Manual: Wet Gas Flow Measurement with Conditioning Orifice Meter Flow Test Data Book and Flow Handbook | Rosemount
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Loading...Rosemount Manual: Wet Gas Flow Measurement with Conditioning Orifice Meter Flow Test Data Book and Flow Handbook | Rosemount Manuals & Guides
Reference Manual
00821-0200-4810, Rev BA
May 2014
Flow Test Data Book and Flow Handbook for
Wet Gas Flow Measurement with Conditioning
Orifice Meter
Reference Manual
NOTICE
00809-0100-4021, Rev GC
Flow Test Data Book and Flow
Handbook for Wet Gas Flow
Measurement with Conditioning
Orifice Meter
Title Page
May 2014
Read this manual before working with the product. For personal and system safety, and for
optimum product performance, make sure to thoroughly understand the contents before
installing, using, or maintaining this product.
Customer Central
1-800-999-9307 (7:00 a.m. to 7:00 P.M. CST)
National Response Center
1-800-654-7768 (24 hours a day)
Equipment service needs
International
1-(952) 906-8888
The products described in this document are NOT designed for nuclear-qualified applications.
Using non-nuclear qualified products in applications that require nuclear-qualified hardware or
products may cause inaccurate readings.
For information on Rosemount
Management
Emerson Process Management satisfies all obligations coming from legislation to
harmonize product requirements in the European Union.
®
Sales Representative.
®
nuclear-qualified products, contact an Emerson Process
iii
Title Page
May 2014
Reference Manual
00821-0200-4810, Rev BA
iv
Reference Manual
00821-0200-4810, Rev BA
Contents
1Section 1: 405C Compact Conditioning Orifice Plate and 1595
2Section 2: Theory of Operation
Table of Contents
May 2014
Conditioning Orifice Plate
1.1 Product Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2.1 Structural Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Independent Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3 Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Technical Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.3 Conditioning Orifice Meter Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3Section 3: Test Facilities and Flow Tests
3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Testing Laboratories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.3 Flow Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4Section 4: Flow Calculations
4.1 Rosemount 405C and 1595 Conditioning Orifice Plate . . . . . . . . . . . . . . . . . . . . .25
4.1.1 Calculated Values and Variables Designations . . . . . . . . . . . . . . . . . . . . . . .25
4.1.2 Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.2 Flow Calculation Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5Appendix A Additional Graphs
Rosemount 1595 Calculated offset from measured versus Lockhart-Martinelli
Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Rosemount 405C Calculated offset from measured versus Lockhart-Martinelli
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
CEESI Facility Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Tab le of C ontents
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Table of Contents
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Table of Contents
Reference Manual
00821-0200-4810, Rev BA
Section 1: 405C Compact Conditioning Orifice Meter
and 1595 Conditioning Orifice Plate
Section 1 405C Compact Conditioning
Orifice Meter and 1595
Conditioning Orifice Plate
Product features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
Product specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
1.1 Product features
The Rosemount® 405C Compact Conditioning Orifice Meter and 1595 Conditioning Orifice
Plate primary flow elements maintain the traditional strengths of orifice plate technology with
improved features / performance.
May 2014
The strengths of the 405C include:
More economical than a Traditional Orifice Plate Installation
Accurate and repeatable
Short straight run requirements
Self centering mechanism
Based on ASME/ISO Corner Tap Design
The strengths of the 1595 include:
Based on the most common primary element in the world with established standards
for manufacture and installation.
Easy to use, prove, and troubleshoot
Accurate and repeatable
Short straight run requirements
Based on ASME/ISO/AGA Standards
The 405C and 1595 Primary Flow Elements are sized using Rosemount's Instrument Toolkit
sizing program. This program provides accurate flow calculations using installation details and
fluid properties for the flowmeter and presents this on a calculation data sheet or specification
sheet.
™
1
Section 1: 405C Compact Conditioning Orifice Meter
and 1595 Conditioning Orifice Plate
May 2014
1.2 Testing
Tests performed on the 405C / 1595 Primary Flow Elements are divided into two major
categories:
Mechanical and structural testing
Independent laboratory testing
All categories are on going and continue to be a part of the current Rosemount test program for
the 405C / 1595 Primary Flow Elements.
