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M. Pusayatanont, P. J. Unsworth, E. H. Higham
TWO-PHASE FLOW MEASUREMENT BASED ON THE ANALYSIS OF THE SENSOR SIGNAL FROM A CONVENTIONAL VORTEX FLOWMETER

This paper presents a new technique for measuring the volumetric flow rates of each phase in a two- phase gas-in-liquid flow regime, by analysis of the sensor signal from a conventional vortex flowmeter. The vortex flowmeter has become established throughout the process industry for the measurement of both liquid and gas flows, principally because of its wide rangeability, coupled with a nearly linear relationship between the vortex shedding frequency and volumetric flow rate, plus the fact that it has no moving parts which are liable to deteriorate in service.
In recent years, the measurement of multiphase flow has become increasingly important in the management of oil wells, and there are also many instances in the process industries where it would be helpful to have on-line measurements of this type. It has therefore been the subject of extensive research because virtually all available flowmeters are suitable for measuring only single phase flows, and when a second phase is introduced their performance is seriously impaired and in some instances they may cease to function.
It has been known for some time that the presence of a second phase increases the ‘noise’ embedded in the sensor signal from the primary transducer of a conventional flowmeters. Hitherto, this has attracted little attention, but recent studies have shown that the introduction of a second phase into the flow increases the range and amplitude of the high frequency components that are embedded in the sensor signal. These high frequency signals carry useful information not only regarding the flow regime in which the flowmeter is operating but also regarding the status of the flowmeter itself, both of which can be recovered by applying well-established analysis techniques to the sensor signal. To be really effective, it is essential to ensure that all the information that is available at the interface between the flowing fluid and the primary sensor is gathered, and that the primary sensor has the widest possible frequency response.
The object of the study is to provide a method of metering two-phase fluid flow using a vortex flowmeter to yield the volumetric (or mass) flow rates of each component. The presence of a secondary phase within a primary phase changes the features of the flow sensor signal. In the case of air being introduced into water flowing at a constant rate, this produces changes in the features of the sensor signal from which the relative magnitude of the two phases in the gas-in-liquid flow regime can be determined.

S. Al-lababidi, M. L. Sanderson
CLOSURE MODEL FOR TWO-PHASE LIQUID-GAS MEASUREMENT UNDER SLUG FLOW CONDITIONS

A series of experiments has been undertaken to investigate the behaviour and the performance of a clamp-on transit-time ultrasonic flowmeter in two-phase air/water flow. The results show the performance of the liquid ultrasonic meter to be seriously affected by the presence of free gas in a manner that is dependent on the actual flowrate of the gas and the flow regime. The data presented here covers water/air flow under slug flow regime and an evaluation of transit-time ultrasonic meter and its suitability for two-phase flow measurements. The factors affecting performance are discussed and a closure method using a transit-time ultrasonic flowmeter is introduced.
The closure method for the liquid flowrate employs a mathematical relationship, under slug flow conditions, between the estimated liquid flowrate Q(Estimated); the indicated liquid flowrate Q(Indicated); a velocity profile correction factor, K2(Re); the partial-filled area of the pipe; the cross-sectional area of the pipe and a height correction factor K1(h). This closure method for the gas flowrate uses measurements from the clamp-on transit-time ultrasonic flowmeter, an axial differential pressure transducer and a vertical differential pressure transducer.
The height of the water is obtained by using the vertical pressure transducer and applying the hydrostatic pressure equation. The height of the film reflects at the same time the functional condition of the ultrasonic flowmeter whether it is in a functional state or not. The acceptable height which keeps the clamp-on transit-time ultrasonic flowmeter to continue to function is above 50% of the pipe diameter. An axial differential pressure sensor gives the pressure drop along the slug body. The flowrate of the liquid is constant throughout the tests; the gas flowrate was increased over the range of tests.
Two main correction factors are implemented in the closure model. The Velocity Profile Correction Factor (VPCF), which is a function of Reynolds number K2(Re) for fully developed pipe flow for an assumed Reynolds Number, and the height of the water film correction factor K1(h). The K1(h) correction factor relates the velocity measured along the beam to the mean flow velocity over the entire cross-section of the flowing medium under partially filled pipe conditions.
It is found that the clamp-on transit-time ultrasonic flowmeter can be successfully applied to a horizontal slug flow regime with the application of this closure method to the indicated ultrasonic flowrate Q(Indicated). The average error of the clamp-on ultrasonic flowmeter measurements in two- phase flow were reduced by 50% to 75% and that is dependent on the height of the water, gas flowrate, and the slug flow characteristics. The average error of the estimated flowrate of the ultrasonic flowmeter is ± 3.5% to ± 6.5% relative to the reference turbine flowmeter. Applying a pressure drop closure model at a given liquid flowrate provides an air flowrate measurement with an accuracy of better than ±10%.

