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Pitot tube deltaflow - an engineering approach systec Controls Meß- und Regeltechnik GmbH Sebastian Fischer Sales Manager. Agenda. Design your deltaflow Select your deltaflow, deltaflow types, calculation software deltacalc, Mounting, Required Parameters, dp-connection, opposite support - PowerPoint PPT Presentation
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Industrial Flowmeters
Pitot tube deltaflow -
an engineering approach
systec Controls Meß- und Regeltechnik GmbH
Sebastian Fischer
Sales Manager
Industrial Flowmeters
Agenda
1. Design your deltaflowSelect your deltaflow, deltaflow types, calculation software deltacalc, Mounting, Required Parameters, dp-connection, opposite support
2. Bidirectional Measurement
3. Splitting Range
4. How to handle polluted media - Air purging system LSP
5. deltaflow for high-pressure applications – DF25HDD3
6. How to calibrate your deltaflow
7. Straight run requirements
8. Using integrated temperature & pressure measurement
Industrial Flowmeters
Chapter 1 - Design your deltaflow
This chapter contains:
• What deltaflow types are available?
• What parameters do I have to know?
• What minimum dp should I have for reliable measurement?
• How can I handle low flows?
• How can I handle big measurement ranges (span)?
• How does a bi-directional measurement look like?
Industrial Flowmeters
Design your deltaflow – deltaflow series
Type Pipe Size Pressure Remarks
DF8 1-25mm 0-690bar Spool piece with integrated orifice
DF10 DN20-DN100 0-690bar Basically replaced by DF12
DF12 DN20-DN100 0-160bar
DF25 DN65-DN2500 0-PN160 (PN250)
DF25 Quick-lock DN65-DN2500 0-100bar Retractable
DF44 200mm-15m 0-100bar
DF25HDD3 60-690bar 0-690bar weld-in (high-pressure)
DF8 DF12 DF25 DF25HDD3 DF25 Quicklok DF44
Industrial Flowmeters
What process connections / types are available?
Design your deltaflow – deltaflow types
Industrial Flowmeters
Flange-type
Cut-Ring Type
Design your deltaflow – deltaflow types
Industrial Flowmeters
Spool Piece Weld-in (DF25HDD3) Weld-in (DF12)
Design your deltaflow – deltaflow types
Industrial Flowmeters
DF8 – spool piece (block) with integrated orifice
DF25 Quick-lock system allows mounting/extraction under pressurized conditions (max. 100bar)
Design your deltaflow – deltaflow types
Industrial Flowmeters
DF8 DF12 DF25
DF25HDD
3
DF44 Remarks
Flange-stud X X X Max. PN250(PN160 for steam)
Cut-Ring X X Max. PN40
Weld-in X X
Quick-lock o.r. X Max. 100bar
Spool Piece X X X X max DN250 (other o.r.)
deltaflow types - Summary
Note: Spool Pieces are available with welding ends or flanges
Industrial Flowmeters
Design your deltaflow – required parameters (1)
Profile crosses whole diameter -> length customized to application
• Internal Diameter ID
• Wall thickness WT
• Thickness of isolation IT
are required
WT
ID
Insulation IT
Stud (e.g. cut ring or flange)
dp-connection
Profile
Industrial Flowmeters
Design your deltaflow – required parameters (2)
Profi
le
Neck
Material Designation
1.4571 (SS316Ti) Stainless Steel, Standard Material (>>90% of all applications), up to 500°C
1.4828 High-temperature applications (up to 1040°C)
1.4539, Hastelloy C4, Haynes Alloy
corrosive media
High-pressue See seperate chapter
• In most cases neck and parts outside of the pipe can be made of standard SS316 (1.4571) also when profile is made of special material• Material of weld-in stud should be equal or similar to pipe material
Industrial Flowmeters
Design your deltaflow – required parameters (3)
Pipe Data
• Wall thickness
• Internal Diameter
• Pipe Material
• Orientation of Pipe (horizontal or vertical
Process
• Flow
• Temperature
• Pressure
Industrial Flowmeters
Calculate (design) your deltaflow – calculation software deltacalc ?
..\..\..\..\Program Files\deltacalc 7\deltacalc7PRO.exe
Industrial Flowmeters
How can I connect my deltaflow with my dp-transmitter ?
