Technical considerations in

designing ultrasonic flow

meters.
J an G. Drenthen
Marcel Vermeulen &
Hilko den Hollander
KROHNE Oil & Gas
ALTOSONIC V12
6 paths with a single reflection in each path
No flow conditioner required
Integrated swirl compensation
ALTOSONIC V12-D
6 paths with direct mode
Flow conditioner required
For low pressure and highCO2
reflective and non-reflective designs.
3
Principle USM
c
d
VCOS
|
|
.
|

\
|

t
1
-
t
1

2
l
= v
ba ab
m
cos
Di L

Trd B
Trd A
send
receive
cos v c
l
=
t
U
ba
cos v + c
l
= t
D
ab
receive
send
Cu
v
|
|
.
|

\
|
+ =
ba ab
t
1
t
1
.
2
L
C
4
Principe USM
|
|
.
|

\
|

t
1
-
t
1

2
l
= v
ba ab
cos
For US meters the velocity is only a function of the time
and the geometry of the meter body.
Therefore:
The measurement is independent from the fluid
properties.
The meter calibration is valid for use at all pressures.
The meter curve is linear
5
Where do the fluid properties and pressure come into
play?
In the correction curve if a Reynolds type correction is
used.
V
D
.
.
Re

=
Pressure:
In a correction factor of the meter, as described in
Chapter 4.7 (a unique feature of the 17089 !)
6
Reynolds dependent Flow profile
Re < 10.000
Re = 1000.000
7
Reynolds correction as function of the path position
8
Single path meter
9
Test result of a single path meter.
Lucky Shot 1:
10
NRLM certificate
Lucky Shot 2:
11
Flow profile distortion
12
Lowest Uncertainty
Highest Reliability
What are the essential requirements for Custody Transfer meters?
Measurement accuracy (Typical technical data sheet)
Uncertainty
0.5% of measured value, uncalibrated
0.2% of measured value, high-pressure flow calibrated
(relative to calibration laboratories)
0.1% of measured value, calibrated and linearized
Repeatability 0.1%
What you see is the top of the iceberg
Dont let datasheets mislead you!
13
The Ice berg specifications
14
Uncertainty
Non-linearity,
Repeatability
Due to Installation effects
Due to possible contamination
Iceberg specification
ISO 17089 +OIML
R 137
AGA 9
Expert systems
Calibration
Commissioning
15
ISO 17089
OIML R137
The transferability of the calibration curve to the field.
-0,50%
-0,40%
-0,30%
-0,20%
-0,10%
0,00%
0,10%
0,20%
0,30%
0,40%
0,50%
0 500 1000 1500 2000 2500 3000
(Initial) Base 15 bar
Base 15 bar FC
Base 10 bar
Diameter step +3%
Diameter step -3%
Elbow10D 0deg
Elbow10D 90deg
OOP 10D 0deg
OOP 10D 90deg
OOP Exp. 10D 0deg
Base 15 bar
REVERSE
Renewedbase 15bar
2008-10-14
Elbow10D 0deg
Renewedbase 15bar
repeat 2008-10-22
-2,00%
-1,50%
-1,00%
-0,50%
0,00%
0,50%
1,00%
1,50%
2,00%
0% 20% 40% 60% 80% 100%
U
n
c
e
r
t
a
i
n
t
y
2%
-2% -0,5%
0,5%
?
Ideal conditions Real conditions
ISO 17089A meter calibration curve without the guarantee that the meter
behaves the same way in the field as at the calibration facility is meaningless
16
-0.8 %
-0.6 %
-0.4 %
-0.2 %
0.0 %
0.2 %
0.4 %
0.6 %
0.8 %
0 1000 2000 3000 4000 5000
D
i
f
f
e
r
e
n
c
e
Diff. %
U (K=1)
U (K=2)
U (K=3)
U (K=4)
How does contamination over time affects the meter performance?
Performance
Monitoring
-2,00%
-1,50%
-1,00%
-0,50%
0,00%
0,50%
1,00%
1,50%
2,00%
0% 20% 40% 60% 80% 100%
U
n
c
e
r
t
a
i
n
t
y
Ideal conditions Real conditions
?
The quality of measurement over time.
17
Fundamentally, after the calibration 2vital questions remain:
How can we guarantee that the meter behaves the same way in the field
as in the calibration facility?
How can one be assured that the meter performance is not deteriorated
by fouling?
18
Why highest possible accuracy?
Because we measure billions of
and accountants appreciate lowest uncertainty.
$
Accuracy
19
The Netherlands: Production CT metering: 8x 24
Examples of metering stations
20
Examples of metering stations
Left:
GERMANY: gas import
1x 30, 2x 20, 2x 16
Right:
OMAN: LNG feed
4x 16
21
Money involved at large metering stations
22
The minimum you could lose
Pay back time
23
At 0.1%, the payback time of the meters is within a few number of weeks.
So the decision on the measurement should be made on the performance
rather than on the lowest price.
Dutch saying:
The bitter taste of a poor performance lasts longer than the sweet taste of a
cheap buy.
24
Accuracy depends on:
Acoustic path configuration
The number of paths
The calculation schedule of individual paths
Major issues are:
Profile distortion
Swirl
Multi-path Flow Meter Configuration
Meter design
1. Using mathematics dating from the 1830s (such as used in the Westinghouse patent from 1968 and still
applied in many parallel paths meters).
And / or..
25
Gauss J acobi Legendre Chebyshev
In selecting the acoustic path configuration there are 2 possibilities:
2. by applying flow research and using physical models such as CFD. Only then the
technology can progress.
CFD goal: the creation of a flow profile database
26
Flow calculation models
CFD:
Results depend on:
the boundary conditions
the calculation grid
Results always look nice, but
experiments are always necessary.
27
Flow calculation models
28
Flow profile distortions
Reducer tests at the University of Erlangen
29
Laboratory tests
Reducer tests at the University of Erlangen
Laser Doppler and CFD calculation
30
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
0
0.5
1
1.5
r/R [-]
v
/
v