J.-F. March
FLOW SENSORS OF HEAT METERS FOR THERMAL SOLAR SYSTEMS

For measurements of thermal energy, produced by thermal solar systems, heat meters, installed in collector circuits of solar systems, must be qualified for the most used propylene glycol-water-mixtures as heat conveying liquid. In the project, sponsored by the “Deutsche Bundesstiftung Umwelt (DBU)” and the heat meter industry, the accuracy of several types of flow sensors at nominal flow rates between 0.6 m³/h and 1.5 m³/h had been investigated using propylene glycol-water-mixtures.

Grzegorz L. Pankanin, Jerzy Berlinski, Ryszard Chmielewski
NUMERICAL MODELLING OF VORTICES DEVELOPMENT IN TAPERED DUCT

The work refers to the vortex flow meter optimisation. Searching of the optimal geometry of the meter became the fundamental task for designers. For many years their attention has been focused mainly on the bluff body as well as on the sensor designing. Numerous experiments made by authors of the paper confirm that not only the bluff body shape but also geometry of the duct impacts the vortices development. Duct walls stabilize the vortex shedding and its development process. Hence the conception of flow duct tapering in the vortices development zone. On the basis of the numerical simulation it is concluded that due to the pipe cross-section contraction (causing the flow velocity increase) the vortex rotation energy enhancement as well as vortex life-time increase has been attained.

M. L. Sanderson, R. H. Al-Rabeh
VELOCITY MEASUREMENT IN BOILER TUBES USING A NOVEL ULTRASONIC FLOW MEASUREMENT TECHNIQUE

A method is reported here for the ultrasonic measurement of flow in boiler super-heater tubes. The tubes are in a tube bank formation running at high temperature (typically 300°C) and pressure (typically 100bar). To enhance heat transfer, the tubes in this application are ribbed internally with thick helical ribs. Further, all measurements have to be made on one side of the tube bank to avoid direct radiation on the fire side. Conventional ultrasound methods are difficult to apply in these conditions. The combination of thick steel walls, internal ribbing and the substantial temperature and density gradients do not provide for a well defined sound beam path. Instead a new method is proposed to measure the flow rate using the properties of the frequency spectrum of the noise imposed on the sound beam by random fluctuations in the velocity and density of the fluid caused by the nature of the flow in such tubes.
The measurement system consists of an ultrasonic beam generated using a conventional piezoelectric disc transducer/buffered from the hot boiler tubes by long threaded steel stalks which are bolted to a bracket welded to the tube bank. A second similar probe is fitted to receive the reflected sound beam signal. A resonant cavity is formed composed of the tubes, the water and the buffer rods. Envelop detection and frequency analysis is then applied to the received signal and the flow rate is deduced from the frequency contents of the noise spectrum. Such noise is caused by small changes to the effective path length of the sound beam caused by the temperature and density variations accompanying the flow. The received spectrum shows random components and its frequency content correlates well with the flow velocity.
A simple theoretical model in which the sound beam is assumed to be deflected by velocity and density variations is used to model the events leading to the observed results. Both laboratory and site measurements made during commissioning of a 300MW boiler are reported showing very similar behaviour when the frequency spectrum of the demodulated signal is considered. A similar observation applies to the frequency spectrum obtained from the theoretical model. A linear relationship is observed in all these cases between the flow velocity and the frequency content of the received signal- within the range of velocities considered. Further experimental and theoretical work is needed to cover a wider range of velocity and include effects of the internal ribbing and other factors not taken into the theoretical or the experimental treatment of the present work.