Industrial Flowmeters
Design your deltaflow - Mounting of dp-transmitter
Direct Mounting
Remote Mounting
Industrial Flowmeters
dp-Connection - 3-way-manifold
direct+ Easy setting of zero point by using by-pass+ Shut-off of media (e.g. allows remove of transmitter)+ high pressure / temperature (PN400)
- Smaller internal piping -> not recommended for wet gases
Industrial Flowmeters
dp-Connection – Ball Valves
Direct
+ Shut-off of media (e.g. allows remove of transmitter) possible
+ big opening -> recommended for wet/dirty gases (e.g. Biogas)
+ Available with threads, welding ends, oval adapters, fittings (ermeto,..)
- Limited concerning Temperature/Pressure (70bar at 35°C, 2 bar at 200°C)
Remote
Industrial Flowmeters
dp-Connection – Shut-off valves
Needle (shut-off) Valves (normally for remote installation of transmitter)
• Double (see pic.) and single valves available
•Available with welding ends, thread, Ermeto, Swagelok. Customized connections possible
+ Shut-off of media (e.g. allows remove of transmitter)
+ big opening + High pressure/temperature (PN400)
Industrial Flowmeters
dp-Connection – Miscellaneous
Fitting (e.g. Ermeto) for remote mounting
Ball Valve with fitting (e.g. Ermeto) for remote mounting
Oval Adapter (direct mounting)(acc. to EN61518)
Welding Ends for remote mounting
Industrial Flowmeters
dp-Connection – Miscellaneous (2)
Weather Protection Box
+ provides heating and protection for electrical equipment (transmitters)+ Can be mounted remotley or direct on deltaflow‘s flange
Industrial Flowmeters
dp-Connection – Summary
• Various possibilities of connections of dp-transmitters are available
• Possibility to shut-off connection to media (valves) is recommended
• If not specified by customer we recommend 3-way-manifold or ball valve (wet / dirty gases) for standard applications
• When using high-pressure equipment double valves are recommended
Industrial Flowmeters
How should I mount my deltaflow?
Industrial Flowmeters
Mounting – Liquid Service
• Mounting should allow gas bubbles to vent off
• When installed sidewards probe should be slightly slanted (-3…0°)
Industrial Flowmeters
Mounting – Gas Service
• Mounting should allow condensate to drain back into pipe
(Otherwise condensate might accumulate in internal piping and generate water column (which generates faulty dp))
• When installed sidewards probe should be slightly slanted (0..3°)
Industrial Flowmeters
Mounting – Steam Service
• Condensate is used to transmit dp to transmitter
• Mounting should allow excessive condensate to drain back into pipe
• When installed sidewards probe should be slightly slanted (0..3°)
Industrial Flowmeters
Design your deltaflow – Required dp
deltaflow requires a minimum differential pressure to ensure reliable measurement:
As rule of thumb you should have at least:
• Gases / Liquids: >0.2mbar @ Qmin
• Steam: >5mbar (steam applications are more sensitive against misinstallation than gas / liquids) @ Qmin
dp‘s can be calculated for each application by using deltacalc software
Industrial Flowmeters
Design your deltaflow – required dp
How can I handle low flows?
• Sometimes velocity is too low to provide sufficient dp values
• Spool Pieces with reduction can be used to speed up mediaReduction
(e.g. DN100/DN65)
Widening (e.g. DN65/DN100
By using spool pieces with reduction deltaflow can serve also typical low flow applications (e.g. Biogas)
Industrial Flowmeters
What‘s about the mechanical stability of deltaflow?
When do I need an opposite support ?
Design your deltaflow – opposite support
Industrial Flowmeters
Opposite Support - Background
Probe has a specific resonance frequency (RF) depending on length and width of probe
Flow generates Vortex („turbulence“) with a specific frequency (VF) at probe depending on velocity and width of probe („probe is stimulated“)[RF and VF are mentioned at deltacalc calculation protocol]
If Vortex frequency = resonance frequency (or multiple) probe might resonate and might break!