g
e
m

[
-
]
Position x: 0R
Disturbed profile 5.5 D after a single 45 bending
measured in a 135 plane
Measured LDA
Theory (30% and 0.6R)
31
Analytical model
Theoretical models:
- Undisturbed fully developed pipe flow theory
- Mathematical hydrodynamic disturbance
functions
- Wall roughness theory
- Cavity correction theory
- Flow integration scheme
Input:
- Experimental LDA/PIV Data
- Geometrical parameters
- Hydrodynamic parameters
(e.g. Reynolds number)
Computation:
Path position optimization
Final design
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
0
0.5
1
1.5
r/R [-]
v
/
v

g
e
m

[
-
]
Position x: 0R
Disturbed profile 5.5 D after a single 45 bending
measured in a 135 plane
Measured LDA
Theory (30% and 0.6R)
32
Analytical model
Example of path sensitivity calculation for a 4 path meter for
30+different pipe configurations

Offset mean error axial disturbances relative to a fully developed pipe flow
-0.5
0.5
1.5
2.5
3.5
4.5
0.1 0.2 0.3 0.4 0.5 0.6 0.7
Position Path xR [-]
O
f
f
s
e
t

e
r
r
o
r

[
%
]
IV beam
33
Analytical model

Offset mean error axial disturbances relative to a fully developed pipe flow
-0.5
0.5
1.5
2.5
3.5
4.5
0.1 0.2 0.3 0.4 0.5 0.6 0.7
Position Path xR [-]
O
f
f
s
e
t

e
r
r
o
r

[
%
]
V beam
Example of path sensitivity calculation for a 5 path meter for
30+different pipe configurations
34
Example of 4 possible configurations
4 Beam
12 Chords
version 1
12 Chords
version 2
Laminar flow
Turbulent flow
Multipath configurations
Triangel
model
Profile distortion
36
Distortions in compliance with
10D
10D
5D
5D
SB Re/Ex DBooP
ISO17089
80D
80D
0D
0D
OIML R137
DBooP/Ex DBooP/Ex/HMP
37
Schematic layout
Testing in Lintorf
Total uncertainty: 0,3%
Repeatability: 0,1%
38
Testing in Lintorf
39
Straight path and reflective path tests
V12_d
V12
Straight path: ideal flow profile
40
Straight path: Flow profile after a single bend
41
42
Straight path Crossed or reflective path
Straight path: Flow profile Double out-of-plane bend
43
44
0,0%
0,1%
0,2%
0,3%
0,4%
0,5%
0,6%
0,7%
0,8%
0,9%
3 criss-
crossed
chords
4 criss-
crossed
chords
3 parallel
chords
5 criss-
crossed
chords
4/5 parallel
chords
5-pat h
triangle
8 chords
crossed in-
plane
12-V
chords
crossed in-
plane
Path Configuration
E
s
t
i
m
a
t
e
d

