IT STARTS AT THE SOURCE - RE-CALIBRATING YOUR PLANT METERS
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1 IT STARTS AT THE SOURCE - RE-CALIBRATING YOUR PLANT METERS NYS AWWA Spring Conference Saratoga Springs, New York April 25, 2017 Robert Lucas, P.E.
2 WHAT ARE WE TALKING ABOUT? Types of Flow Measuring Devices (Primary Elements) Orifice Plates Venturi Tubes ie. PFS, B-I-F Insert Propeller Meter Mag-meter & Ultrasonic Flow Nozzle
3 WHERE ARE THEY USED? Well Heads deep vertical turbine Horizontal Split-case Booster GST Reservoir Clearwell Boosters short-coupled VT Transfer pumps 3
4 HYDRAULIC PRINCIPLE OF PRIMARY ELEMENT Based on Differential Pressure measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full think manometer Bernoulli's principle states that there is a relationship between the pressure of the fluid and the velocity of the fluid. When the velocity increases, the pressure decreases and vice versa. 4
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11 DIFFERENCES BETWEEN ELEMENTS Orifice Plate Inexpensive Small Footprint Higher head loss due to turbulence (energy loss) Venturi Tube Higher Cost Large Footprint - inside / vault used outside Much more efficient / less pressure loss Straight pipe upstream/downstream very important! 11
12 PREFERRED DESIGN - VENTURI TUBE Reduced pressure loss Fluid can flow with much higher velocity without turbulence Curved, streamlined section, long & gradually expanding downstream xx% more flow than orifice plate 12
13 SECONDARY ELEMENTS Differential Pressure Gage with Switch Still used to satisfy safety Set min. value confirms flow (reads inches of water ) Pressure Transmitter (digital) interprets DP Digital Processor part of pressure transmitter PLC: Programmable Logic Control software Digital Display Chart Recorder SCADA - Remote Monitoring & Control 13
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16 SO WHY DO WE NEED ACCURATE FLOW MEASUREMENT? To determine total quantity of fluid pumped Know your system outflow Accurately determine non-revenue water Ensure Accuracy & Performance of your equipment Selling or purchasing water Accurate treatment & equipment safety Safety Interlock / Chemical Safeties Used for chemical dosing on variable flow applications (flow pacing) 16
17 WHY CALIBRATION? All elements can & will develop error and need to be checked Exposure over time due to: Temperature fluctuations Humidity Vibration Pollutants / chemicals Everything wears : Sensing elements Diaphragms Gages 17
18 WHY CALIBRATION? What can go wrong? Wear in the throat of the Venturi Tube Clogs in the sending lines Iron & Manganese Minerals / Calcium Air!! - very common * must keep the main flooded [after the check valve is best ] 18
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21 CALIBRATION HOW OFTEN? AWWA recommends source metering to be calibrated annually Nov Feb: good time of year due to low pumpage in the off season January: start the year off right 21
22 CALIBRATION - WHY IT S IMPORTANT Verify proper equipment performance & that it is operating satisfactorily Getting a pulse of your system Planning for maintenance or capital improvements Pump Efficiency / Wear Efficiency = $$$ 22
23 CALIBRATION Employ services of a reputable controls contractor Check the elements starting at the pressure transmitter Problems most often occur in the PD gage or transmitter Typically flow is checked with calibrated DP gage & hand pump Isolate components and connect calibrated gage & hand pump Pump up to obtain various DP values Compare each DP value of DP gage to that of pressure transmitter Verify value to Calibration Chart / Flow Sheet / Design Table Every model VT has its own calibration chart Inches of water = flow in GPM MUST use digital process calibrator HART protocol 23
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25 CALIBRATION A quick double-check of flow accuracy is also employed using a calibrated clamp on Ultrasonic Flow Meter UFM used when pump is running and measuring system flow 2-3% difference in results compared to calibrated components is acceptable 25
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28 CALIBRATION The 4-20 ma signal is then checked as it continues to the subsequent components in the system. To and through the PLC > > > output display Digital display Chart recorder SCADA modules.. Via graphical user interface The value may have to be adjusted / tweaked at each component to maintain accuracy Otherwise a compound of error will result 28
29 CALIBRATION Historical Data can be very helpful when calibrating: Can see what readings and GPM you had last time Confirm last calibration date and degree of error Prudent designs incorporate multiple transmitters to maximize accuracy Small span/wide range for low flow & larger span for high flow 29
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31 CALIBRATION Industry standardizing on open universal protocol that converts DP to 4-20mA electronic signal - HART Protocol In years past, the each manufacturer had their own calibration protocol for calibrating the pressure transmitter Rosemount Foxboro ABB Endress + Hauser Honeywell 31
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33 VENTURI LOCATION OPTIONS Inside the plant if you have the room Outside in a vault if limited space inside IMPORTANT: proper installation requires straight length pipe upstream & downstream of the element Typically 10 pipe diameters upstream 5 pipe diameters downstream 33
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36 IMPROPER CALIBRATION If your controls contractor asks you what s your pump putting out and then starts adjusting the transmitter, ask him/her to leave and call another contractor. This is not calibrating, its guessing! If the readings are bouncing the sensing lines must be flushed & purged 36
37 TAKE-AWAY THOUGHTS Budget calibrations annually but if something doesn t look right, don t wait Employ a reputable controls contractor For revenue reasons don t be afraid to explore the reality of meter error when it comes to your top 10 or 25 users explain / examples 37
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39 IT STARTS AT THE SOURCE - RE-CALIBRATING YOUR PLANT METERS Presented by: Robert J. Lucas, P.E. 538 Broad Hollow Road, 4 th Floor East, Melville, New York t f Computer Drive West, Suite 102, Albany, New York t f South Main Street, Suite 500, New City, New York t f Cherry Hill Road, Suite 200, Parsippany, New Jersey t f
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