flow meter audit typical method

8/20/2019 Flow Meter Audit Typical Method

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YATESMETER

FLOWMETERCALIBRATION

METHODOLOGY

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Flowmeter Calibration Methodology

Advanced Energy Moni to ri ng SystemsTEL #: 01404-812294 F AX#: 01404-812693 -2-

- CONTENTS -

1 BACKGROUND & PROCEDURES 3

1.1 INTRODUCTION 3

2 THEORY 4

2.1 C ALCULATION OF P UMP E FFICIENCY 4

2.2 C ALCULATION OF V OLUME F LOW R ATE , 4

3 TEST APPARATUS 5 3.1 S TANDARD E QUIPMENT 5

4 TAPPING ARRANGEMENTS 6

4.1 C ONVENTIONAL S URFACE MOUNTED P UMPS 6

4.2 S UBMERSIBLE P UMPS 6

4.3 S USPENDED B OWL P UMPS . 6

5 METHODOLOGY 7

5.1 C ALIBRATION 7

5.2 T EST P OINT 7 5.2.1 Power Monitoring 7 5.2.2 Connection Arrangement for 3 Phase Power Measurement 8

6 GENERIC METHOD STATEMENT 9

6.1 INTRODUCTION 9

6.2 S UMMARY OF TESTING PROGRAMME 9

6.3 D ESCRIPTION OF P ROCEDURES 10

6.4 C ALIBRATION OF 4-20 M A SIGNAL FROM F LOWMETER 12

7 APPENDICES 14

7.1 APPENDIX 1: T YPICAL T APPING A RRANGEMENT 14

7.2 APPENDIX 2: C ONVENTIONAL H ORIZONTAL S PLIT -C ASE P UMP 15

7.3 APPENDIX 3: S UBMERSIBLE P UMP 16

7.4 APPENDIX 4: S USPENDED B OWL P UMP 17


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Advanced Energy Moni to ring SystemsTEL #: 01404-812294 F AX#: 01404-812693 -3-

1 BACKGROUND & PROCEDURES

1.1 INTRODUCTION

Testing is carried out using the Mark IV Yatesmeter, which is a pump performance meterbased on thermodynamic principles.

The thermodynamic principles have been well documented in the pumping field and thetechnique is accepted in the following documents:

ISO-5198 precision class, Testing Class A, for pumping heads greater than 100m.

Pump Centre (UK) - Code of Practice for Pump Efficiency Testing by the DirectThermodynamic Method. Pump Centre report 695/27

Class B - Pumping heads greater than 25m.

Class C - Pumping heads greater than 10m.

The thermodynamic method is based on measuring the energy gained per unit mass offluid as it passes through the pump.

This energy gain is the sum of the increase in total pump head and the energy lossesinherent in the pump.

From the measurement of generated head and the increase in fluid temperature betweenthe measuring points, the true hydraulic efficiency between the measuring points may bedetermined. The flow through the pump is determined by equating the efficiency of thepump to its generated head and input power.


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2 THEORY A simplified form of the method is given as follows:

2.1 C ALCULATION OF P UMP E FFICIENCY Work input to a system is equal to the work gained from the system plus the lossesinvolved:

LossesWW outin += , and

pump efficiency,in

outp W

W=η .

Thus,

out

out

outp

WLosses

1

1LossesW

W

+

=+

=η ,

where,.g.Hm

.dT.cm

WLosses p

out &

&= .

Therefore,

g.H

dT.c1

1

pp

+

=η .

2.2 C ALCULATION OF V OLUME F LOW R ATE By measuring the electrical power input into the pump’s drive, taking the drive efficiencyfrom the manufacturer’s data and the pump efficiency calculated as above the volume flowrate can be derived:

Volume flow rate,.g.H

..PQ pmgr

ρ

ηη= ,

Or,.dT)c.(g.H

.PQ

p

mgr

+ρ

η= .

