Flowmeter Calibration Procedure
Flowmeter Calibration Procedure
1
Description of the test installation
The tests are performed in the calibration rig for flowmeters. A schematic diagram of this rig
is shown in Figure 1.
1.1
Principle of operation
To perform a calibration of a flowmeter, water is pumped from a supply reservoir to a
constant head reservoir.
From there water flows to one of the weighing tanks through the measuring section with the
flowmeter under test.
In order to maintain a constant flow rate sufficient water is pumped to the constant head
reservoir.
Excess of water flows back to the supply reservoir over a large weir at a height of 24 m,
relative to the measuring section.
The flow rate is adjusted with a special control valve situated at the downstream end of the
test section above the diverter which deflects the flow either into the weighing tank or back
into the supply reservoir.
The control valve has a long narrow nozzle, in order to obtain a short switching distance and
switching time. Because of the short switching time the uncertainty in time, caused by the
diversion is reduced to a minimum.
To prevent cavitation the measuring section is located lower than the diverter.
The flowmeter is calibrated by weighing the quantity of water that passes the flowmeter
during a certain measuring time. Hereto the water is collected in the weighing tank, whereby
the mass increment is measured by calibrated load cells.
1.2
Calibration method
The method of calibration is based upon ISO 4185 weighing method
1.3
Upstream requirements
The fittings in the test installation upstream of the flowmeter are a constant head reservoir, a
90 (vane) bend, a Mitsubishi flow conditioner and a reducer.
For measuring orifice plates, the total length from the reservoir to the orifice plate shall never
be less than 30D (see ISO 5167-2:2003 Measurements of fluid flow by means of orifice
plates, nozzles and venturi tubes inserted in circular cross-section conduits running fullsee
table 3).
The minimum straight length between the reducer (closest fitting to primary device) and the
flowmeter shall be 22D ("zero additional uncertainty").
In the standard the minimum straight length is described for several fittings, other than 90
bends, placed in series upstream of the primary device ([11: section 6.2.8).
Since the actual situation is not described in the ISO standard, the general requirements with
respect to a fully developed velocity profile and a swirl free flow (6 installation requirements:
section 6.2 ) must be applied.
Downstream requirements
The fittings in the test installation downstream of the orifice plate are a reducer, an expander,
two 90 (vane) bends and a control valve (see Figure 1).
The minimum straight length between the reducer (closest fitting to primary device) and the
orifice plate shall be 8D (see zero additional uncertainty).
2.
Measuring equipment
Determination of the mass flow rate requires measurement of the mass increment and filling
time. Determination of the volumetric flow rate requires a liquid density measurement
additionally. If the flowmeter is a pressure differential flow meter, Dp measurements are
required in addition to the previous instruments in order to derive the discharge coefficient.
Therefore the uncertainty of the discharge coefficient is greater than the uncertainty of the
volumetric flow rates, which is greater than the uncertainty of the mass flow rates.
Absolute pressure and temperature are measured for informative purposes. The measured
values are reported, but are not affecting the flow rates, discharge coefficients or
uncertainties.
2.1
Weight measurement
For the weight of the 8 and 80 tons weighing tanks the following equipment is used:
The weight of the 8 tons tank is measured using three high precision GWT load cells type
PR6143/50S. Range: 0 - 5000 kg (uncertainty : 0.015%)
The weight of the 80 tons tank is measured using three high precision Philips load cells;
type PR 6222/54H. Range: 0 - 50.000 kg (uncertainty: 0.01%).
For the reading of the output of the load cells a GWT Weight Indicator type PR 1713 is
used.
For the calibration of the weighing system certified 500 and 1000 kg weights are used.
2.2
Time measurement
For the time measurement the following equipment is used:
A data acquisition card, ADwin type L16-PCI for the measurement of the filling time
The time counter is activated and deactivated by a displacement transducer. The
displacement transducer is activated and deactivated by the movement of the diverter,
whereby the switch point coincides with the middle position of the diverter.
The diversion time depends on the actual flow rate. A correction on the measuring time
is applied according to ISO 4185. The diversion time is measured for informative
purposes. For the measurement of the diversion time (order of hundredths of seconds) a
data acquisition card type ADwin type L16 PCI is used.