1.2.1 Structural testing
Rosemount performed integrity testing for:
Allowable stress limits
Hydrostatic pressure
Thermal effects
Vibration
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At the following labs:
Hauser Laboratories, Boulder, CO
Rosemount Vibration Laboratory, Eden Prairie, MN
1.2.2 Independent testing
Rosemount 405C and 1595 Primary Flow Element models were tested in wet gas conditions at
the following independent laboratories:
Colorado Engineering Experiment Station, Inc. (CEESI)
Certified flow-data sheets were supplied from each of these facilities. Representative samples of
tests conducted at the independent laboratories are in Section 3: Test Facilities and Flow Tests.
1.3 Product specifications
The above testing has enabled Rosemount to provide product which conforms to the following
specifications in wet gas applications. See Appendix A for graphical representations of how well
the curve fit matched the actual data.
Table 1-1. Rosemount 405C Compact Conditioning Orifice
Beta ratio Discharge coefficient uncertainty
= 0.40 ± 0.50%
= 0.50 ± 1.0%
= 0.65 ± 1.0%
2
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00821-0200-4810, Rev BA
Section 1: 405C Compact Conditioning Orifice Meter
and 1595 Conditioning Orifice Plate
May 2014
Table 1-2. Rosemount 1595 Conditioning Orifice
Beta ratio Discharge coefficient uncertainty
= 0.40 ± 0.50%
= 0.50 ± 1.0%
= 0.65 ± 1.0%
3
Section 1: 405C Compact Conditioning Orifice Meter
and 1595 Conditioning Orifice Plate
May 2014
Reference Manual
00821-0200-4810, Rev BA
4
Reference Manual
QKDP=
P
1
1
2
-- -
V
1
2
+ P
2
1
2
-- -
V
2
2
+=
00821-0200-4810, Rev BA
Section 2: Theory of Operation
Section 2 Theory of Operation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Technical detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Conditioning orifice meter technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 6
2.1 Overview
The Rosemount® 405C and 1595, based on orifice plate technology, is a device used to measure
the flow of a liquid, gas, or steam fluid that flows through a pipe. It enables flow measurement
by creating a differential pressure (DP) that is proportional to the square of the velocity of the
fluid in the pipe, in accordance with Bernoulli's theorem. This DP is measured and converted into
a flow rate using a secondary device, such as a DP pressure transmitter.
The flow is related to DP through the following relationship.
May 2014
Equation 1
where:
Q = Flow rate
K = Units conversion factor, discharge coefficient, and other factors
DP = Differential pressure
For a more complete discussion on the flow equation, refer to Section 4: Flow Calculations.
2.2 Technical detail
As stated previously, traditional orifice plate flowmeters are based on Bernoulli's theorem,
which states that along any one streamline in a moving fluid, the total energy per unit mass is
constant, being made up of the potential energy (the pressure energy), and the kinetic energy of
the fluid. Where:
where:
P
= Upstream pressure
1
P
= Downstream pressure
2
p = Density
= Upstream velocity
V
1
V
= Downstream velocity
2
When fluid passes through the orifice the velocity of the fluid through the orifice increases. This
increase in fluid velocity causes the kinetic energy of the fluid immediately downstream of the
orifice plate to increase, while simultaneously decreasing the static pressure energy of the fluid
at that same point. By sensing the static pressure on the upstream and downstream sides of the
orifice plate, the fluid velocity can be determined.
5
Section 2: Theory of Operation
Actual
Theoretical
May 2014
Some assumptions were made in deriving the theoretical equation, which in practice are not
valid:
a. Energy is conserved in the flow stream.
b. Pressure taps are at ideal locations.
c. Velocity profile is flat.
These items are corrected by the discharge coefficient which is derived from experimental data
and is different for each primary element.