U
n
c
e
r
t
a
i
n
t
y

(
%
)
V12 meter
Flow Profile Effects (no swirl)
Gregor Brown: NEL conference 2006, KL.
Swirl
+
-
0
46
Chord configurations
Paths in the
same direction
Criss-
crossed
Triangle
model
V 12
technology
47
Swirl comes in 2variations
After a
single
bend
After a
double out-
of-plane
bend
The swirl velocity vector at the bottom changes in direction !
48
Flow profile distortion and swirl
49
Swirl elimination in each of the individual measurement planes
50
Swirl elimination
Reflective or crossed -technology
Difference between in-plane and out-of-plane designs
In-plane designs have 2 chords in the same
horizontal plane to completely eliminatethe
swirl.
Out-of-plane designs have the cords which
are supposedly aimed to compensatefor the
swirl at the different positions in the vertical
plane.
The paths do not cross in the same horizontal
plane.
51
Difference between in-plane and out-of-plane designs
In-plane designs have 2 chords in the same
horizontal plane to completely eliminatethe
swirl.
Out-of-plane designs have the cords which
are supposedly aimed to compensatefor the
swirl at the different positions in the vertical
plane.
The paths do not cross in the same horizontal
plane.
52
53
Out-of-plane chord designs
Out-of-plane chord designs try to compensate for the swirl by combining
cords at the same radius position.
Bottom path
changes in direction
Paths in same direction Paths in criss-cross
arrangement.
54
2 parallel chords in detail, paths in same direction
-
+
-
-
Ideal swirl profile Real swirl profile
Swirl compensation with out-of-plane paths
(paths in same direction)
++
--
++
-
56
2 parallel chords in detail, in a criss-cross arrangement
+
+
+
-
Ideal swirl profile Real swirl profile
Swirl compensation with out-of-plane paths
(paths criss-crossed)
++
++
+++
+
58
The difference between in plane and criss-crossed path configurations
Each of them is optimized for either:
. a single bend configuration
. or for a double out-of-plane bend
. But neither of them can handle both !
. Both are unsuitable for non symmetrical
swirl
The only way to overcome these problems is by eliminating the swirl in
each of the individual the measurement planes
The impact of Swirl on the measurement result in practice
High level swirl test
Low level swirl in an official AGA9 Meter run
Bill Frasier, Ceesi
Ceesi Colorado Springs Ultrasonic Workshop 2011
59
60
Benchmark ultrasonic gas flow meters 20 /DN500
Archive photo: GL Flow Centre Bishop Auckland
Participants
61
62
Out-of-plane
swirl compensation
UFMs in compared in the Gazprom test.
In-plane swirl elimination
Latest model
Zanker flow conditioner upstream of a 28D straight pipe
PTB plate, swirl angle 45
Zanker flow profiler Fully developed flow (ideal conditions)
Disturbed flow with swirl (mimicking Header +Tees)
Real world conditions: Header with 2 Tees
Courtesy:
64
CFD: Computational Fluid Dynamics
Test set-up Bishop Auckland 20 (DN500) / ANSI600 / natural gas @ 40 bar
13D =6.5m 28D =13.9m
Meter 1 Meter 2
Meters 1 & 2
ideal conditions
ideal conditions
swirl
Meters 3, 4 & 5
ideal conditions
swirl
Real world conditions with swirl:
Ideal conditions:
Meters 3, 4 & 5
Meters 1 & 2
-1
-0,8
-0,6
-0,4
-0,2
0
0,2
0,4
0,6
0,8
1
0 2000 4000 6000 8000 10000 12000
m3/h
%

e
r
r
o
r
0,36%
0,61%
Test 1
Test 2
M1
M1 M2
M2
Test 2, meter2
Test 1, meter2
Test 1, meter1
Test 2, meter1
Ideal conditions: Meters 1 & 2
-1
-0,8
-0,6
-0,4
-0,2
0
0,2
0,4
0,6
0,8
1
0 2000 4000 6000 8000 10000 12000
m3/h
%

e
r
r
o
r
0,36%
0,61%
-1
-0,8
-0,6
-0,4
-0,2
0
0,2
0,4
0,6
0,8
1
0 2000 4000 6000 8000 10000 12000
m3/h
%