Rainer Engel, Hans-Joachim Baade
NEW-DESIGN DUAL-BALANCE GRAVIMETRIC REFERENCE SYSTEM WITH PTB’s NEW "HYDRODYNAMIC TEST FIELD"

PTB’s new "Hydrodynamic Test Field", which represents a high-accuracy water flow calibration facility, will serve as the national primary standard for flow measurands: volumetric and mass flow rate, respectively, and total flow measurement, i.e. the quantity of fluid (volume or mass) passing a flowmeter. As most accuracy determining component parts, it comprises three different-size dual-balance gravimetric reference systems: 300 kg, 3 tons and 30 tons. This type of gravimetric references were realized as a combination of a strain gauge based and electromagnetic force-compensation load cell based balance, each. Though each of these two weighing principles fulfils the individual accuracy requirements that have been derived from the total measurement uncertainty budget of the calibration facility as a whole, the electromagnetic force-compensation load cells reveal several advantages concerning linearity error, hysteresis error and sensitivity.

Esa Luntta, Harri Nystedt, Jouko Halttunen, Juha Kortelainen
EXPERIENCES OF PULP FLOW MEASUREMENTS WITH ELECTRO- MAGNETIC FLOWMETERS

Electromagnetic flowmeters are today practically the only meter type used in the measurement of pulp flows in paper mills. Usually, these meters have the required accuracy (or at least they are believed to have), the price of them is reasonable, and they are almost maintenance-free. However, electromagnetic flowmeters are usually calibrated in water flow and the effect of the change of the flowing medium to pulp on the accuracy has been investigated rather little. The possible error sources in pulp flow measurements can be for example non-uniformity of conductivity or air content of pulp suspension. Incomplete mixing of dilution water may also affect the measurement accuracy. Moreover, the position of the flowmeter has to be selected often after the process plant has been built up. Therefore, the disturbance-free pipe lengths upstream and downstream of the meters can be too short. This paper presents the results of the experiments carried out with five electromagnetic flowmeters of different manufacturers with different water and pulp flows.

Ryouji Doihara, Yoshiya Terao, Masaki Takamoto
DEVELOPMENT OF A NEW TYPE OF CORIOLIS FLOWMETER WITH INDEPENDENT VIBRATION FRAMES FOR DRIVE AND TORSION

A new design concept for improving the sensitivity of a Coriolis flowmeter is proposed. The differences between the developed flowmeter and current commercial products lie in adoption of acceleration sensors and reinforcement frames. These features impart an interesting characteristic: sensitivity improves with increasing drive frequency. A flow tube has been fabricated on the basis of the new design concept, and subjected to basic experiments in order to confirm the characteristics of the measurement system. Although some problems still remain, the characteristics have been partially confirmed.

Helmut Többen
NOVEL TECHNIQUE FOR CALIBRATION PIPE PROVER MEASURING VOLUME

The measuring volume of a pipe prover used as a volumetric standard measuring device in the hydrodynamic test field was calibrated by a geometrical measuring method, having been implemented for the first time. Using incremental length measuring devices for the axial and lateral direction a more precise characte rization of the volume is feasible.

Yeh-Chan Ahn, Byung Do Oh, Moo Hwan Kim
A CURRENT-TYPE ELECTROMAGNETIC FLOWMETER FOR TWO-PHASE FLOW

The theory for the current-sensing electromagnetic flowmeter was newly developed. The current-sensing flowmeter has a high temporal resolution so that it can be applied to measure the flows with fast transients like two-phase flow. The signal prediction and the calibration of the current-sensing flowmeter in two-phase flow and the measuring of the characteristics of two-phase flow are the major concerns.
To do this, using a finite difference method, the three-dimensional virtual potential distributions for the electrodes of finite size were calculated for single-phase flow, annular flow and slug flow. With the gradient of the virtual potential, the rectilinear weight functions for the single-phase flow and the annular flow which were the main parameter for the conventional voltage-sensing flowmeter were deduced and compared with existing analytic solutions for the point-electrode. There was a reasonable correspondence between the present and existing results. Particularly the axial weight function and the radial weight function for single-phase flow, annular flow and slug flow were newly defined and computed by taking the gradient of the virtual potential.
The flow pattern coefficient f was introduced to simplify the calibration process for two-phase flow. It was calculated from the solved virtual potential distributions of single-phase and two-phase flow. For annular flow, the coefficient was well-fitted with two decaying exponential functions of the normalized film thickness δ*, f = 1 + 1.3 exp(-7 δ*) + 7.3 exp(-31 δ*). For the slug flow, it was provided as a function of the normalized film thickness δ* and the normalized position of a slug bubble tail L*. The coefficient by the numerical simulation was compared with experimental results obtained by Frequency Response Analyzer (FRA) and Potentiostat/Galvanostat. The comparison clearly showed the agreement between the numerical and the experimental results.

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