Chapter (5)

Flow measurement
and
maintenance
 Flow Measurements
 ­ment:
There are two kinds of flow measurement
a) Flow Rate
b) Total Flow.
 Flow rate:

is the amount of fluid that moves past a given

point at any given instant.
 Total flow

is the amount of fluid that moves past a given

point during a specified period of time.
 Factors affects on flow measurement

 Pressure
 Density

 Viscosity

 Velocity
Flow Profiles



Reynolds Number
 the nature of flow can be described by a number
called Reynolds number .(has no dimensions).


VDρ



R =
µ
: Where
V = velocity (feet / sec)
D = inside diameter of pipe (feet)
P=fluid density (lbs. Cu. Ft)
U= viscosity centipoises
 If the Reynolds number is less than 2000 the
flow is laminar.
 If the number is greater than 4000, the flow
is turbulent.
 Between these two values; the nature of the
flow is unpredictable.
 In most industrial applications, the flow is
turbulent.
Differential pressure meters
(Orifice Meter)
 Notice that the main flow stream takes the
shape of a venturi tube with the smallest
stream cross section occurring slightly
downstream of the plate.
 This points is called the vena contracta. At
this point, the pressure is at its minimum.
From this point on, the fluid again begins to
fill the pipe, and the pressure rises.
 The pressure, however, does not rise fully to
its upstream value. There is a loss of
pressure across the plate.
 Beta ratio
 It is the ratio of the orifice opening (d) to
the internal diameter of the pipe (D).

β = d/D

Ratios from (0.2) to (0 .6) generally provide

best accuracy.
 As flow passes through the opening (orifice) some
of the upstream pressure head is converted into
velocity head.
 The velocity head is greatest and pressure head
smallest at the "vena contracta" located slightly
downstream of the orifice.
 The differential pressure across the orifice is
related to velocity (bernoulli equation). When the
­tial pressure and static pressure are
differential
measured, and the orifice size, pipe size, and the
gas properties are known, the flow rate can be
calculated. The fluid flow is proportional to the
square root of this pressure difference.
 Bernoulli's equation
 states that the sum of static energy
(pressure head), the kinetic energy
(velocity head), and the potential
energy (elevation head) of the fluid are
approximately conserved in the flow
across a constriction in a pipe and by
continuity.
 . A typical working equation for liquids is:

Q = 19.65 x d2 x E x √ h

where:
 Q is the flow rate (gl./m),

 19.65 units constant,

 d is the orifice diameter (inch.),

 E is the efficiency factor or flow coefficient,

 h is the differential pressure (inch.),

Orifice Meters Types
Daniel Orifice
To Remove Orifice Plate
 (a)  Open No. 1 (Max. two turns only).
 (b) Open No. 5.
 (c)  Rotate No. 6.
 (d) Rotate No. 7.
 (e)  Close No. 5.
 (f)   Close No. 1.
 (g)  Open No. 10 B.
 (h)  Lubricate through No. 23.
 (i)    Loosen No. 11 (Do not remove No. 12).
 (j)    Rotate No. 7 to free Nos. 9 and 9A.
 (k)  Remove Nos. 12,9 and 9A.
To Replace Orifice Plate
 (a)   Close 10B.
 (b)   Rotate No. 7 slowly until plate carrier is clear of
sealing bar and gasket level. Do not lower plate carrier
onto slide valve.
 (c)   Replace Nos. 9 A, 9 and 12.
 (d)   Tighten No. 11
 (e)   Open No. 1.
 (f)     Open No. 5.
 (g)  Rotate No. 7.
 (h)  Rotate No. 6.
 (i)    Close No. 5.
 (j)    Close No. 1.
 (k)  Open 10 B.
 (l)    Lubricate through No. 23.
 (m) Close No. 10 B.
 Orifice plate inspection

