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SPE 19074 Investigation of the Error Sources While Measuring Air Flow Rate by an Orifice Meter
by A. Bouhroum, A. Saleh, and C. Marx, Technical U. of Clausthal
SPE Members

Copyright 1989, Society of Petroleum Engineers, ho, This pafmr was prepared for presentation al the SPE Gaa Technology Symposium hafd in Dallas, Texaa, June 7-9, 19SS. TM paper wae aalactad for praaantatlon by an SPE Program committee foffowingreview of infcfmation contained in an abstract aubmiffad by the author(a). Contenla of the paper, ss Weaantadi hava not baan re~awad by the SOCiC4y Of Petrofeum Enginaare and are aublact to cormotlon by the author(s). Tho material, as praaantad, does nor MSOSSWIIYrOtfOCI any positionof the Sooiety of Petroleum Engineers, its ofticera, or members. Papain Presented at SpE Maaflntla we SUM*110P*l~t~ * W EdhMd *mlffaaa oft~ y of PetroleumEnginaam. Parmiaaionto is reafrkfad to an abstractof not mrxa than ~ wda. Illuafdona rnayw@c@ad. Thaab@racfaho@demafnm+umtfa~ of wtmre and by whom the papar ia presented. Write Publkationa Manager, SPE, P.O. Sox S3SS3S, Rkhardaom, TX 7S0S34S% Tafax, 730SSS SPEDAL.

ABSTRACT The accuracy of differential pressure flowmeters can be strongly affected by gas flow rates obtained from a pulsating source. This work discusses the error sources present when air flows through an orifice flowmeter which is installed d~wnstream of a positive displacement rotary compressor in a gas-processing plant. Air velocity profiles were used. successfully to identify the error sources, which indicate pulsation interference in a specific frequency band. This came in addition to an acoustic resonance caused by an installed pressure regulator in the flow system. In order to improve the system the installation of the following devices were suggested: - a diffuser downstream of the orifice plate - an inline silencer to control valve noise - a pulsation damper to damp pulsation wavelengths of 7.83 and 7.33 m (23.86-23.34 ft) corresponding to frequencies of 38.57 and 41.33 Hz respectively. INTRODUCTION The instrument accuracy of the orifice type flowmeter as is given by the manufacturer can only be used when at the calibrated conditions is measured. Deviations from these conditions may affect the prescribed accuracy range. Compressors, oscillating control valves and pumps generally produce cycling flow rates with an acceptable deviation in accuracy over a long periode of time - cycle with small flow rate changes /1/. At large flowrate changes reciprocating and/or positive Displacement rotary compressors cause an undesirable deviation in accuracy. Usually, this is due to a superposition effect of the

existing waves of different forms, frequencies and amplitudes. The effeet of such frequencies and amplitudes can be seen by inspecting the shape of fluid flow velocity profiles at laminar, and/or turbulent flow conditions. At lam.i.nar flow, disturbance amplitudes grow with increasing frequency which on its tvrn affects the velocity profiles. The flow profile through laminar flow tends to decrease in the center and to increase towards the walls /s2/. In case of turbulent flow, the shape of the velocity profiles can change at high amplitude and low frequency as a result of the pulsation of the compressor. When the frequency increases, the velocity profiles becomes more deformed /3/. The problem under investigation in this work is to identify the error sources while measuring the air flow rates with an orifice flowmeter, which is installed downstream ofa positive displacement rotary compressor. The measuring fault can reach relative values up to 20 %. Therefore, the orifice meter readings could not be used to regulate accurately the required air flow rate in the gasprocessing-plant. A work program has been suggested.in order to obtain the actual relationship between air flow rate as a function of compressors rotational speed (RPM), by comparing the orifice meter and a linear flowmeter (mini turbine flowmeter) as a reference measurement instrument. Velocity profiles have been plotted to obtain the mean velocity to be used for flow rate calcula-

References and illustrations at end of paper. 107

INVESTIGATIONS OF THE ERROR SOURCES WHILE MEASURING AIR FLOWRATE BY AN ORIFICE METER

SPE 1;074

tions. By using the actual velocity profiles the effect of pulsation, acoustic resonance a~s swirl has been demonstrated for the spzcific range of rotational speeds (RPM) c the air compressor. MEASURVJIENTS . The first measurements performed show the actual relationship between the volumetric air flow rate determined from the orifice meter as a function of rotational speed of the compressor. A recording instrument have been used to record continuousl~?compressor rotations. (n = l/rein),air flow temperature (grad K)r gauge pressure (kPa) which is measured upstream of the orifice and the volumetric air flow in (M3/h (Vn)). Flowrate of air was converted to standard conditions. These measurements cover a compressor rotational speed rangefrom n = 320 to 720 l/rein*. The relationship between volumetric air flow measured under standard conditions with the orifice meter as a function of rotational speed of the compressor is illustrated lli IAgure 1. To investigate the non-linearity of the curve plotted in figure 1. a second programm was suggested. This program aims to measure and plot the actual velocity profile of the air stream. Fxom this profile, the mean velocity was determined by means of a cornputer program and then used to calculate the volumetric air flow under standard conditions. The actual measured air velot?itywas obtained with the help of a calibrated mini turbine flowmeter (linear flowmeter) which was inserted in 7.72 cm (3.04 Inch) holes drilled at prescribed locations in the flow pipe of a diameter equal to 486 mm (1,48 ft). Two different cross-sections of the air flow pipe have been choosen at distances of 3.3 and 11 D upstream of the orifice plate. At these locations, the air flow may be slightly affected by elbow effects. They were mounted additional downstream of an inline conditioner. The cross-sections axis, see figure 2, at 11 D inclined 45 with reference to that at 3.3 D. Seven different compressors speeds were carefully selected to cover the RPM range from n = 320 to 680 l/rein.The seiected RPMs were 320, 460, 540, 580, 620, 645 and 680 l/rein.The values 580, 620, 645 and 680 l/reinhave been selecte& to clarify the largest peak observed in figure 1. The *This range was limited because of the results changes in.operation capacity of othe gas-processing sections, also, to avoid a sudden break-down.in the operation process. . ---la