Notation: η p = pump efficiencyη m = motor efficiencyW = work doneQ = volume flow rateH = headdT = change in temperaturecp = specific heat capacity of fluidP gr = motor input powerg = gravitational accelerationρ = density of fluidm = mass flow rate


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3 TEST APPARATUS

3.1 S TANDARD E QUIPMENT

Photograph of Yatesmeter Equipment

• Yatesmeter (Data Acquisition Unit ).• Laptop and program disk.• Printer, cable and carrying case.• 2 Temperature Sensors.• 2 Pressure Transducers.• 2 stainless steel tees and connectors.• Power Meter.• 3 Current Transformers.• 4 Voltage Transformers.• Serial data link from the Yatesmeter to the Laptop.• Carrying cases for the Yatesmeter, and Laptop• Motor Monitor Data Cable Extension.• Borehole Temperature Probes and Pressure Sensors.


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4 TAPPING ARRANGEMENTS All the tappings are f itted with ½” gate valves, which will take ½” BSP T-pieces. This isillustrated in the Appendices, in section 7.1.

Tappings need to be positioned in different ways according to the pump arrangement.

4.1 C ONVENTIONAL S URFACE M OUNTED P UMPS

The figure in section 7.2 of the appendices shows a drawing of a typical centrifugal pumpwith delivery and suction pipework connected to it by two flanges.

Two ½’’ BSP tappings are installed a minimum of two pipe diameters from the flanges. Itis important to install the delivery tapping upstream of the isolating valve so that the pumpcan be throttled during testing.

4.2 S UBMERSIBLE P UMPS

The figure in section 7.3 of the appendices shows a drawing of a typical submersiblepump. In this case two tappings are (½" BSP) are made in the delivery pipework. Bothprobes are inserted into the pipework and the offset is calculated only using a single ten-minute calibration period.

4.3 S USPENDED B OWL P UMPS .

The figure in section 7.4 of the appendices shows a typical suspended bowl pump with itssuction inlet held well below the water level of the sump.

In this case only one tapping needs to be made in the delivery pipework, as shown. For apump test the suction pressure transducer and temperature probe are lowered into thesump next to the pump inlet.


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Method 2: In the HV switch-room, a single revolution of the Ferraris wheel is timedusing a stop-watch. This is done at each test point, and the power is calculated each time.

Medium Voltage

On medium voltage systems monitoring equipment is attached the starter panel and adata lead run from the power monitor to the Yatesmeter.

The power equipment consists of:

• power monitor

• fused voltage connector × 3

• clip on current transformer × 3

• earth/neutral connector.

Once the monitor is connected and the panel door closed there is usually no need toaccess the starter panel again until the end of the test.

5.2.2 Connection Arrangement f or 3 Phase Pow er Measurement


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6.3 D ESCRIPTION OF P ROCEDURES

1. Set up Yatesmeter on Pump

As previously shown the Yatesmeter comprises of two sets of monitoring equipment.

• Pump Efficiency Meter (Hydraulic monitor)

• Power Meter (Electrical monitor)

The pump Efficiency monitor uses two temperature probes and two pressuretransducers to monitor and measure the pump efficiency in real time. The probes areinserted into the pipework via the T-pieces, and the following information is recorded:

• Station name

• Flowmeter name

• Height of suction pressure transducer above datum

• Height of delivery pressure transducer above datum

• Diameter of suction pipework at tapping location

• Diameter of delivery pipework at tapping location

• Motor power

• Motor speed

• Test equipment serial numbers

2. Connect 3 phase power meter to starter panel

This is the first disruption to the plant. To connect the power meter the pump mustbe stopped and electrically isolated. Once isolated the panel can be accessed andthe power meter connected. The power meter is then connected, the panel closedand the pump is ready to be returned to service.

3. Install 4-20 mA logger

A digital multimeter is connected to the 4-20 mA loop to record/measure thegenerated 4-20 mA signal from the flowmeter.

4. Isolate pump for zero flow measurement

5. Run pump and calibrate Yatesmeter

The pump is started and allowed to stabilise. Once the pump has stabilised theYatesmeter is calibrated to correct for any variation between the home basecalibration and the site conditions.