Discharge Coefficient C =
2.3 Conditioning orifice meter technology
The Rosemount 405C and 1595 Conditioning Orifice Plate has the added advantage of being
able to operate with reduced straight run requirements. With its multiple orifices in the flow
stream it is much less susceptible to velocity profile distortion, swirl, and secondary flows. If the
velocity profile is skewed, each of the orifices will conduct a part of the total fluid flow within the
pipe. The fluid pressure on the downstream side of the conditioning plate that is attributable to
each of the separate orifices will be averaged within the fluid to provide an average downstream
pressure. The average downstream pressure is compared with the upstream pressure to provide
an average differential pressure for whatever velocity profile is presented to the multiple orifice
plate, resulting in an accurate measurement of the rate of fluid flow in the pipe.
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As mentioned in an earlier section, every 405C and 1595 is flow calibrated as part of the
manufacturing process. The purpose of this calibration is to determine a calibration factor
which is applied to the flow calculations as an adjustment to correct for bias error from the
ISO-5167 discharge coefficient equations. This results in an accurate flowmeter which conforms
to the ISO-5167 equations.
6
Reference Manual
00821-0200-4810, Rev BA
Section 2: Test Facilities and Flow Tests
Section 3 Test Facilities and Flow Tests
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
Testing laboratories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
Flow tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
3.1 Overview
The following descriptions of tests and testing methods are abbreviated versions. For detailed
descriptions of the individual laboratories contact the facility in question.
3.2 Testing laboratories
May 2014
CEESI, Colorado
Colorado Engineering Experiment Station, Inc. (CEESI) in Nunn, Colorado has a multi phase flow
test facility using natural gas and hydrocarbon liquids. The facility accommodates line sizes from
2 to 8 inch at a max pressure of 1440 Psi. The facility operates at temperatures ranging from
ambient to 122 °F. See Appendix A Additional Graphs for a diagram of CEESI facility.
Lean natural gas is brought into the CEESI complex at a low pressure of near 0.3 Mpa (50 psi). A
charging compressor is used to pressurize the test loop to the desired operating pressure for the
test being conducted. The normal operating pressure range is between 0.7 to 9.9 Mpa (100 to
1440 psi). Once the loop is pressurized, any combination of the four positive displacement
compressors can be used to circulate the natural gas around the test loop at the desired
velocity. Both a turbine meter and a subsonic venturi measure the mass flow rate of the natural
gas. The difference in mass flow rate between these two meters is monitored; and if the
difference exceeds a specified amount, the data is scrutinized for detrimental effects such as
pulsation. If the difference is within tolerance, then all other meters installed in the test loop can
be compared to the natural gas mass flow rate as measured by the turbine meter.
The hydrocarbon liquid, which resides in the liquid storage vessel, can be injected into the gas
stream by positive displacement pumps (triplex pumps). Coriolis meters measure the liquid
mass flow rate and the density of the injected liquid. The gas stream carries the liquid through
the meter test locations to the horizontal separator where it is then returned to the liquid
storage vessel. Coriolis meters again measure the mass flow rate and the density of the returned
liquid. When the injected liquid mass flow rate is equal to the return liquid mass flow rate and all
pressures and temperatures within the loop are constant with time; the system is at a steady
state condition and test data can be acquired.
7
Section 2: Test Facilities and Flow Tests
May 2014
3.3 Flow tests
A summary of the tests is provided on the following pages (see Section 4 for descriptions of
terminology and calculation methods used).
Table 3-1. Natural Gas, 0.65 Beta Ratio
Model: 1595 Pipe Size: 3-in. (76.2 mm) Schedule 40
Fluid: Natural Gas Pipe I.D.: 3.068
Beta Ratio: 0.65 Tes t Date: 4/1 2/04
Figure 3-1. 200 PsiA Baseline
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Test laboratory: CEESI, Colorado
Table 3-2. Decane and Natural Gas, 0.65 Beta Ratio
Test laboratory: CEESI, Colorado
Model: 1595 Pipe Size: 3-in. (76.2 mm) Schedule 40
Fluid: Decane & Natural Gas Pipe I.D.: 3.068
Beta Ratio: 0.65 Tes t Date: 4/1 4/04
Figure 3-2. 200 PsiA Wet Gas CEESI
8
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