September 23, 20041 Fuji Electric Ultrasonic Flowmeters

September 23, 2004 1

Fuji ElectricUltrasonic Flowmeters

September 23, 20042

Introduction

Ultrasonic waves travel in the same manner as light or microwaves, however being elastic waves, they can propagate through any substance whether solid, liquid & gases. And by utilizing the properties of ultrasonic waves clamp on flowmeters with unique feature of being able to measure fluid flow in the pipe externally was developed.

In 1975, Fuji Electric introduced its first ultrasonic flowmeter and since then Fuji Electric USFMs have been very successfully in many applications both domestically and internationally.

September 23, 20043

Contents

1. Why use ultrasonic flowmeter?

2. Who needs ultrasonic flowmeter?

3. What’s unique in Fuji’s ultrasonic flowmeter?

4. References

5. Application notes

September 23, 20044

1.1 ） Why use ultrasonic flowmeter?Benefits of A NON-INTRUSIVE sensor (CLAMP-ON type) Cost saving Easy maintenance (No moving parts) No pressure loss No plugging/clogging No corrosion No leakage

IT IS AN IDEAL SOLUTION TO PROBLEMS OF ORDINARY INTRUSIVE/SPOOL PIECE TYPE OF FLOWMETERS.

Differential Pressure, Magnetic Flow, Turbine, Coriolis & Etc.

September 23, 20045

1.2 ） Why use ultrasonic flowmeter?Wide operating conditions more than your expectationsTemperature : -40 ~ +200 °CPipe Diameter : Ø13mm ~ Ø6000mmFlow Velocity : 0.3 ~ 32m/s (High turndown ratio) Measured Fluid : Sound conductive fluids even with bubbles.Accuracy : ±0.5 ~ 1.0%Response Speed : 0.5second

September 23, 20046

1.3 ） Why use ultrasonic flowmeter?Check if you have right choice of flowmeter on line! Ultrasonic Electromagne

ticDifferential Pressure

Vortex

Measuring Media

Fluid

Gas X X

Vapor X X

Slurry X X X

ApplicationControl

Monitor

Supply X X X

Operating Condition

Temperature -40 to 200 °C -20 to 120 °C -40 to 600 °C -10 to 200 °C

Pressure - -1 to 2MPa -0.1 to 42MPa 5MPa

Pressure loss None None Yes Yes

Rangeability Large Large Large Large

Installation Condition

Bore 13 ~ 6,000mm

2.5 ~ 300mm 25 ~ 3,000mm 4 ~ 100mm

Upstream/Downstream

10D/5D 5D/2D 10D/5D 7D/3D

Piping works Not Required Required Required Required

Explosion proof X X

Performance

Accuracy 0.5 % of rate

0.5 % of rate

2.0 % of FS 1.0 % of rate

Velocity range -32 to 32m/s 0 to 15m/s - 0.3 to 4m/s

September 23, 20047

0

10,000

20,000

30,000

40,000

50,000

25mm

50mm

80mm

125mm

200mm

300mm

400mm

500mm

700mm

900mm

1200m

m

Pipe（Φ）

(US$)

MAGFLOWUSFM

1.4 ） Why use ultrasonic flowmeter?Cost Comparison

September 23, 20048

2.1 ） Who needs ultrasonic flowmeter?Increasing demands by 11% per year through 2001 (Forecasted by ARC, USA Advisory Group)

Government regulation requires reporting the amount of discharged fluid from plants. (Especially in Chemical + Refining + Wastewater)

Improving efficiency of plant operation needs measuring flow rate of the process which is not measured currently.

September 23, 20049

2.2 ） Who needs ultrasonic flowmeter?Applications Pulp & Paper Chemical Plants Power Plants & Generating

Facilities Water Service & Sewage

Treatment Semiconductor Manufacturing Plating & Finishing Operations Food and Beverage Process Building Maintenance Pumping Efficiency Leakage Detection

September 23, 200410

2.3 ） Who needs ultrasonic flowmeter?

3.9

3.7

254.2

1.3

3

7.5

9.5

1.4

11.1

10.419.1

0 5 10 15 20 25

Other

Sewer Monitoring

Influent & Effluent

Check Metering

CEM

Stack Monitoring

Custody Transfer

Utilities

Leak Detection

Nonconductive Liquids

Process Control

Process Monitoring

(%)

Total 36,900 units sold in 1996

Shipments Worldwide By Applications


2.4 ） Who needs ultrasonic flowmeter?

