond the manufacturers minimum recommended pipe diameters upstream
of the orifice. Normal process operating conditions as well as potential start up
contaminants (pipe scale, welding slag, etc.) should be considered.
4.5.6 If high accuracy is needed, the integral orifice should be flow tested
prior to use and a calibration curve developed.
4.6 Wedge Type Meters
Advantages:
• Excellent for slurries and very dirty fluids
• Relatively low permanent pressure loss
• Self-cleaning
• Good for low Reynolds number applications. Minimum Reynolds number of 500
• May be used in bi-directional service Limitations:
• Some installations may require remote seals
• More expensive than orifice installation
4.7 Turbine Meters (Liquid)
Advantages:
• High accuracy
• High turndown
• Easy to install
• Low permanent pressure loss
• Linear output (frequency or analog output available)
• Insertion style available, subject to special installation requirements
Limitations:
• Easily damaged
• Typically requires more maintenance than other meters due to moving parts
• Fluid must be clean
• Sensitive to viscosity changes
• Bearings wear and will reduce accuracy
• Requires special techniques for start-up
4.7.1 Turbine meters may be used in fluids that are clean, provide lubricity,
in single phase (not operated near the liquid vapor pressure), and are limited in
viscosity changes.
4.7.2 Full line sized turbines are typically used in lines 8 inches and
below. Insertion type turbine meters may be used on larger lines.
4.7.3 Bearing types and materials of construction should be evaluated for
fluid and process stream compatibility.
4.7.4 For high accuracy services, turbine meters used in low density or high
viscosity fluids may have to be operated over a reduced range of flows. Refer to
manufacturer’s guidelines.
4.7.5 Strainers, filters, air or vapor eliminators or other protective
devices should be provided upstream to remove solids or gases that will cause wear
and measurement errors.
4.7.6 Turbine meter damage can occur when the process lines are blown clear with
gas or steam. Special provisions may be required to protect the meter.
4.7.7 Liquid turbine meters should only be used in moderate to low viscosity
services. Turbine meters are velocity profile sensitive and flow profile
conditioning devices upstream of the turbine should be considered.
4.7.8 Refer to API MPMS Chapter 5 for high accuracy application guidelines.
For plant applications refer to ISA RP 31.1.
4.8 Turbine Meters (Gas)
Advantages:
• High turndown
• Easy to install
• Low permanent pressure loss
• Linear output (frequency or analog output available)
• Insertion style available, subject to special installation requirements
Limitations:
• Easily damaged
• Typically requires more maintenance than other meters due to moving parts
• Fluid must be clean
• Bearings wear and will reduce accuracy
• Requires special techniques for starting up
4.8.1 Gas turbine meters may be used in clean and liquid free gas services;
however, these meters are not typically used in chemical process service.
4.8.2 Gas turbine meter factors shift with density changes and should be used
only after calibration within intended density range.
4.8.3 In-line gas turbine meters should be provided with block and bypass
valves and piping for maintenance. The full bore block valves should be installed
so they do not introduce flow profile disturbances to the meter.
4.8.4 Manufacturer recommended upstream and downstream lengths should be
followed.
4.8.5 The insertion type gas turbine meter is available for use in large line
sizes. If on-line removal is required, refer to Section 3.6 of this document for
guidelines.
4.8.6 Liquid separation and removal from the stream ahead of the turbine
meter should be considered.
4.8.7 Gas turbine meters should not be installed in pulsating flow
conditions.
4.9 Positive Displacement Meters (Liquid)
Advantages:
• High accuracy
• Wide rangeability
• Suitable for high viscosity
• No straight upstream piping required
• Linear volumetric output
• Good for local totalization
• Can be installed at remote locations without power Limitations:
• Moving parts are subject to wear which introduces measurement error
• Requires periodic maintenance
• High permanent pressure drop
• Not suitable for fluids with entrained or abrasive solids or gases
• May completely disrupt the flow if mechanical failure jams or locks the
moving parts of the meter
4.9.1 Strainers and air eliminators should be considered upstream of
the meter.
4.9.2 Liquid positive displacement meters may be used for custody transfer if
other meters capable of operating in the service conditions do not meet accuracy or
rangeability requirements.
4.9.3 Manufacturer’s recommendations should be followed for viscosity and
flow rate limitations.
4.10 Magnetic Flow Meters
Advantages:
• No flow obstruction
• Low or no pressure loss
• Good for plugging services and slurries
• Good for corrosive services by using liners
• Not effected by physical property changes in fluid other than conductivity
• Minimal straight piping requirements
• Can be set up for bi-directional flow Limitations:
• Fluid must have electrical conductivity (generally 2 micromhos per cm or
greater)
• Liners can be fragile or be easily damaged
• Cannot use on gases
• Grounding is a major concern to prevent errors due to stray field currents
• Requires separate power source
• Large meters are heavy
• Installed cost may be prohibitive on large meters
• Coating of electrodes may be a problem
• May be temperature limited
4.10.1 Magnetic flow meters may be used on conductive fluids that are:
a. Corrosive
b. Contain suspended or abrasive solids
c. Very low flow
4.10.2 Proper liner material and electrode selection is needed for process
fluid compatibility. The manufacturer should be consulted for material
availability.
4.10.3 A minimum fluid conductivity in micromhos/centimeter is needed for the
meter to operate properly. Consult with the manufacturer for the minimum
requirement.