 Check plate for flatness

 Check for sharpness

 Measure all bore sizes with a good pair of

micrometers.
 Check for smoothness.
 Orifice Plat handling & Storing
 Store new or reusable plates in proper storage
containers.
 Never hang plates on any- thing which will
damage the sharp edge, e.g., nails, wire, valves,
etc.
 ORIFICE MAINTENANCE
 Check orifice for wear, size, and squareness of edge.
 Plate should be examined for warping with straightedge.
 Plate should be examined for watermarks indicating
condensate damming.
 Check pressure taps.
 Test dp transmitter with dead weight pressure tester and
rescale if necessary.
 Resize orifice, if necessary.
 When orifice is resized, stamp the new diameter and
coefficient on the holder.
 Flush all trapped sediment from unit.
 Reinstall orifice plate in a correct position.
 Sensor lines should be blown down at regular intervals.
 .Flow Transmitters
 Flow transmitters allow the readout or
totalization device to be located in a convenient
remote location while the primary device is
located where ease of mechanical connection is
considered.
 Transmitters for differential pressure indicative
of flow convert the actual sensed differential
pressure to either a 3-15 psig or 4-20 ma signal.
 The signal can then be transmitted by tubing or
wire to the receiver.
 Removing the transmitter from service
This is accomplished by:
 Opening the bypass valve at the transmitter
while it is still in service, exposing both sides of
the differential pressure transmitter are exposed
to the same pressure.
 Other valves, such as valves to the taps or
transmitter drain or vent valves, can then be
opened without damaging the transmitter
 Placing the transmitter in service
This is accomplished by:
 Opening the bypass valve at the transmitter with
the flow meter system not in service.
 The valves to the taps are opened, which allows
fluid to flow through the impulse lines.
 The bypass valve is closed to place the
transmitter in service.
 Tap and Impulse Tubing Pluggage

 Dirt and foreign matter in the fluid can plug the

tap or impulse tubing.
 When this is suspected, the bypass valve can be
opened with flow in the pipe in an attempt to free
the contamination by allowing the differential
pressure developed across the orifice plate to
push the contaminant out of the system and back
into the pipe.
 If this does not work and the pluggage cannot be
opened, some dismantling of the impulse tubing
may be required to remove the pluggage.
 Chart Recorder
 The charts are a circular and constructed of heavy, good
quality paper.
 The four most commonly used charts have been
designed to make one complete rotation on the meter in
24 hours, seven days, eight days or thirty one days.
 The front of each chart is printed with a special ink,
which cannot be seen by electro scanner.
 The back of each chart is printed so that it provide a
space for important data or information.
 There are two basic types of chart, the linear or direct
reading chart and the square root or L-10 chart.
 On the linear chart, the circular lines are spaced
equal distances apart and represent the actual
values of the differential and static pressures.
The chart scale must correspond exactly to the
differential and static pressures ranges.
 On the square root (L-10) chart, the circular
lines represent the square root of a percentage of
the meter's full range. These charts have outer
lines labeled 10 which mean that 10 is the square
root of 100 or 100% of the meter's range.
 Chart Processing
 Charts are sent from the field locations to data
services for processing and analysis.
 Charts of good quality can be read on a device
called an electro scanner.
 Charts of poor quality must be read on manual
integrator.
 Electro scanning is accurate and take only ten
seconds.
 Manual integration requires a skilled analyst
from one to five minutes to manually trace the
recorded chart lines.
 After the chart have been read and checked by
analyst, the information is feed into a computer.
 The computer calculates oil/gas flowrate and
generates reports which are used for various
purposes.
 Chart Scanning Problems
 Pens have stopped inking for some reason, e.g. out of
ink, plugged, not touching chart, improper pen tension.
 Ink lines are smeared because of poor handling, not
blotting the chart, pen problems, etc.
 Chart is overrun because of late changing.
 Chart is torn or wrinkled due to poor handling weather
or vandalism.
 Chart has inaccurate zero line because the differential
pen is not zeroed.
 Time is not correct because the pens are not arcing
properly or chart was not started at accurate time.
 Chart has excessive pulsations due to rapid changes in
differential pressure.
 Chart has unwanted marks on the front, e.g., ink,
grease, fingerprints, notes, etc.
 Removing the old Chart

