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Industrial Flowmeters
Topics
Applications
Measurement Principle
Heat Rate Measurement
Target Markets
Prices
Competing systems / Competitors ClampOn
Hands-On
Summary
Industrial Flowmeters
Applications – Overview (1)
Flow metering for Waste Water Pipes
Flow metering for Pumping Stations
Industrial Flowmeters
Applications – Overview (2)
Flow metering for Heating Systems
Others:
• Cooling / Feeding / Drinking Water
• Beverages / Pharmaceuticals
• Oil / Fuels
• Air conditioning systems
Industrial Flowmeters
Prinzip der Laufzeitmessung
T1
L D
Measurement Principle – Time-of-Flight (2)
Ultrasonic Transducers
T2
cos221
)12(
TT
TTLv
4cos221
)12( 2D
TT
TTLQ
Piezo Element
Industrial Flowmeters
Signal Propagation
Prinzip der Laufzeitmessung
L D
vs_tr
V2 e.g. 2500m/s)
Mounting Distance X
-> Path fractures because of different speed of sounds of material(s) / fluid-> X depends on media and pipe material (coating if applicable)-> X is calculated by deltawaveC depending on given parameters
Speed of sound
V3 e.g. 1480m/s)
Industrial Flowmeters
Reynolds-Compensation (1)
Viscosities µ (Examples):
Water (25°C): 0.00089
Oil: 2.9
]sm
kg[Viscosity (dynamic)
[kg/m3] liquid ofDensity
[m]Diameter
]s
m[ velocity average
[-] Reynolds ofNumber Re
Re
D
v
Dv
-> Flow Profile depends on Number of Reynolds
-> Influence of Reynolds has to be compensated
Industrial Flowmeters
Reynolds-Compensation (2)
Laminar Flow Profile
Re < 2000
(only when very low flow and/or media with high viscosity)
LaminarFlow Profile (acc. to Pai)v,max in middle of pipe
0.000
0.200
0.400
0.600
0.800
1.000
1.200
1.400
1.600
1.800
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1
r / r, pipe [-]
v(r
) / v
,ma
x [
-]
V( r) / V,max [-]
V ( r) / v,mean
Industrial Flowmeters
Reynolds-Compensation (3)Turbulent Flow Profile (acc. to Pai)
v,max in middle of pipe
0.000
0.200
0.400
0.600
0.800
1.000
1.200
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1
r / r, pipe [-]
v(r)
/ v,
max
[-]
V( r) / V,max [-]
V ( r) / v,mean
Turbulent Flow Profile
Re > 8000
[most of applications Re is > 8000
e.g. water 20°c, v=0.04 m/s
-> Re =10,000 ]
Industrial Flowmeters
Reynolds-Compensation (4)
Flow needs to be corrected (slightly) depending on number of Reyndols.