4.10.4 Microprocessor based, digital magnetic flow meters are preferred.
4.10.5 The application of magnetic flow meters should be evaluated for startup
and cleanout conditions (fluids, conductivity, and temperature).
4.10.6 Grounding method should follow manufacturer’s recommendations.
4.10.7 Avoid liner damage due to over tightening of bolts and crushing the
liner during installation.
4.10.8 Do not subject the meter to thermal shock or exceed the meter’s
specified temperature limits.
4.10.9 Magnetic flow meters generally require a separate power source.
4.11 Mass Meters (Coriolis)
Advantages:
• Accurate direct mass measurement
• Good for just about all types of liquids and some high density gases
• Minimal restriction to flow, though in some cases head loss may be high
• Can measure density of fluid in addition to mass flow Limitations:
• High cost
• Installation may be more critical than other meters
• Somewhat more complex to maintain
• Slugs of gases will effect the measurement
• Typically temperature limited to 400° F
• Available in limited sizes
• High pressure drop
4.11.1 Coriolis meters should be sized for the desired accuracy at minimum and
normal flow rates without exceeding the permissible pressure drop at the maximum
flow rate.
4.11.2 Corrosion mechanisms should be given extra consideration. Vibration of the
meter tube increases the potential for stress related corrosion. Other alloy
materials may be required in applications where 316 SS would otherwise be
acceptable. Most meter tubes have no corrosion allowance, particularly galvanic
corrosion from dissimilar metals.
4.11.3 If the density measurement offered as an option by the manufacturer is to be
used, the accuracy provided should be evaluated for the application.
4.11.4 Adequate discharge back pressure should be insured in liquid service to
prevent flashing in meter tube.
4.11.5 Meters should not be located in areas susceptible to vibration. External
sources of vibration in frequency ranges and harmonics of the meter operating
frequency may effect meters. Installing two meters in series can be susceptible to
crosstalk. Consult with the meter manufacturer.
4.11.6 Care should be taken to avoid subjecting the meter body to piping induced
stresses.
4.11.7 When entrained gas is present, evaluation of the application with the meter
manufacturer is advised. Meter performance will deteriorate significantly due to
the presence of entrained gases in the liquid.
4.11.8 Secondary containment should be considered when using coriolis meters for
measuring highly corrosive or hazardous materials.
4.11.9 Coriolis meters to be used in highly viscous slurries, shear-sensitive
slurries, or fluids that could solidify or settle out to block the flow path may
require additional tube/sensor design considerations.
4.11.10 Coriolis meters are available with either or both digital and analog type
outputs. Care should be taken to insure that output is compatible with control
system I/O (i.e., pulse width, pulse height, edge trigger, etc.).
4.11.11 The application of coriolis meters should be evaluated for startup and
cleanout conditions (entrained gas, temperature extremes, plugging, slug flow,
etc.).
4.12 Mass Meters (Thermal)
Advantages:
• Good for low velocity pure component gas or air measurement
• Very low pressure loss
• Probe type thermal meters are cost effective for large flows
• Cost effective flow switch Limitations:
• May be effected by coatings on probe-fluid should be relatively clean
• Some designs are fragile
• Relatively slow response time
• Generally used in gas and vapor service
• Must be flow calibrated for accuracy
• Cost is generally higher for low flow applications (flow-through type meters)
Custody Transfer generally applies to those flow metering applications where fiscal
or custodial information is developed. Metering information is used for exchange of
moneys, materials, or trades between two parties, companies, business units, or
financial institutions. The design of a custody transfer measurement system usually
has a requirement for higher integrity and accuracy than conventional process
measurement. Industry standards such as American Petroleum Institute are available
as a resource.
Table 1
Selection of Flow Elements
Service Conditions
Clean fluid, low-viscous
PIP PCEFL001
Flow Measurement Guidelines ossibly resulting in a
low Reynolds Numbe ended in the fluid June 1998 e material in the fluid
rosive fluid
Gas in liquid or liquid in gas
Low accuracy (2%+) is accepta
Low flow rates Medium flow rate High flow rat
Primary Flow Element
(>5 to
Orifice, Concentric Y P N N P N N Y P N
Y Y P Y
Orifice, Eccentric or Segmental N N P N P P N Y
N N Y Y N Y
Orifice, Quadrant or Conic Edge P Y P Y P N N Y
N N Y Y N Y
Flow Nozzles Y N P P P P P P P N Y
Y P Y
Venturi Y N P Y P P Y P P N Y Y
P Y
Averaging Pitot R N N N P N Y Y N N Y
Y N Y
Wedge Meters N Y Y Y P P P Y N P Y
Y N Y
Integral Orifice R N N N P N N Y N Y N
N P Y
Turbine Meters (Liquid) R N N N P N P P Y
Y Y Y Y Y
Turbine Meters (Gas) R N N N N N P P Y Y
Y Y Y Y
Positive Displacement Meters (Liquid) Y Y N N P N N
P Y Y Y P Y N
Magnetic Flow Meters (Conductive fluids only) Y N Y P Y N
Y Y N Y Y Y Y P
Mass Meters (Coriolis) Y Y Y P P N N Y Y Y
Y N Y N
Mass Meters (Thermal) P N P N P N Y P N P
Y Y N Y
Ultrasonic (Transit-Time) Y N N N P N Y P P
Y Y Y P Y
Ultrasonic (Doppler) N N R P P R Y P N N
Y Y P Y
Vortex Shedding Meters Y N P N P P P Y P N
Y P Y Y
Variable Area Meters Y N N N P N N Y N Y
P N Y N