e
r
r
o
r
0,36%
0,61%
Test 1
Test 2 R S M1 M2
M1 M2
M1, Test 2 repeatafternoon
M1, Test 1 morning
M1, Test 1 repeatafternoon
M1, Test 2 morning
Meter 1 showed irregular behavior even under ideal conditions
Meter M1 suffered from irregular baseline behavior and was
therefore disqualified
-1,00
-0,80
-0,60
-0,40
-0,20
0,00
0,20
0,40
0,60
0,80
1,00
0 2000 4000 6000 8000 10000 12000
%
m3/h
Ideal conditions: all manufacturers (scale 1%)
Test 2 M1 M2
Test 5 M3 M4 M5
M3
M2
M4
M1
M5
rejected on irregular baseline behavior
-20,00
-17,50
-15,00
-12,50
-10,00
-7,50
-5,00
-2,50
0,00
2,50
5,00
7,50
0 2000 4000 6000 8000 10000 12000
%
m3/h
rejected on irregular baseline behavior
69
Real world conditions; flow with swirl (scale + 7.5 to - 20%)
Test 3 M1 M2
Test 4 M3 M4 M5
M1
M3
M2
M4
M5
Out-of-plane swirl compensation
Out-of-plane swirl compensation
In-planeswirl elimination
-5,00
-4,00
-3,00
-2,00
-1,00
0,00
1,00
2,00
3,00
4,00
5,00
0 2000 4000 6000 8000 10000 12000
%
m3/h
rejected on irregular baseline behavior
In-plane swirl elimination
70
Real world conditions; flow with swirl (scale 5%)
Test 3 M1 M2
Test 4 M3 M4 M5
Out-of-plane swirl compensation
KROHNE V12
M2
M4
M1
M5
71
Summary
swirl
The KROHNE ALTOSONIC V12 is the only ultrasonic gas flow meter that measures within
custody transfer limits even under very strong swirl conditions.
Flow profile scanat five levels Swirl eliminationin eachmeasuringplane
-2,00
-1,00
0,00
1,00
2,00
0,00 2000,00 4000,00 6000,00 8000,00 10000,00 12000,00
%
KROHNE V12
Southstream countries involved
72
Southstream facts / Timeline
73
Southstream gas measurement
Russian terminal (near Anapa)
4 measuringlines 16, each 2 UFM in series, ANSI2500 pressure rating
Bulgarian terminal (near Varna)
4 measuringlines 16, each 2 UFM in series, ANSI2500 pressure rating
74
75
Performance of an out of plane swirl meter in an official AGA9 meter run.
Bill Frasier
Ceesi Ultrasonic Workshop
Colorado Springs 2011
10D
Flow
straightener
Out-of-plane swirl
compensating
meter
76
The official recommended AGA meter run
Real conditions: CFD of header with 2 Tees.
Courtesy:
CFD: Computational Fluid Dynamics
Comment from
CPA:
The CPA plate
takes
approximately
95% of the swirl.
But there is still
some swirl
remaining!
This results in a
substantial shift
of the meter
error.
Real conditions: CFD of header with 2 Tees
Courtesy:
CFD: Computational Fluid Dynamics
Comment from
CPA:
The CPA plate
takes
approximately
95% of the swirl.
But there is still
some swirl
remaining!
This results in a
substantial shift
of the meter
error.
No straight lines!
There is still
some swirl
present.
79
Flow pattern in the north run in the field; clockwise deposit
80
Flow pattern in the south run in the field; counter- clockwise deposit
81
Measurement error of the out-of-plane swirl compensating meter.
Conclusions on swirl
Meters having their swirl compensationnot in the same plane of
measurement are very vulnerable to high swirl levels such as can be
encountered in real world conditions.
Even if its design is theoretically compensating for a certain swirl type, slight
asymmetries in the flow can result in large measurement errors. Therefore
out-of-plane designs should always be installed with a flow conditioner,
reducing the swirl.
Even when mounted into an official AGA9 meter run, including a flow
straightener, the additional measurement error of an out-of-plane meter is still
in the order of 0.3% to 0.4%. This means that the highest attainable OIM
Class for such meters is Class 1.
Only by in-plane swirl correction the impact of swirl can be totally cancelled
out and an OIML classification 0.5 can be achieved using 5 measurement
planes.
82
Final path configuration
84
Velocity profile changes
2 stable profile
supports at 0.5R
85
Flow profile correction with KROHNE
3
additional
paths
for
correcting
the impact
of
profile
distortions
86
ALTOSONIC V12; The Power of Reflection
Item Benefit Drawback
Doubling the path
length
Higher accuracy
less suitable for
high CO2
applications
more powerful
transducers
Swirl In the plane swirl
elimination.
none
Multipoint
interrogation of the
pipe wall
Detection of fouling
Assuring
measurement
quality
(expert system)
none
87
OIML R137
ALTOSONIC V12: the onlyUSM within class 0,5
Transducer selection
89
Transducers
. There is not a one-first-all solution.
. Transducers have to be chosen dependent on the application.
Key selection criteria:
pressure range
temperature range
chemical resistance
acoustic attenuation
control valve noise
90
Transducer design
Various types of designs and frequencies:
Epoxy based:
excellent acoustic and chemical properties
Temperatures -50 C t/m100 C
pressures up to 500 bar
Full Titanium:
Temperatures - 40C t/m +180C
Pressures up to 150bar@180C
Wave guides for higher temperatures
& special applications
91
Titanium transducer for wet gas and high temperatures
92
Application chart
Application
Transducer type
Dry natural gas Wet gas Sour gas Methanol
High
temperature
High
pressure
Epoxy
++
-