Equalize the differential pressure on the

meter by:
 Closing the vent valve (may be called bleed-off)
 Opening one of the by-pass valves.
 Opening the other by-pass valve.
 Closing either tap-valve (may be called shut-of
valve).
 Remove the old chart from the chart plate
after the differential pen comes to rest by:
 Opening the meter door.
 Raising the pen lifter gently.
 Removing the chart hub nut.
 Removing the chart from the hart plate.
 Blotting the chart carefully between two
stationery blotters.
 Placing chart and blotters in chart case to protect
the chart.
 Wind the clock with a clock key if the meter has
a mechanical chart drive.
 If the chart drive is electrical, then you need only
to check the battery change date.
 Good batteries are important for accurate chart
drive and should be replaced as required.
 Wipe the chart plate clean of spilled ink, dust,
etc. and clean the bottom of the meter case if
necessary.
 Instruments operate more accurately and require
less maintenance when they are kept clean.
 Installing the new chart
Select the correct chart for the meter by
checking the:
 a) Type of meter.
 b) Old chart (linear or square root).
 c) Differential and static ranges.
 d) Clock rotation period.
 Verify and complete data on the back of the new
chart.
 Place the new chart over the chart hub but don't
tighten the hub nut .
Zero the differential pressure en by:-
 Lowering the pen lifter gently.
 Adjusting the micrometer screw to zero
differential pen.
 Turning the chart manually 1/8" to make
differential pen recording.
 Raising the pen lifter gently.

install the new chart on the chart plate by:-

 Adjusting the chart under the clips on the
plate.
 Aligning the chart to the correct time/day.
 Tightening the chart hub nut.
 Lowering the pen lifter gently.
 Check the pens are on the chart and inking
properly.
 Re-check the differential pressure pen for

proper zeroing.
 Place the meter in service by:-
 a) Opening the tap-valve you closed earlier.
 b) Closing one of the by-ass valves.
 c) Closing the other by-pass valve.
 d) Opening the vent valve.
 complete the data on the back of the old
chart by:-
 Removing the old char from the chart case.
 Entering the time and date off.
 Checking for any recording irregularities.
 Identifying the correct zero marks on the chart.
 Writing important data in the remarks section
(don't write on the front of the chart).
 Putting the chart between blotters and back in
the chart case to protect it.
 Chart Handling techniques
 Always use the correct chart for each meter station.
 Always submit the chart regardless of condition.
 Use extreme care when changing the chart.
 Never fold or crease the chart.
 Don't allow the chart to become wet.
 Change each chart as close to the same time as possible.
 Never write in the front of chat.
 Explain important data in the remarks section on the
chart back.
 Don't use a pen that will bleed through to chart front.
 Keep chart lean from fingerprints, grease, ink,..
 Always use the pen lifter to raise pens.
 Blot charts with recommended stationery blotter
only.
 Keep old and new charts in chart case to protect
them.
 Maintain good housekeeping in meter housing.
 Report equipment problems to proper person.
 Reading the Chart
Linear charts
 Linear charts record the actual values of the differential
and static pressures.
 The chart scale must correspond exactly to the
differential and static pressure ranges of the orifice
meter.
 This linear chart has a maximum differential range of
100 inches of water and static range of 5000 psig.
 The differential range increments of 10 inches of water.
The static range increments of 500 psig.
 Square Root (L-10)
 The chart scale is always 0-10 and can be used
with any differential and static range orifice
meter
 The circular lines radiating out from the center
represent the square root of a percentage of the
meter's full range.
 The outer line labeled "10" means that 10 is the
square root of 100 or 100% of the meter range.
To convert differential reading to actual
differential pressure, follow these steps:
 Square the differential reading.

 Multiply the answer in step one by the

differential range of meter.
 Divide the answer in step two by 100.