2.3
Measurement of liquid density
For the measurement of the liquid density the following equipment is used:
A certified Solartron (Schlumberger) twin tube liquid density meter; type NT1762;
serial number F347, P1116
The average period (frequency) output of the density meter is read using a data
acquisition card type ADwin type L16-PCI.
2.4
Dp measurement
The Dp measurement applies to Dp flowmeters only and is required to derive the discharge
coefficient of the flow meter. For the p measurement the following equipment is used:
A Honeywell ST3000 Smart Transmitter, Differential Pressure Model STD130; Pressure
range: 0 - 7 bar (adjusted to: 0 - 2 bar); Frequency range: 1 Hz
A Honeywell ST3000 Smart Transmitter, Differential Pressure Model STD120; Pressure
range: 0 - 1 bar (adjusted to: 0 -2,5, 10, 20, 50 and 100 kPa); Frequency range 1 Hz
To adjust the ranges of the Smart transmitters a Honeywell Smart Field Communicator is
used.
A stabilised 24 V Power Supply
A certified Huyser Precision Resistance (250 ohm; serial number 870516); Tolerance:
0.01%
For the calibration of the Dp measuring system a certified Barnet dead weight tester, type
5410-4 (serial number 279971), range 0 - 36 bar, accuracy 0.035%, is used for pressures
above 10 kPa
For the range below 10 kPa a Druck DPI 285 measuring device is used, range 0-70 mbar
and 0-300 mbar
2.5
Absolute pressure measurement
For the absolute line pressure measurement a pressure transducer is used: Ecotronics Type
891.13.500 range 0-10Bar accuracy is 0.5 %. The line pressure is measured for
informative purposes.
2.6
Temperature measurement
For the liquid temperature measurement the following equipment is used:
PT 100 sensor; range 0-100 C
Rosemount transmitter; type E32100 (serial number 130)
For the reading of the transmitter a data acquisition card type ADwin type L16-PCI is
used.
For the calibration of the temperature measurement system a Leeds & Northrup
thermometer, accuracy 0.025C is used.
3.
Traceability and calibrations
The following calibrations are performed at Delft Hydraulics:
weighing tanks
diverter mechanism of weighing tanks
density meter
Smart transmitters
Thermometer
3.1
Calibration weighing tanks
The overall weighing system is calibrated by using certified dead weights.
Details of the measuring equipment are described in section 2.1.
The calibration procedure of the 8 and 80 tons weighing system is as follows:
To settle the weight tank on its supports the tank - two or three times - is filled and
emptied with about 8000 litres of water.
The 5 digit weight indicator is adjusted to zero
A weight of 500 kg is put on the edge of the empty weight tank, and the readout from this
weight is registered.
After this a second 500 kg is put on the edge of the weight tank and the readout from this
weight is registered.
Now a 1000 kg weight is put on the edge of the weight tank, and the readout from this
weight is registered.
In a similar way the weight of 2000 to 8000 kg are put on the weight tank and will be
registered.
This will also by done for decreasing the weight from 8000 kg to 0 kg.
The calibration of the 80 tons weighing system will be done in a similar way only after 40000
kg the weights are taken off and the weight tank is filled with 40 tons of water; the available
weights in the laboratory is 40000kg. The calibration of the weighing tank is performed two
times per year.
3.2
Calibration p measuring equipment
The overall Dp measuring system is calibrated against a dead weight tester. Details of the
measuring equipment are described in section 2.4.
The two Smart transmitters are calibrated in the range of 20% to 100% of their span set. The
calibration of the Dp measuring system is performed once per year.
3.3
Calibration of diverter mechanism
The measurements of the filling time is started and ended half way the diversion of the flow in
to respectively out of the weighing tank (under half flow conditions). Due to non-linearities
during diversion from no flow to full flow and vice versa an error is made in the measurement
of the filling time.
For these effects a correction is made (see section 4.2). The calibration of the diverter
mechanism is performed once per year.
3.5
Calibration liquid density meter
The liquid density meter is calibrated by NMI. As a result the uncertainty in the density range
of 998 to 1000 kg/m3 is 0.05 kg / m3. The calibration of the liquid density meter is performed
every two years.