To ensure mechanical stability an opposite support might be required
Vortex
Industrial Flowmeters
Frequency calculation without opposite supportApplication: Steam, DN200, 7bar, 200°C, various flows, without opposite support
v=7.73m/s v=24.58m/s v=61.46m/s
RF VF SF VF SF VF SF
DF25 248.9 70,2 3,55 234,1 1,06 585,3 0,43
DF32 264.5 43,8 6,04 145,9 1,81 364,7 0,73
DF44 383.3 33,5 11,44 111,7 3,43 279,4 1,37
RF = Resonance Frequency of Probe / VF=Vortex Frequency
Saftey Factor SF = RF/VF
SF should be >= 1.3 to ensure mechanical stability
Industrial Flowmeters
Application: Steam, DN200, 7bar, 200°C, various flows, with opposite support
v=7.73m/s v=24.58m/s v=61.46m/s
RF VF SF VF SF VF SF
DF25 995,8 70,2 14,19 234,1 4,25 585,3 1,7
DF32 1058,0 43,8 24,16 145,9 7,25 364,7 2,9
DF44 1535,2 33,5 45,83 111,7 13,74 279,4 5,49
Opposite Support quadruples Resonance Frequency and Saftey!
The bigger the profile the higher the resonance frequency
Frequency calculation with opposite support
Industrial Flowmeters
Opposite Support – Examples
High-pressure probe withopposite support
DF25 prepared for use with (upper) and without (lower) opposite support
Industrial Flowmeters
Opposite Support – Summary / Design RulesOpposite Support Required if:
• Pipe Size >= DN1000
• dp >= 20mbar and RF/VF <= 1.3
• High-pressure probe
Check (if required or not) is done automatically by deltacalc (except because of size!)
Industrial Flowmeters
Chapter 2 – Splitting Range Measurement
How can I handle big measurement ranges?
Industrial Flowmeters
Splitting range
• deltaflow offers a span of typically 1 to 7..10
• 1 to 10 in flow means 1 to 100 (!) in dp
How does that influence my measurement?
Example: dp_min = 2mbar / dp_max = 240mbarspan dp-transmitter: 250mbar, uncertainty 0.1% (=0.25mbar)
0.25mbar at 2mbar means relative uncertainty of 12.5%
With splitting range. e.g:
1. Transmitter: 0…20mbar
2. Transmitter: 20…240mbar
Industrial Flowmeters
Design your deltaflow – splitting range
How can I realize a splitting range measurement?
• You need two (or more) (stacked) transmitters
• You need evaluation unit (e.g. flowcom or PCS) which decides which transmitter should be used (depending on dp)
Connectors („T-bone“)
Industrial Flowmeters
Splitting range - summary
• With splitting range up to 4 dp-transmitters can be used
• Span of 1..30 and more can be realized(pay attention to mechanical stability)
Industrial Flowmeters
Chapter 3 – Bi-directional Measurement
Industrial Flowmeters
Bi-directional measurement
Flow (splitting range)Back Flow
(splitting range)
• Thanks to symetrical profile deltaflow can measure bidirectional
• Each direction requires it‘s own transmitter(s)
• Flowcom (or PCS) controls measurement
Industrial Flowmeters
When do I need an air purging system (LSP)
Chapter 4 – Air purging
Industrial Flowmeters
Air purging system LSP
• Highly Polluted media might clog deltaflow‘s dp-tappings
• When dust-load >=50mg/m3 automatical cleaning is required
• systec offers automatic air purging system LSP for periodical cleaning
• LSP blows pressurized air into deltaflow pressure chambers
Industrial Flowmeters
Air purging system LSP - Principle
Connections for dp-impulse pipes (Ermeto, others on request)
Connection for pressurized air (max. 6bar)
Valves: When purging connection to dp-transmitter is closed and connection to pressurized air is open
Purging is controlled by SPS. Frequency of purging as well as length of purging can be set by user
dp-transmitter can be mounted directly on LSP by using mounting plate
Industrial Flowmeters
Air purging system LSP - Example
Connected by impulse piping
LSP with mounted dp-transmitter
Shut-off (ball valves)
deltaflow DF50 (old style), flange type
Industrial Flowmeters
Air purging system LSP - Summary
• With LSP measurements at high degrees of pollution (up to 200 g/m3 (!)) become possible
• During purging dp is hydraulically locked -> no lost of dp-signal during purging
• Option „Signal holding“ available. Here, last value of dp before purging is holded electronically by SPS
• Direct mounting of dp-transmitter possible (on top of LSP)
• Pressurized Air required on site (max. 6 bar)
• Impulse piping required (LSP - deltaflow)
Industrial Flowmeters
When do I need a high-pressure probe and what‘s about it ?
Chapter 5 – deltaflow for high-pressure applications
Industrial Flowmeters
High pressure probe
When do I need high pressure probe?