 Round of answer in step three to whole number

and add the label "inches of water".
 To convert the static reading to actual static
pressure, follow these steps:-
 Square the static reading.

 Multiply the answer in step one by the static

range of meter.
 Divide the answer in step two by 100.

 Subtract the atmospheric pressure base of your

location from the answer in step three.
 Round of answer in step four to whole number
and add the label psig.
 Calculating Flow Rate
Linear Chart
 When calculating the flow rate from linear chart,
you simply multiply the orifice flow constant by
the square root of the differential and static
pressure.
 Differential pressure is read directly from chart
while absolute static pressure is the static
pressure reading from chart plus the
atmospheric pressure at your location.
To calculate the flow rate, follow these steps:
 Add the atmospheric pressure based to the static
pressure reading to change gauge pressure to
absolute pressure.
 Find the square root of the differential pressure.
 Find the square root of the absolute static
pressure.
 Multiply the orifice flow constant by the square
root of the differential and static pressure.
 Round off answer in step four to label "cubic feet
per day"
 Example
 You have been given an orifice flow constant of
152.91 for a certain meter, and an atmospheric
pressure based of 14.73, from the chart, you can
read the differential pressure as 43 inches of
water and the static pressure as 1000 psig.
 Square Root (L-10) chart

 When calculating the flow rate from a square

root chart, you simply multiply the orifice flow
constant by the differential and static pressure
readings from the chart.
 The static pressure from the chart will be the
absolute static pressure (psia).
 To calculate the flow rate, follow the
following steps:-
 Multiply the orifice flow constant by the
differential and static pressure readings from the
chart.
 Round off answer in step one to whole number
and add the label "cubic feet per day".
 Example
 You have been given an orifice flow constant
of 592.23 for a certain meter. From the chart
you read the average differential reading as
5.86 and the average static reading as 8.44
calculate the flow rate.
 MAINTENANCE AND MAINTENANCE
RECORDS
 Meters must be tested and calibrated prior to
installation and subsequently on a schedule
recommended by the manufacturer.
 Meters must be calibrated at least annually.
 Skilled technicians must be assigned to maintain and
service meters.
 Records of all maintenance, inspection, and
calibration actions must be kept to verify the status
and accuracy of the meter.
 Historical records should be reviewed to determine
whether calibration is performed frequently enough to
maintain meters in good working order.
.TURBINE METER
 OPERATION
 Inside a turbine flowmeter, the flowing medium
engages a vaned rotor, causing it to rotate at an
angular velocity that is directly proportional to
the flowrate.
 As the turbine rotates, an ac voltage is induced in
a magnetic pickup coil mounted outside the fluid
process.
 As each turbine blade passes the base of the
pickup coil, the magnetic flux density is affected,
inducing a voltage pulse.
 The pulse rate generated is thus a very accurate measure
of flowrate, and the total number of pulses an equally
accurate measure of displaced volume.
The K-factor
 It is the number of output pulses the flowmeter
 produces per engineering unit of volume throughput.
 The factor is represented by the expression:

K = 60f/Q
where:
 f= pulses per second
 Q= flow rate, in gallons per minute
 K= pulses per gallon
 The rotor is mounted on a shaft parallel to the flow
direction.
 Turbine flowmeter rotors are supported by ball
bearings or ball sleeve bearings.
Bearing life depends on several factors
 The actual operation expressed as a percentage of total
time.
 Corrosive impurities in the process.
 Lubricating qualities and cleanliness of the process
stream have a positive effect on bearing longevity.
 solid particles present has a negative effect.
 To minimize stream contamination by solids, A strainer
should be installed upstream of the turbine flowmeter.
 Turbine flowmeters provide
 • Wide flow rangeability
 • Outstanding accuracy at low cost
 • Construction materials that permit use with
many process fluids
 • Simple, durable, field repairable construction
 • Flexibility in connecting to associated electronic
readout devices for flow control and computer
interface
 • Operation over a wide range of temperatures
and pressures
 Limitations.
 Turbine meters are restricted to clean fluids.
 Insertion turbine meters require a clear space of
at least 4 feet perpendicular to the pipe for
installation.
 Temperature operating range
for standard units is -73°C to
+427°C.
 Special ranges are available.
 Pressure limit is 3,000 psig.
 .Maintenance