+ -
++
Full Titanium
+ ++ +
H2O>
10%
++ +
Wave guide
(non custody transfer)
-
-
+/- +
++
++
93
Frequency selection:
Valve present: high frequency.
CO2 / low pressure: low frequency.
94
Absorption of the acoustic pulse (by CO2)
CO2 is a symmetrical molecule.
It resonates within a specific frequency band and thereby takes a lot of
energy away from the acoustic pulse.
95
CO2 Theoretical absorption curves
The attenuation coefficient is almost constant
between 80 kHz and 1 MHz
96
Attenuation equation:
In this equation:
C is a constant depending on the transducer efficiency
L is the path length.
is the attenuation coefficient (almost constant
between 80 kHz and 1 MHz)
Therefore the path length is the determining factor !
CT Products
|
.
|

\
|

+
=
100
% 100
100
%
2
lg
2
2
CO CO
L
transducer
as natura CO
e L C P

CO
2
tests: Test set up
97
CO
2
tests: Primary results
98
~
1

~
~
%

CO
2
tests: Attenuation factor
99
100
4 meter, minimum pressure requirements
1.0 2.0 4.0 8.1
16.3
32.7
65.5
130.9
261.1
519.2
1029.2
0.5
0.7
1.0
1.4
2.0
2.8
4.0
5.7
8.0
11.3
15.8
0.0
200.0
400.0
600.0
800.0
1000.0
1200.0
0.0 20.0 40.0 60.0 80.0 100.0 120.0
%CO2
p
r
e
s
s
u
r
e

[
b
a
r
]
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
18.0
Reflective path Dir ect path
4 inch
101
0.8 2.0 5.2 13.5 34.8
88.6
224.7
566.8
1424.0
3563.8
8889.4
0.4 0.6
1.1
1.9
3.3
5.7
9.7
16.4
27.5
46.1
77.0
0.0
1000.0
2000.0
3000.0
4000.0
5000.0
6000.0
7000.0
8000.0
9000.0
10000.0
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0
%CO2
p
r
e
s
s
u
r
e

[
b
a
r
]
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
Ref lect ive pat h Dir ect pat h
6 meter, minimum pressure requirements
6 inch
102
8 meter, minimum pressure requirements
8 inch
5 11 23 51
110
237
512
1107
2391
5163
11141
2
3
5
8
11
17
25
38
56
84
125
0.0
2000.0
4000.0
6000.0
8000.0
10000.0
12000.0
0.0 10.0 20.0 30.0 40.0 50.0 60.0
%CO2
p
r
e
s
s
u
r
e

[
b
a
r
]
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
Ref lect ive pat h Dir ect pat h
103
10 meter, minimum pressure requirements

10 i nch
7 14 27
53
106
210
417
827
1639
3249
6436
3
4
6
9
13
18
26
37
53
75
107
0.0
1000.0
2000.0
3000.0
4000.0
5000.0
6000.0
7000.0
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0
%CO2
p
r
e
s
s
u
r
e