-> In deltawaveC number of Reynolds and Factor k are automatically calculated depending on flow velocity
(k ≈ 0.94…1 )
4cos221
)12( 2D
TT
TTLQ Re
2
4cos221
)12(k
D
TT
TTLQ
Industrial Flowmeters
Prinzip der Laufzeitmessung
Propagation Losses (1)
Ultrasonic Transducers
Scattering: Modification of direction of signal caused by reflections from gas bubbles, particles…. (Effect is higher at higher transducer frequencies )
Scattering
Industrial Flowmeters
Propagation Losses (2)
Ultrasonic Transducers
Absorption: Conversion of acoustic energy into heat by friction between the water molecules (sound waves cause compression and expansion of water) (function of frequency squared)
Absorption
Industrial Flowmeters
Prinzip der Laufzeitmessung
Propagation Losses (3)
Ultrasonic Transducers
-> Both effects (increase exponentially with increase in path length
-> Different transducers / mounting options are available to get stable and reliable measurement
AbsorptionScattering
Industrial Flowmeters
Prinzip der Laufzeitmessung
T1
LD
Mounting – Z-Mounting (1)
Ultrasonic Transducer
T2
Prinzip der LaufzeitmessungL
D
Ultrasonic Transducer
Industrial Flowmeters
Measurement Principle – V-mountings vs. Z-mounting
Easy mounting Only half of Path length
->Higher Signal Strength
Recommended for big pipes and/or high particle load / gas load
Industrial Flowmeters
Ultrasonic Transducers
2 MHz: DN15-DN100
1 MHz: DN100-DN400
500 kHz
Highest Signal Strength
DN200-DN6000
Industrial Flowmeters
Signal Analysis – Cross-Correlation (1)
time
3 2 2
Phase Shift 180°
Phase Shift 180°
Industrial Flowmeters
Signal Analysis – Cross-Correlation (2)
Real Signal (Due to inertance of transducers perfect rectangular pulses can not be generated by the transducers
Industrial Flowmeters
Signal Analysis – Cross-Correlation (3)
Reference SignalSend Signal
Maximum of Correlation
Industrial Flowmeters
Signal Analysis – Cross-Correlation (4)
-> Use of Cross-Correlation gives a unique shape of signal
-> (weak) Signals can be detected also in case of noise
-> Measurement possible also in case of challenging conditions (e.g. Gas load / Particle load)
Industrial Flowmeters
Signal Analysis – Cross-Correlation (5)
Single Puls Burst 4 Barker 7 (322)
-> Depending on Type of Transducer proper signal will automatically be selected by electronic unit
Industrial Flowmeters
Prinzip der Laufzeitmessung
L
D
Required Straight Run (1)
Ultrasonic Transducers
cos221
)12(
TT
TTLv
+∆
Industrial Flowmeters
v1D
Required Straight Run (3) – crossed paths
Ultrasonic Transducers
+∆ -∆
221 vv
v
v2
Error caused by cross flow is compensated
Industrial Flowmeters
Integrated Heat Transfer Measurement (1)
Flow
Pipe
Heater
PT100 Temperature
T_hot
PT100 Temperature T_coldFlow
Industrial Flowmeters
Integrated Heat Transfer Measurement (2)
4.181) C)(50 water of c
4.192 C)(10 water of c e.g.(
)/([capacity heat
]/[
[m/s] velocity Flow
][msection Cross
)(
w
w
3
2
KkgkJc
mkgDensity
v
A
TTcvAQ
W
coldhotw
Thermal Output
Industrial Flowmeters
Integrated Heat Transfer Measurement (3)
dtQQ
TTcvAQ coldhotw
)( Thermal Output [W, kW]
Heat Rate [J, kWh]
-> continuous Output (e.g. 4…20mA Signal)
-> Normally puls (counter, totalizer) output
Industrial Flowmeters
Electronic Units (1)
Portable Stationary
No. of Paths 1 1 / 2
Physical Quantities Flow, velocity, Thermal Output, Heat Rate, Flow direction, Accumulated Flow
Totalizers Volume, Mass, Heat Quantity
Diagnostic Functions Sound velocity, Signal Amplitutde, SNR, Signal Qualits (SQ),Signal Scan @ Display
Analog Outputs 2x 4…20mA 2x 4…20mA
Digital Outputs 1 x Relay 1/2x Relay
Inputs 2x PT100 2x PT100
Interfaces USB USB
Industrial Flowmeters
Electronic Units (2)
Portable Stationary
Accuracy up to 1% of measured value
Measuring Cycle 4 Hz (250ms) (Update of Display and Outputs)
Signal Damping 1…60 sec (adjustable) (moving average)
Human-to-machine interf.
Soft Keys
Menu language German, English,….