 Maintenance should be performed

every 6 months.
 The turbine blades should be checked
for deformation.
 The counter should be checked for
accuracy and calibrated if necessary.
POSITIVE DISPLACEMENT METERS
 Positive displacement meters splits the flow into
incremental volumes and then count the number
of these volumes that pass.
 Accuracy as good as (± 0.1%) can be achieved
with proper installation and calibration.
 positive displacement meters have many closely
machined parts, which make positive displacement
meters more expensive and produce higher
maintenance costs than other flow metering
instruments.
 The receivers for these devices usually provide
4-20 ma analog output if it is needed for input to
recorders, controllers or other analog instruments.
 Maintenance
 The possibility of electronic failures.
 positive displacement flowmeters are subject to
deterioration due to wear, corrosion, exposure to
a dirty liquid.
 Pluggage can occur if the flowmeter is exposed
to a dirty liquid.
 The flowmeter must then be disassembled and
thoroughly cleaned.
 Line cleaning prior to commissioning a new
system is strongly recommended.
 Positive displacement flowmeters should not be
exposed to steam, which is often used to clean
pipes, as this can result in damage.
Leaks
 The flowmeters are subject to leakage due to the
gaskets and seal that may be required for the
body and sensor assembly.
Electronic Failure
 Electronic failures can occur and are usually
remedied by board replacement.
 Calibration
 The K-factor establishes the relationship between
the frequency output of the flowmeter, the
volumetric flow, and the output of the converter .
 A frequency signal that corresponds to the
output of the flowmeter primary at a known flow
is injected into the converter so as to verify
operation of the converter and set zero and span.
 Maintenance of Flow Instruments
General considerations
 Ensure the proper isolation and/or removal
from process, following the appropriate
procedures and company safety rules (ie.
Putting the control loop on manual in case of
work to be done on a transmitter, Overriding
shutdown loop in case the instrument is flow
switch, Proper draining, proper venting etc.).
 The instrument is then transported to the Inst.
Workshop in case of full inspection and, repair
and calibration are going to be carried out,
otherwise the instrument can be checked and
calibrated at its service location after proper
isolation from process.
 Inspect against any signs of damage,
 Replace any suspected part following the
manufacturer instructions,
 Prepare the instrument for calibration.
 suitable calibrator to be used.
 Connecting tubing and fittings
 Suitable pressure indicator for output in case the
inst. Is pneumatic type.
 Connecting leads with suitable power supply and
Digital Multimeter and/or HART communicator
in case of electronic analoge or smart instruments
 Suitable hand tools and cleaning aids.
 Flow Transmitter Calibration (electronic type
D/P cell)
 Connect pressure calibrator to transmitter high input
port ensuring proper connections and correctly rated
tubing. Keep low side port at atmospheric pressure.
 Connect Ammeter (for 4-20 mA range) to the
appropriate terminals (if transmitter is of Analog
type). See electrical connection drawing.
 If transmitter is Smart type connect Hart
communicator to transmitter Terminals. See vendor
documentation for application Procedures and
Calibration.
 Confirm Range of the transmitter as per Data Sheet.
 Apply lower range D.pressure (0%) to the transmitter
noting the output current or indication.
 Apply set 25% incremental changes to the transmitter
and note output as follows:
 Apply D.pressure (lower range), record output mA.

 Apply D.pressure (25% range), record output mA.

 Apply D.pressure (50% range), record output mA.

 Apply D.pressure (75% range), record output mA.

 Apply D.pressure (100% range), record output mA.