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6. Measure nor mal f low rate

With the Yatesmeter calibrated, the non-running pumps on the system are isolated

(to prevent any re-circulation through faulty NRV’s), the 1st

test point is obtained.7. Reduce flow rate

8. Record data

Collect data for 2 nd test point

9. Reduce flow rate

10. Record data

Collect data for 3 rd test point

11. Disconnect power meter

The delivery valve is opened to return the pump back to it’s normal operatingposition. Once the system has stabilised, the pump is stopped and the powermeter is disconnected.

12. Disconnect 4-20 mA logger

13. Return plant to normal operation

All valves that have been isolated for the duration of the test are returned to thecondition found.

14. Disconnect Yatesmeter


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A comparison of meters will be made at zero f low. If the meter is not recording zero f lowwhen flow is stationary (i.e. The pump is off and isolated) then an adjustment is made.This adjustment is made by making the signal from the flowmeter’s converter unit equal 4mA which corresponds to zero flow. The magnitude of this adjustment represents theoffset error.

The station is returned to normal operating conditions, and as stated previously, threefurther test points are taken. These points give a linear representation of how the station’sflow varies with the reference flow (i.e. flow calculated by the Yatesmeter). Any remainingerror will be removed by adjusting the velocity range setting on the meter. This error is therange error.

Below is a worked example of the calculation involved in finding the actual flow rate, giventhe flow rate seen by the station flow meter. Using data from a tested flowmeter, thefollowing values have been calculated,

Offset error, E O = -4.58 m 3/hr

Range error, E R = -0.99%

At open valve, the station’s flowmeter recorded a flow, Q l = 144.6 m 3/hr. Therefore, theactual flow,

Q = (Q l – E O)/(1 – E R) m 3/hr

= (144.6 + 4.58)/(1 – 0.0099) m 3/hr

= 147.72 m 3/hr.

This flow corresponds to the flow recorded by the Yatesmeter, at the same open valve

conditions.


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7 APPENDICES

7.1 APPENDIX 1: T YPICAL T APPING A RRANGEMENT


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7.3 APPENDIX 3: S UBMERSIBLE P UMP


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7.4 APPENDIX 4: S USPENDED B OWL P UMP


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7.5 APPENDIX 5: R ISK A SSESSMENT F ORM FOR P IPE -WORK T APPINGS

HAZARD RISK LEVEL CONTROLMEASURE

LEVEL

WorkingMachinery

EntanglementCrushing

Medium Machinery Guards Area Cordoned off

Low

Working below1.2 metres

Floodedchamber

Gas

High Pump out chamberLower gas detector

Tripod/safetyharness

Low

Working above2 metres

Falling Medium Fixed ladderTower

Safety line

Low

Portable Tools Electrocution Medium Tested 110Vequipment

Low

Noise Chronic hearing

damage

High Ear defenders Low

Manual handling Sprains, strains,fractures etc.

Low Trained personnelLifting aids

Low

General Working Trips; slips; falls;cuts; bruises etc

Medium Working practicePersonal safety

equipment

Low

Raw water;

sewage; oils;greases;additives

Ingestion

Internal damageIllness

High Protective clothing

Safe workingpractice

Low


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7.6 APPENDIX 6: R ISK ASSESSMENT F ORM FOR P UMP P ERFORMANCET ESTING AND F LOWMETER A SSESSMENT

HAZARD RISK LEVEL CONTROLMEASURE

LEVEL

WorkingMachinery

EntanglementCrushing

Medium Machinery Guards Area Cordoned off

Low

Working below1.2 metres

Floodedchamber

Gas

High Pump out chamberLower gas detector

Tripod/safetyharness

Low

Working above2 metres

Falling Medium Fixed ladderTower

Safety line

Low

ConnectingPower

monitoring equip

Electrocution Medium Safe workingpractice; isolation;

insulated connectors

Low

Portable Tools Electrocution Medium Tested 110Vequipment

Low

Noise Chronic hearingdamage

High Ear defenders Low

Manual handling Sprains, strains,fractures etc.

Low Trained personnelLifting aids

Low

General Working Trips; slips; falls;cuts; bruises etc

Medium Working practicePersonal safety

equipment

Low


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flow meter audit typical method

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