[
b
a
r
]
0.0
20.0
40.0
60.0
80.0
100.0
120.0
Ref lect ive path Dir ect path
104
Altosonic V12-D
Conclusions on CO2 .
Path length is the dominant factor whether a meter will
function or not.
The calculation model can predict the performance at the
quotation level.
The impact of fouling and the
diagnostic Expert System
106
Inlet 12 piping
Bill Frasier Ceesi, Ceesi Colorado
Springs Ultrasonic Workshop 2011
107
108
109
The straight path meter could not detect this shift!
110
Clean and dry gas applications?
111
IHSM pictures on fouling
Clean dry gas ?
112
Variations in fouling
1. Liquid layer on the bottom of the pipe (condensates, water, spill-over)
2. Asymmetrical fouling (wax deposits)
3. Symmetrical wall build-up (black powder)
4. Dirt build-up on the transducer (wax)
5. Liquid contamination in the transducer ports
113
Examples of Fouling
1: Fouling as a small flow on the bottom of the pipe
114
Variations in fouling
1. Liquid layer on the bottom of the pipe (condensates, water, spill-over)
2. Asymmetrical fouling (wax deposits)
3. Symmetrical wall build-up (black powder)
4. Dirt build-up on the transducer (wax)
5. Liquid contamination in the transducer ports
115
Examples of Fouling
Original clean situation
116
Examples of Fouling
2: Fouling, asymmetrical stuck to the pipe wall
117
Variations in fouling
1. Liquid layer on the bottom of the pipe (condensates, water, spill-over)
2. Asymmetrical fouling (wax deposits)
3. Symmetrical wall build-up (black powder, corrosion)
4. Dirt build-up on the transducer (wax)
5. Liquid contamination in the transducer ports
118
Examples of Fouling
3: Fouling, evenly distributed coating
119
Variations in fouling
1. Liquid layer on the bottom of the pipe (condensates, water, spill-over)
2. Asymmetrical fouling (wax deposits)
3. Symmetrical wall build-up (black powder, corrosion)
4. Dirt build-up on the transducer (wax)
5. Liquid contamination in the transducer ports
120
4. Dirt built-up on the transducer.
121
Variations in fouling
1. Liquid layer on the bottom of the pipe (condensates, water, spill-over)
2. Asymmetrical fouling (wax deposits)
3. Symmetrical wall build-up (black powder)
4. Dirt build-up on the transducer (wax)
5. Liquid contamination in the transducer ports
122
5. Liquid contamination in the transducer pockets.
123
Testing in Lintorf
124
Testing in Lintorf, 2 x ALTOSONIC V12, 6
125
18 observation points
Performance Monitoring: Symmetrical wall built-up
126
3. Fouling of evenly distributed inside the pipe.
Expected diagnostic key indicators:
Irregular changes in the Speed of Sound as well as the Reflection coefficient (trending)
127
3. Fouling of evenly distributed inside the pipe; the velocity profile
The flow velocity profile is much sharper.
-14.0%
-12.0%
-10.0%
-8.0%
-6.0%
-4.0%
-2.0%
0.0%
2.0%
4.0%
6.0%
8.0%
-1.00 -0.80 -0.60 -0.40 -0.20 0.00 0.20 0.40 0.60 0.80 1.00
fouling
clean
128
3. Fouling of evenly distributed inside the pipe; the reflection coefficient .
The signal strength varies with the thickness of the layer.
S
i
g
n
a
l

s
t
r
e
n
g
t
h
60.0
62.0
64.0
66.0
68.0
70.0
72.0
74.0
76.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
GAINAB3
GAINAB6
GAINAB3
GAINAB6
GAINAB1
GAINAB2
GAINAB3
GAINAB4
GAINAB5
GAINAB6
Change in signal strength on the reflecting paths
6
3
129
3. Fouling of evenly distributed inside the pipe.
There is are irregular changes in the standard deviation; both the
thickness of the layer and the surface roughness have an effect.
S
t
a
n
d
a
r
d

d
e
v
i
a
t
i
o
n
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
SDCh_SoS[3]
SDCh_SoS[6]
SDCh_SoS[3]
SDCh_SoS[6]
SDCh_SoS[1]
SDCh_SoS[2]
SDCh_SoS[3]
SDCh_SoS[4]
SDCh_SoS[5]
SDCh_SoS[6]
Change in the SOS standard deviation of the reflecting paths
6
3
130
3. Fouling of evenly distributed inside the pipe; SOS.

Relative SOS at evenly fouling
-0.10%
-0.05%
0.00%
0.05%
0.10%
0.15%
0.20%
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
m/s
131
3. Fouling of evenly distributed inside the pipe; error curve