6.2

3.8

36.8

7

1.1

5.7

2.6

5.8

13.3

10.2

7.5

0 5 10 15 20 25 30 35 40

Other

District Heating

Water & Wastewater

Power

Metals & Mining

Pulp & Paper

Pharmaceutical

Food & Beverage

Chemical

Refining

Oil & Gas

(%)

Shipments Worldwide by Industry since 1996


3.1 ） What’s Unique in Fuji’s USFMFull Range Line-Up Of Fuji Electric USFM!

Fixed Type For Monitoring & Control (Model FLV/W)

Fixed Multi-Channel (Model FLH/W)

Portable Type For Checking (Model FLC/D)

Open Channel (Model FLH/X)

M-Flow Low Cost Version (Model FLS/R)


3.2 ） What’s Unique in Fuji’s USFMFuji Electric’s USFM Family

Time Delta Ⅱ(FLV/W) Portaflow-X (FLC/D)

Open Channel (FLH/X)Multi Channel (FLH-

3)M-Flow


3.3 ） What’s Unique in Fuji’s USFMSuperior Measurement Performance by High Speed Digital Signal Processing(MPU: DSP-Digital Signal Processor- Texas Instruments 32bit)

Basic principle = Transit time differenceHigh accuracy (0.5%) & quick response (0.5second)Broad measuring range (0.3~32m/s)Real time auto temperature and pressure compensation Auto calculation for unknown sonic velocity Advanced anti-bubble measurement (Up to 12% volume)


3.4 ） What’s Unique in Fuji’s USFMBasic Principle = Transit Time Difference Type

Upstream SensorOscillator Wedge

Pipe

θfDQ

τ/2 τ/2

T1

T2

DownstreamSensor

Cross-sectional areaAverage velocityon cross section

Average velocity on propagation path

•Q : Flowrate•D : Inner pipe diameter•K : Conversion factor

of average velocity•θf: Incident angle into liquid

•T1, T2 : Transit time•T0 : Transit time between sensors

when flow is at rest(≒(T1+ T2 )/2)

•τ : Transit time in pipe walls & sensors

ΔT=T2 － T1

(Note)Ultrasonic waves are carried with the motion of fluid.

Q = x xx

Clamp-on sensors Transit Time Difference Method Principle Expression

　　 πD2 　１ D ΔT

　　４　Ｋ sin2θf 　 (T0-τ)2


Reynolds Number :Non-dimensional figure to determine flow

profile V x D

Re = ν

Conversion factor of average velocity :– Turbulent flow (Re≧5000)

2n+1K = n = 2.1 log Re-1.9 2n ,

– Laminar flow (Re≦2300) ４

K = ３

3.5) What’s Unique in Fuji’s USFM

V : Average velocityD : Inner diameterν: Kinematics viscosity

Flow Profile Compensation

1.4

102

1.3

1.2

1.1103 104 105 106

Turbulent flow(Trapezoidal)

Laminar flow(Parabolic)

K

Laminar flow

Transition region

Turbulent flow

Re

Flow profile :

Enough straight pipe length should be taken so that laminar flow will be well developed.


3.6 ） What’s Unique in Fuji’s USFM

-5

0

5

10

15

0 5 10 25 50 100

FLC

Product C

Flow (%)Accu

racy(%

of

rate

)

High accuracy (0.5%) & quick response (0.5second)

Flow (%) Standard Output (%) Accuracy (% Of Rate)FMQ FLC Product C FLC Product C

0 0.06 -0.01 0.06 -0.01 0.065 5.18 5.17 5.82 -0.19 12.36

10 10.17 10.13 10.84 -0.39 6.5925 24.60 24.62 24.46 0.08 -0.5750 50.41 50.42 51.04 0.02 1.25

100 95.91 95.93 98.74 0.02 2.95

Pipe: Ø80mmPipe material: SGPRange: 0~2m/s

Comparison Test Data in Actual Flow


Principle Expression:

　　 πD2 1 D 　 ΔT Q = 4 Ｋ sin2θf　　 (T0-τ)2

　　 πD2 1 Cf 　 ΔT 　 = 4 Ｋ 2 sinθf　　 T0-τ(Cf: Sound velocity in measured liquid)