equal annular area method has been choosen to set the measuring points on two perpendicular traverces. The number of the measured velocity points was set to be 8 on each traverce (see figure ~). This method guaranteesaccuracy of - 1 $. At each point on the two traverces, 3 successively velocity values were recorded at one of the above mentioned RPM-values. The average was calculated and then used to plot the velocity profiles. RESULTS AND DISCUSSIONS A non linear relationship between the volumetric air flow and the rotational speed of the compressor is depected in figure 1. A large peak can be seen between n = 580 through 680 l/rein.This peak has ? Progressive tendency with apparentlncrease of the flowrate. This is based on laboratory analysis obtained from the gas-processing p?.antwhich shows no existence of a sudden or additional increased air flow rate in this RPAYrange. Other peaks are noticed with relatively small amplitudes compared with the above discussed one. TO investigate these peaks - so called hills and valleys-, the second program was suggested. The main purposes of that program are the following: - to determine the relationship between the flow rate and the rotational speed of the compressor by applying a linear flowmeter (mini turbine flowmeter) - to compare both relationships obtained from the cliff ential pressure flowmeter and the line 8 flowmete=. . The results from.these experiments indicate the seriousness of erzor sources of the orifice readings. As is illustrated in figure 1 a linear correlation have been determined. Th$s correlation has an average $rror of - 2.6 % and standard deviations of - 2.75 $. The linearity of the correlation is of a significant importance which means that the relationship between the air flow rate and the rotational speed of the compressor shows no hills in the air flow rate as has been measured with the help of the orifice in the RPM range of n = 580 through 680 l/rein. The non-linear relationship measured is caused by the following effects: - The ekfect of pulsation which is generated by air compressor on the second divice of the square edged orifice meter. - The effect of an acoustic wave reflection on the orifice plate. - A standing wave with a significant wave -length.

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SPE 19074

A. Bouhroum, A. Saleh, C. Marx - Pulsation of frequency range from 38.67 to 41.33 Hz, introduced by the installed positive-displacement rotary compressor. - The presence of swirl inspitd of installation of conditioners. Suggestions for the gas-processing plant to avoid the error sources: - Replacement of the oscillating valve as indicated beforceor the installation of an in-line silencer to control valve noise. Installing a pulsation damper for the wavelengths of 7.83 through 7.33 m. - If the last suggestions are not desirable, a linear flowmeter can be installed or a mini linear flowmeter for one point measurement method. The location of the mini flowmeter can be selected from the velocity profile constructed in this work. ACKNOWLEDGEMENT

is is illustrated in figure 4, an acoustic resonance was measured in a RPM range of The velocity 1 = 580 through 620 l/rein. ?rofilec illustrated in figure 5, 6, 7, 8 shows clearly the effect of both pulsation and swirl. The pulsation effect can be observed on the right side of the velocity >rofiles as the frequency increases. The Erequency occurs by pulaatiion,varies from 18.67 to 41.33 Hz with,reference wave lengths >f 7.83 to 7.33 m. (23.86-23.34 ft). [nspite of thp installation of flow conditioner, the velocityprofile illustrated in Figure 8 shows the effect of swirl. rhe source of acoustic resonance (figure 4) ?as found to be the control valve which >scillated in the discussed range. This ~alve regulate the pressure of gas required lnd generate a considerable noise in the messure range of about 75 - 76 KPa (1.1 psi), inally, the total measuring error of the lsed mni-turbine flowmeter was determined + LO be - 7.13 %. This includes an assumed !rror due to deviation of the measuring .nstrument axis from the horizontal and Fertical planes, an assumed error due to .ndicated swirl angle of 11O. Error-given ~y the manufacturer for measured gauge messure and one for the turbine flowmeter, k calculated error related to be average ~elocity which is calculated from each of I successively velocity values, an assumed !rzor due to the variation in the pipe liameterand an error ~f using equal annular Lreas measurement method. !0iW2LUSIONS !he error sources of the measurement by the irifice meter are: . Acoustic resonance observed at n = 580 to 620 l/rein,which is caused by an oscillatintjpressure control valve installed in the pipe system.

The authors wish to thank ML. Llibcke, Mr. Schopp and Mr. Kramer, Mobil Erd151Erdgas GmbH for their assistance in various phases of this work. REFERENCES 1. Nieh, C.D., H. Zengyan, Estimate Exchanger Vibration. Better Method for Determining Resonaut Frequencies of Exchanger Tubing Provides Operating and Design Flexibility without Sacrificing Reliability, Hydrocarbon Processing (April 1986) 61 - 65 Edwards, M. F., M. A. Wilkinson, Reviewof Potential Applications of Pulsating Flow in Pipesn, Trans.Inst. Chem.Engrs.,Vol. 49 (1971) 85 - 94 . Mizushina, T., T. Maruyama, H. Hirasawa, Structure of the Turbulence in Pulsating Pipe Flowsw, J. Chemical Engineering of Japan, Vol. 8, No. 3
(1975] 210 216

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