Evenly fouli ng
-0.20
0.00
0.20
0.40
0.60
0.80
1.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
base downstream
evenly fouling
First order correction using GC data as input
M
e
t
e
r

e
r
r
o
r
Using information of a GC to calculate the SOS, a good
correction is possible with an uncertainty of 0.1% - 0.15%.
132
Performance Monitoring: Bottom fouling
133
Applying thin strip of regular grade anti -seize lubricating compound
meter
Inlet pipe
134
-12.0%
-10.0%
-8.0%
-6.0%
-4.0%
-2.0%
0.0%
2.0%
4.0%
6.0%
8.0%
-1.00 -0.80 -0.60 -0.40 -0.20 0.00 0.20 0.40 0.60 0.80 1.00
1. Fouling on the bottom; the velocity profile
The changes in the flow velocity profile are so minimal, that it cannot be used as an indicator !!
F
o
u
l
i
n
g
With fouling
clean
G
a
s
f
l
o
w
135
1. Fouling on the bottom: change in reflection coefficient
With thin layers, the fouling has hardly any impact on the signal strength.
60.0
62.0
64.0
66.0
68.0
70.0
72.0
74.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
Signal strength with and without
bottom fouling
136
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
Path 3
Path 6
6
3
The standard deviation of the path reflecting at the bottom increases with increasing fouling
1. Fouling on the bottom: standard deviation with and without bottom fouling
137
1. Fouling on the bottom; change in the SOS of path 6
SOS comparison; bottom fouling
-0.30%
-0.20%
-0.10%
0.00%
0.10%
0.20%
0.30%
0.40%
0.50%
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
m/s
%

d
i
f
f
e
r
e
n
c
e
SOS change in path 6
138
1. Fouling on the bottom; error curve

Bottom fouling
-0.20
0.00
0.20
0.40
0.60
0.80
1.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00
m/s
%

e
r
r
o
r
base downstream
bottem fouling
First order correction
Many more fouling tests done, such as
139
140
Key diagnostic indicators
V
e
l
o
c
i
t
y

p
r
o
f
i
l
e
F
o
o
t
p
r
i
n
t
r
e
f
l
e
c
t
i
o
n

c
i
e
f
f
i
c
i
e
n
t
s
i
g
n
a
l

s
t
r
e
n
g
t
h
s
t
a
n
d
a
r
d

d
e
v
i
a
t
i
o
n
s
i
g
n
a
l

t
o

n
o
i
s
e
S
O
S
Bottom foul ing X X X
A-symmetrical fouling X X X
(wax deposits)
Symmetrical fouling X X X X X
(black powder)
Fouling on transducers X X
(wax deposits)
Liquid contamination in the transducer pockets X
(water & condensates)
All the different ways of fouling are clearly detectable!
(simplified diagram)
Krohne
the Diagnostic Expert System
142
Diagnostic Expert System
It is much more than Condition base Monitoring
IDENTICAL
Condition Based Monitoring
|
31
-
143
144
Condition Based Monitoring
Definition:
Maintenance when need arises
What you need is
Predictive Monitoring!
Expert System
|
31
-
145
an expert system is a
computer system that emulates
the decision-making ability of a
human expert
146
Diagnostic Expert System
Elements in the design:
Maintenance BEFORE the need arises
Based on experimental & Analytical/numerical investigations
Based on real time data and historical data
Sophisticated software presenting Expert diagnostics
147
We have asked our people how to diagnose problems
Bottomfouling
Asymmetrical fouling
Symmetrical fouling
Transducer fouling
Profile distortion
Trend analysis
We put our intelligence
148
into the meter
149 149
PGC
T-transmitter
3144
P-transmitter
3051
KROHNE Care
INTERNET
TCP/IP
HART
Modbus
- The highest level of diagnostics
TCP/IP
KROHNE Care expert system
150
Predictive maintenance
by trending
Expert system
151
Diagnostic Expert system: Absolute Monitoring
Absolute Monitoring (Trend)
0
20
40
60
80
100
120
Ti me
P
u
l
s
e

A
c
c
e
p
t
a
n
c
e

[
%
]
152
Diagnostic Expert system: Relative to Path Monitoring
153
Velocity dependant Monitoring
0
0.05
0.1
0.15
0.2
0.25
0 5 10 15 20 25 30
Velocity [m/s]
S
t
a
n
d
a
r
d