Housing Material Aluminium, PVC PVC
Industrial Flowmeters
Electronic Units (3)Portable Stationary
Degree of Protection IP 54 IP 67
Display 320x240,Backlight 320x240 Backlight
Weight
Power Supply Battery (Li-Ion)230VAC
230VAC
Operating Temperature
-20…60°C
Loggable values All physical quantities, totalized values and diagnostic values
Log cycle Adjustable 1sec…60min
Capacity Adjustable (standard 1 GB)
Industrial Flowmeters
Ultrasonic Transducers
2 MHz 1 MHz 0.5 MHz
Pipe Size DN10-DN100 DN40/50-DN400 DN200-DN6000
Material PEEK, Aluminium (Mounting Frame)
Mounting Spacer Bar + Chains Textile belt
Temperature -40…150°C -40…80°C (150°C)
Industrial Flowmeters
Prinzip der Laufzeitmessung
deltawaveC vs. Magnetic Flowmeter IDM
+ High Accuracy / Linearity (typcial 0.3%)
- Interruption of Process / Cut-off of pipe required
- Minimum conductivity (1mS) required
- Electrodes sensitive against dirt / sedimentation
U = k x B x D x v
U: induced Voltage, proportional to flow
K: Calibration Factor
D: Distance between Electrodes (=ID)
v: Average Flow Velocity
Industrial Flowmeters
Prinzip der Laufzeitmessung
deltawaveC vs. Inline Ultrasonic
+ High(er) Signal Strength
+ Defined Measurement Section
- Cut-off of pipe required
- Heavy (with bigger diameters)
- Interruption of Process
- Contact to media (abrasion, hygienic,..)
Industrial Flowmeters
Prinzip der Laufzeitmessung
deltawaveC vs. Turbine Flowmeter
+ High Accuracy- Penetration of Pipe- Pressure Loss- Rotating Parts- Sensitive agains dirt (friction coefficient might change)
• Rotation speed of Turbineproportional to Flow• Q = f / K• K: Calibration Factor
Industrial Flowmeters
Target Markets / Applications – Power Plants
Cooling Water
Feeding Water / Condensate
Heat Transport
Process Water
….
Industrial Flowmeters
Target Markets / Applications – Water / Waste Water
Measurement of Inlet / Outlet of Waste Water Plants
Verification of other flowmeters (e.g. Magnetic flowmeters)
Drinking Water Networks (Distribution / Consumption)
Leakage Detection
Chemical Flows (small pipes and low flows)
Sludge
Industrial Flowmeters
Target Markets / Applications – Facility Management
Hot and cold water
Optimization of Heating Systems
Leackage Detection
Analysis / Optimization of Energy Flows
Industrial Flowmeters
Target Markets / Applications – Oil and Gas / Chemistry Basic Materials (Oil) as well as intermediate and finale
products (Kerosine, Petroleum,….)
Chemical Waste Water / Process Water
Aggressive, corrosive and toxic chemicals
Non-conductive media
heat transfer media (thermal oil)
Industrial Flowmeters
Target Markets / Applications – Food & Beverages
Supplies (Hot Water, Cold Water, Process / Waste Water…)
Thermal Energy measurement in energy supply
Products
Hygienic contact-free measurement of liquids
Industrial Flowmeters
Target Markets / Mechanical Engineering
Leak Detection on hydraulic systems
Measurement of cooling lubricant
Monitoring of pumps
Industrial Flowmeters
Target Markets / Pharmaceutical and semiconductor Non-invasive measurement of ultra pure fluids, even
in plastic pipes (PVC)
Industrial Flowmeters
Benefits (1)
High Accuracy (up to 1%)
Independet from Changes in Temperature and Pressure
Easy Mounting (Just minutes), low mounting costs
Contact-Free (to media) measurement
-> perfect for sensitive media like pharmazeuticals, beverages..
Feasibility can be easaly checked in advanced
-> reduces customer complaints
Integrated Heat Transfer measurement enlarges sales possibilites
Industrial Flowmeters
Benefits (2)
100% Plant availability (can be installed during normal operation)
No blockage of pipe, no pressure loss
Leak-proof: No additional risk of leakage caused by the measuring equipment
Pressure Resistant: No pressure limit, No extra charge for high pressure applications
Wear-free: No wear and tear e.g. by abrasive media