• Limits for standard DF25: PN160 (steam), PN250 (Liquids)
Finally, it has to be determined by customer, but there are indications when to use high-pressure probe:
• When weld-in probe is required (e.g. sealings are not accepted)
• When pipe is made of high grade material (e.g. P91, 10CrMo 9 10))
Industrial Flowmeters
High pressure probe
For high pressure applications a special version of the DF25 (DF25HDD3) is available
• Profile made of massive block (no welding seams)
• Material of Profile: 1.4828
• Materials of weld-in parts:16Mo3, 10CrMo 9 10, P91
• Material of valves:16Mo3, 10CrMo 9 10
• opposite support always required
Profile
Weld-in part („neck)
Condensate Pots (for steam only)
Double valves
Industrial Flowmeters
High pressure probe - Examples
- Steam, 535°C, 190bar - spool piece- Profile: 1.4828- Weld-in part: P91- Condensate Pots: P91
- Steam, 540°C, 100bar - Profile: 1.4828- Weld-in part: 10 CrMo9 10- Condensate Pots:10 CroMo 9 10 (=1.7380)
Industrial Flowmeters
High pressure probe – Required certificates / testings
Requirements are regulated by PED97/23/EG
16 Mo 3(1.5415)
13CroMo44(1.7335)
10CrMo9 10(1.7380/1.7383)
X20CrMoV12 1(1.4922)
P91(1.4903)
X-Ray X
TÜV acceptance test (dye penetration, hardness test, material identification check)
x x x x X
Heat treatment
x x x x
Documentation incl. 3.2 certificate
x x x x x
Industrial Flowmeters
Chapter 6 – Calibration
Industrial Flowmeters
Calibration
dpdqm 2²4
1 Formula for flow calculation
• During calibration flow, dp (at deltaflow), p, T are measured at different points
• Corrected Blockage Factor Zeta is extracted
• Corrected Zeta will be then used for your appliaction
-> Improved accuracy (0.4%)
• Calibration can be done at PtB or at systec
• Spool Piece always required
• PtB or systec issue calibration certificate
Industrial Flowmeters
Factory Certificate
PtB Certificate
Industrial Flowmeters
Chapter 7 - Straight run requirements
What is the best mounting position for my deltaflow?
Industrial Flowmeters
Straight run requirements
Industrial Flowmeters
Straight run requirements - ImproveIT
•ImproveIT is a data base which offers calibration factors for typical obstacles in inlet (curves)
• Factors are provided by systec on request
• Factors can be put into deltacalc
Industrial Flowmeters
Chapter 8 – Integrated pressure and temperature measurement
Why could p/T-compensation improve the accuracy?
How does it look like?
Industrial Flowmeters
Integrated pressure/temperature measurement - background
dpdqm 2²4
1Density, depends on pressure (p) and Temperature (T)
• If pressure and/or temperature change, density also changes
• Density influences flow (e.g. T +10% -> density +10% -> q +srt(10%)=3.16%
• To compensate influence, p and/or T should be measured in order to calculate correct density (flowcom / multi variable transmitter)
• Only recommended/required when p and/or T fluctuate
Industrial Flowmeters
Flowcomputer flowcom
• p&T compensation + Mass flow calculation
• Heat transfer measurement
• Data Logger + Display
• Easy handling (on-site with buttons)
Industrial Flowmeters
Integrated pressure/temperature measurement
Integrated PT100
- Can be removed under pressurized conditions- 0…400 (600°C)- direct PT100 or 4…20mA (with transmitter)
Cable Box
Presseure measurement(here: Steam Service)
- Can be removed under pressurized Conditions (when having valve)- direct PT100 or 4…20mA
Industrial Flowmeters
Integrated pressure/temperature measurement - Examples
DF44 with preparation for external pressure transmitter (supplied by customer)
(here: Liquid Service)
DF12 with spool piece, integrated temperature measurement(Gas Service)
Industrial Flowmeters
Integrated pressure/temperature measurement - Examples
DF10 with integratedtemperature (Gas Service)
DF8 with preparation for pressure measurement (Gas Service)
DF8 with preparation for pressure measurement (Steam Service)
Industrial Flowmeters
Integrated pressure/temperature measurement
Model Integrated pressure
Integrated Temperature
DF8 X X Integrated in spool piece
DF10 X X Integrated in spool piece
DF12 (x) (x) Only with spool piece
DF25 X X
DF25HDD3
DF44 X X
Industrial Flowmeters
References
• deltaflow Data Sheets
• deltacalc calculation software
• deltaflow manual
• flowcom manual
• LSP manual