D
e
v
i
a
t
i
o
n

S
o
S
SDSoS1
SDSoS2
SDSos3
SDSoS4
SDSoS5
SDSoS6
Diagnostic Expert system: Velocity Dependent Monitoring
154
Diagnostic Expert system: Application Dependent Monitoring
Gas Composition
Temperature Calculated SoS
Pressure
Measured SoS
155
Diagnostic key parameters
Available key information:
Parameters
Flow velocity for six paths
Speed of Sound for six paths
Pulse acceptance for six paths
Amplification for 12 transducers
S2N for 12 transducer
Values:
For each parameters Live, Average, Standard Deviation, Minimum & Maximum
Parameter checks:
Absolute
Relative per path
Velocity dependent
Additional:
For each parameter Historical application specific reference data.
Total
42
x
5
210
x
3
630
(1260)
156
SD Vg
Evenly fouling
Approval
Bottom fouling
Materials
Gunk
Condensate
Noise
Wall roughness
Trending
Black powder
FAT
Flow profile
Measuring points
Asymmetrical fouling
Calibration
CO2
SD SOS
Signal strength
P
T
Gas composition
Pulsation
Operating envelope
Reflection
coefficient
SOS
Footprint
Inlet conditions
Flow conditioner
Signal to noise ratio
Relationship between diagnostic parameters is complex.
157
Thats why KROHNE Care has been designed
To detect failures automatically
To propose measures
To check 24/7
To validate your CT
measurement
158 158
KROHNE Care - WEB-server built-in
159 159
PGC
T-transmitter
3144
P-transmitter
3051
KROHNE Care
INTERNET
Ethernet
HART
Modbus
- WEB-server built-in
160
Diagnostic Expert system (data)
Multiple variables
SoS, V, GAIN, S2N, PulseAccept.
Multiple monitoring types
Absolute, Relative,
Velocity & application dependant
Multiple values
Average & Standard Deviation.
Reference data
Multiple Quality Checks
Quality Status
Overall status
161
Diagnostic Expert system (software)
Multiple Quality Checks
Quality Status
Overall status
And has been working fine over
the whole passed period
This meter works fine, no issues expected
163
Warning; meter still ok, but corrective action required
Event
Reason for warning
ALTOSONIC V12 web page: Expert system
164
Reason for warning
ALTOSONIC V12 web page: Diagnostics
165
ALTOSONIC V12 web page: Live data
166
167
168
ALTOSONIC V12 web page: reporting (full ISO 17089 compliance)
169
ALTOSONIC V12 web page: Data upload & download
170
CONCLUSION
Expert System
171
Reflective Technology Detection of fouling
Complex and fast increasing amount of data requires understandable solutions
Expert system: KROHNE Care
with features:
24/7 Diagnosis by Expert System
Remote control by web based functionality
Flow computer functionality
To assure your billing is correct!
Verification of ultrasonic flow meters
Reference values:
Factory acceptance test
High pressure flow calibration
Possibilities for in situ verification:
1. In situ verification by the meter itself: expert system.
2. In situ verification by comparing the SOS calculated and measured
in compliance with AGA Report No. 8 or 10.
3. 2 meters in series
4. Master meter design
In situ verification possibilities
Reference values: Factory Acceptance Test (FAT)
Zero flow condition
Pressurized (appr. 150psi)
Filled with 100% Nitrogen
P&T measured
SOS calculated (AGA10)
SOS compared
Path length check
Path angle check
Functional test
Second set of reference values: Flow calibration
High pressure
Natural gas
Typically 6 flow rates
1: In situ verification by the meter itself:
The diagnostic expert system.
Sensitivity:
0.1%-0.3%
on fouling
2: Speed of Sound comparison.
gas composition
actual flow
T
P
Can also be done as part of
the Expert system.
Sensitivity:
0.1 - 0.2% on SOS
3: Two meters in series
Ultrasonic meter and turbine meter
Commonly done in Europe for border stations.
Ultrasonic meter and ultrasonic meter
Common practise in Europe for bi-directional measurement
Sensitivity:
2* OIML class +
0.2-0.3% for fouling
4: Master meter (Z-bridge)
100% duty meter
Comparison between
duty meter (possibly
contaminated) and clean
master meter
Comparison on a
periodic base
Master meter (Z-bridge)
100% duty meter
Comparison between
duty meter (possibly
contaminated) and clean
master meter
Comparison on a
periodic base
Sensitivity:
2* OIML class
Master meter (Z-bridge)
2x 50% duty meter
Comparison between duty
meter (possibly
contaminated) and clean
master meter
Comparison on a periodic
base
182
In reflection
There are things that we know
There are things that we dont know
There are things of which we know that we dont know.
There are things that we dont know that we dont know.
The same is true with the measurement under fouling
conditions.
In reflection
183
If you use a straight path non reflecting design:
you know that there might be fouling
you dont knowif there is any fouling
you know that you dont knowwhen there is any fouling
you dont knowthat you dont knowwhat hits you
However, using a reflective design:
you know that there might be fouling
you knowif there is any fouling
you know that you knowwhen there is any fouling
you knowthat you knowwhat hits you
In reflection