Compensation for liquid temperature & pressure change– Physical Phenomena:

– Real time compensation (Applied For Patent)

Calculation of propagation path and fluid sound velocity every output cycle

3.7 ） What’s Unique in Fuji’s USFMReal time auto temperature & pressure compensation

Upstream SensorPipe

θfD Q

τ/2 τ/2

T1

T2

DownstreamSensor

Cf

Effect of temperature & pressure change

Fluid temperature& pressure change

Change of Cf

Change of θf & τ Output change

Measured values T1 & T2

Successive calculation of Cf , θf & τ Compensated output

x x x

xxx


Sound Velocity of Water

Sound Velocity Vs Water Temperature(Extracted From Steam Tables )

Note:In general, the

dependenceof sound velocity to fluidtemperature and/or pressure is not well

knownexcept for a few liquids, such as water and sea

water.



-2

-1

0

1

2

3

4

5

6

7

8

0 50 100 150 200

Time(Minutes)

Erro

r (%

Of Rat

e)

0

5

10

15

20

25

30

35

40

Tem

pera

ture

( ℃)

FLCProduct CTEMP.

Real time Auto Temperature & Pressure Compensation Comparison Test Data For Temperature Effects



Digital sampling of received signals :– Ultrasonic Oscillator ････ 2MHz For Small Sensor

1MHz For Large Sensor– Sampling Rate ･･････････ 16MHz

Synchronized summation of received signals :– Normal propagation

– Interrupted propagation

Received signal :

t

v

Received signal :

Digital data of received signals :

t

v

In case of analog system measurement failure will occur

t

vEnough level can be achieved for signal processing.

Summed 128 or 256 times for one output

flowbubble

flow bubble

Nothing!

Advanced Anti Bubble Measurement (Up to 12% Volume)



RESULTS OF BUBBLE IMMERSION TEST (New Time Delta UFM)

1.20.4 0.03 0.02 0.02

12.0

7.0

4.0

1.5 1.00

2

4

6

8

10

12

1.0 2.0 3.0 4.0 5.0

Flow Velocity (m/ s)

Perm

issi

ble

Air

Volu

me-

rate

(vo

l%)

Traditional typeNew type

Advanced Anti Bubble Measurement (Up to 12% Volume)


Common Features Fuji’s USFM Series

• High accuracy & quick response

• Compact & lightweight

• Excellent air bubble resistance (Advanced ABM)

• Excellent temperature characteristics (New sound velocity measurement)

OFFERED BY 32BIT DIGITAL SIGNAL PROCESSOR


Wet Calibration

1. Weighing method

2. Volumetric method

3. Comparative method


Wet Calibration

• Measure the Mass of Water Flowed into Primary Weighing Tank for certain period.

• Compare the Indication of USFM and Mass of Water.

Weighing method

Primary Volumetric Tank

Water

Upper Tank

Stop Valve

ThermometerUSF to be calibrated


Wet Calibration

• Measure the Level of Water Flowed into Primary Volumetric Tank for certain period.

• Compare the Indication of USF and Volume of Water.

Volumetric method

Level Meter

Water

Upper Tank

Stop Valve

ThermometerUSF to be calibrated

Primary Volumetric Tank


Wet Calibration

• Measure the Flow Rate by Primary Flowmeter for reference.

• Compare the Indication of USFM and the Primary Flowmeter

Comparative method

USF to be calibrated

Primary Flowmeter

Stop Valve


Wet Calibration

• Volumetric methodWith 2.5 to 300mm Ø pipes (1 to 12 inch Ø)with primary tank inspected by Japanese Authority of Measurement.

• Comparative methodWith electromagnetic flowmeter calibrated within ±0.2% FS.

• For larger bore pipes than 300mmDry calibration based on the wet calibration for 300mm pipe according to Japanese Standard JEMIS032.

Fuji’s USFM calibration (Upon request) by


References Australia Bangladesh Brunei Indonesia Japan Malaysia Myanmar New Zealand Pakistan Philippines Singapore Thailand Vietnam All countries

Please kindly click on the individual country to view customers database.


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September 23, 20041 Fuji Electric Ultrasonic Flowmeters