3.6
Calibration thermometer
The temperature measuring system is calibrated in an accurate regulated temperature bath
against a Leeds & Northrup thermometer (see section 2.6). The temperature is registered for
informative purposes. The calibration of the thermometer is performed once per year.
4.
4.1
Measuring procedure
The measuring procedure is as follows:
The pressure tappings of one type (D-D/2, corner or flange tappings) are connected to the
Dp-measuring equipment.
The pumps of the calibration rig are started and a high, cavitation-free flow is adjusted.
The rig is de-aerated using the vent holes. Under static flow conditions the zero-values of
the Dp-measuring equipment are registered.
The cavitation inception point is found auditively by increasing the flow slowly until the
first collapsing of cavitation bubbles will be heard.
The flow is decreased to about 98 % of abovementioned flow. This flow is denoted as
Qmax.
The discharge coefficients are now measured at several flow rates.
The minimum Pressure difference is 2 kPa.
Reproduction measurements are performed at every measured flow rate.
During the measurement of a discharge coefficient the following read outs are registered:
weighing tank (8 or 80 tons)
adjusted range of Smart transmitter
adjusted filling time
water temperature
position of control valve
begin weight weighing tank
end weight weighing tank
diversion time at the beginning
diversion time at the end
actual filling time
fluid density
Dp of Smart transmitter
In order to increase the accuracy of the mass flow measurements the filling time is chosen in
such a way that the begin and end weights of the weighing tank are smaller than 12.5 %,
respectively greater than 75 % of the maximum possible weight. In order to increase the
accuracy of the Dp measurements the Smart transmitters are used in the lowest possible range.
Consequently the different ranges are partly used (for instance: the 50 kPa range is only used
from about 20 to 50 kPa).
4.2
Data acquisition, data processing and calculation methods
The measurement data (readouts) are read in the computer by a data-acquisition card using a
program for flowmeters with signal output and flowmeters based on pressure difference
(orifice plates, nozzles and venturi tubes).
The data processing takes place on line using the following calculation methods:
The mass flow rate Qm is calculated from:
Qm =
In which:
Dm me - mb
=
t
t
Qm
Dm
mb
me
t
=
=
=
=
=
flow rate
increasing weight weighing tank
begin weight weighting tank
end weight weighting tank
filling time
[kg/s]
[kg]
[kg]
[kg]
[s]
The fact that the weighing system is calibrated with calibration weights, whereas the weighing
tank is filled with water, causes a difference in buoyancy. The water volume and calibration
weights are actually submerged in air, causing the buoyancy force. The buoyancy effect is
corrected as follows:
m = (me - mb )(1 + e )
e = 1, 05 10-3
Dt is a correction on the filling time t due to non-linearities during diversion to and from the
weighing tank.
The correction is determined during calibration of the diverter mechanism. The Dt correction
is established as a function of the mass flow rate in the following way:
At seven mass flow rates covering the total span of the test facility, the weighing tank is
filled and weighed twice.
The first measurement is carried out in accordance with the normal measurement
procedure (see section 4.1).
The second measurement is carried out in 10 steps. The diverter switches 10 times to and
from the tank.
The difference in average mass flow rate is caused by the 9 extra diverter switches, from
which Dt is calculated
The volume flow is now ;
Qv =
Qm (me - mb )(1 + e )
=
r
r (t + Dt )
The expanded uncertainty of the volumetric flow rate is determined from uncertainties in
weight measurement, filling time measurement, their corrections and the density
measurement. The ratio of uncertainties in weight, filling time and density is approximately 3
: 3 : 2. Hence these uncertainties are equally important, resulting in an expanded uncertainty
better than 0.05%.
The expanded uncertainty of the discharge coefficient is determined from uncertainties in
weight measurement, filling time measurement, their corrections, the density measurement
and the Dp measurement. The Dp measurement uncertainty dominates the other uncertainties,
resulting in an expanded uncertainty of the discharge coefficient of 0.1% to 0.3%, depending
on the measured Dp.
The flowmeter gives a value at every measured flow rate. Each flow rate is reproduced at least
once. The average difference between the flowmeter reading and the measured flow rate is the
systematic error of the flowmeter. The uncertainty of the flowmeter is calculated from the
measurement uncertainty (0.05%) and the uncertainty in the systematic error, according to
EA-4/02.