 Apply upper range D.pressure and note output. Also

check values on decreasing increments by repeating
steps and note output mA or reading. It should be
20, 16, 12, 8 & 4 mA respectively.
 If the output values are not matching the
correct values, repeat the injection of input
values as shown above and adjust the Zero,
Span (and linearity if applicable) with
reference to vendors Calibration Procedure and
record the final Calibration results.
 When transmitter is acceptable, return to the
plant and fixes it in its location.
 ENSURE that the correct De-Isolation
procedure is implemented, making sure all vent
ports are plugged and all connections are leek
free. Now the transmitter is back in service.
 The control loop now can be placed in AUTO
following the relevant procedures.
 After work is completed, Ensure work place is
clean, all tools and test equipment are
withdrawn.
 Ensure that the work permit is signed off, that
test results are recorded in the appropriated
logs sheets.
 Flow Element Maintenance (senior orifice
fitting and other fixed elements)
Senior orifice fitting
 Isolate the orifice fitting (by isolating the related
process line, drain and depressurize).
 Follow the manufacturer procedures to take out
the orifice plate with its carrier and frame.
 Inspect, clean and replace any affected item.
 Dismantle the upper half of the orifice fitting.
 Inspect and clean the inside of the fitting as
required.
 Inspect the seat and the sliding valve (gate) for
smoothness, repair by lapping and polishing as required.
 Ensure the sliding valve (gate) springs are in good
condition and number required. Replace if affected.
 Inspect the gears on the rotating shafts and repair or
replace as required.
 Inspect the seal 'O' rings of the rotating shafts and
replace as required.
 Reassemble upper half to the lower half of the orifice
fitting with new gaskets and 'O' rings, tighten and
perform a leak test.
 Inject suitable grease sticks into the seat/sliding valve
and Insert the required size orifice plate with its
carrier & frame as per the manufacturer procedures.
 Return the orifice into service.
 Turbine Flow Meter Maintenance
Calibration
 The meter is pre-calibrated with water at factory
and tagged with the calibration factor in pulses-
per-volumetric unit (ie. Pulse/Gallon, Pulse/
cubic meter etc).
 For maximum accuracy with fluids other than
water, the meter should be calibrated with the
actual fluid being measured.
 Maintenance and Repairs

 The frequency of periodic checks depends on

the service to which the meter is applied.
 Significant variations from normal flow rates
should be sufficient notice to remove the meter
from the line and examine its internal parts for
damage or wear to ensure the free movement of
the turbine rotor, magnetic pick up &
preamplifier are giving healthy signal and the
flow computer is will adjusted and gives
accurate indication.
 Follow the manufacturer instructions to
dismantle the internal parts (rotor, bearings and
upstream/downstream hanger units) and install
new ones then readjust the flow computer
according to the new turbine meter 'K' factor .
 The calibration is based on injecting frequency
signal into the flow computer from a frequency
generator (instead of the turbine meter)
equivalent to the flow range of the process fluid.
 The value of the frequency signal can be
determined by knowing the value of turbine
meter 'K' factor and the process fluid flow range
using the equation below:
Q = tf / k
Where:
 'Q' is the max. Process fluid flow,

 't' is time unit in seconds,

 'K' is the turbine flow meter factor in pulses per

volumetric units.
 From the above equation, the frequency signal in Hz
= QK / t
 Inject 0 Hz into the flow computer (if min. range value
is zero) and adjust the flow computer zero to read zero
flow,
Inject max. Calculated frequency into the flow
computer and adjust the flow computer span to read
max. flow.
 carry out proving operation (if applicable) for the meter.
 FLOW STRAIGHTENERS, INSTALLATION
KITS AND STRAINERS

Flow Straightening
 Proper application of a turbine flowmeter requires that
there be a suitable piping section both downstream and
upstream of the meter if it is to achieve optimum
accuracy.
 Whereas an inlet straight pipe run of 10 pipe diameters
and an outlet straight pipe run of 5 pipe diameters
provide the necessary flow conditioning in general, some
applications require an upstream flow straightener.
 A flow straightener consists of a section of piping which
contains a suitably dimensioned and positioned thin
walled tube cluster to eliminate fluid swirl.
THANKS