YAT E S M E T E R

FLOWMETER
CALIBRATION
METHODOLOGY

AE M S L t d . , T h e E n e r g y C e n t r e , F i n n i m o r e In d u s t r i a l E s t a t e , O t t e r y S t . M a r y , D e v o n . E X1 1 1 NR
~ Tel.: +4 4(0) 140 4 81 229 4 ~ Fa x: +4 4(0) 140 4 81 260 3 ~

K:\METHOD\methodflow1.doc

Flowmeter Calibration Methodology

- CONT E NT S -

BACKGROUND & PROCEDURES

1.1

INTRODUCTION

THEORY

2.1

CALCULATION OF PUMP EFFICIENCY

2.2

CALCULATION OF VOLUME FLOW RATE,

TEST APPARATUS
3.1

STANDARD EQUIPMENT

TAPPING ARRANGEMENTS

4.1

CONVENTIONAL SURFACE MOUNTED PUMPS

4.2

SUBMERSIBLE PUMPS

4.3

SUSPENDED BOWL PUMPS.

METHODOLOGY
5.1

CALIBRATION

5.2
TEST POINT
5.2.1 Power Monitoring
5.2.2 Connection Arrangement for 3 Phase Power Measurement

GENERIC METHOD STATEMENT

7
7
8

6.1

INTRODUCTION

6.2

SUMMARY OF TESTING PROGRAMME

6.3

DESCRIPTION OF PROCEDURES

10

6.4

CALIBRATION OF 4-20 MA SIGNAL FROM FLOWMETER

12

APPENDICES

14

7.1

APPENDIX 1: TYPICAL TAPPING ARRANGEMENT

14

7.2

APPENDIX 2: CONVENTIONAL HORIZONTAL SPLIT-CASE PUMP

15

7.3

APPENDIX 3: SUBMERSIBLE PUMP

16

7.4

APPENDIX 4: SUSPENDED BOWL PUMP

17

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Flowmeter Calibration Methodology

1 BACKGROUND & PROCEDURES

1.1 INTRODUCTION
Testing is carried out using the Mark IV Yatesmeter, which is a pump performance meter
based on thermodynamic principles.
The thermodynamic principles have been well documented in the pumping field and the
technique is accepted in the following documents:
ISO-5198 precision class, Testing Class A, for pumping heads greater than 100m.
Pump Centre (UK) - Code of Practice for Pump Efficiency Testing by the Direct
Thermodynamic Method. Pump Centre report 695/27
Class B - Pumping heads greater than 25m.
Class C - Pumping heads greater than 10m.
The thermodynamic method is based on measuring the energy gained per unit mass of
fluid as it passes through the pump.
This energy gain is the sum of the increase in total pump head and the energy losses
inherent in the pump.
From the measurement of generated head and the increase in fluid temperature between
the measuring points, the true hydraulic efficiency between the measuring points may be
determined. The flow through the pump is determined by equating the efficiency of the
pump to its generated head and input power.

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Flowmeter Calibration Methodology

2 THEORY
A simplified form of the method is given as follows:

2.1 CALCULATION OF PUMP EFFICIENCY

Work input to a system is equal to the work gained from the system plus the losses
involved:
W in = W out + Losses , and
pump efficiency,

p =

W out
.
Win

Thus,

p =

Wout
=
W out + Losses

where,

& .c p .dT
Losses m
=
.
& .g.H
Wout
m

Therefore,

p =
1+

1
,
Losses
1+
Wout

1
.
c p .dT
g.H

2.2 CALCULATION OF VOLUME FLOW RATE

By measuring the electrical power input into the pumps drive, taking the drive efficiency
from the manufacturers data and the pump efficiency calculated as above the volume flow
rate can be derived:
Volume flow rate,

Q=

Or,

Q=

Notation:

p
m
W
Q
H
dT
cp
Pgr
g

Pgr .m . p
.g.H

Pgr . m
.(g.H + c p .dT)

= pump efficiency
= motor efficiency
= work done
= volume flow rate
= head
= change in temperature
= specific heat capacity of fluid
= motor input power
= gravitational acceleration
= density of fluid
= mass flow rate

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Flowmeter Calibration Methodology

3 TEST APPARATUS
3.1 STANDARD EQUIPMENT
Photograph of Yatesmeter Equipment

Yatesmeter (Data Acquisition Unit ).

Laptop and program disk.
Printer, cable and carrying case.
2 Temperature Sensors.
2 Pressure Transducers.
2 stainless steel tees and connectors.
Power Meter.
3 Current Transformers.
4 Voltage Transformers.
Serial data link from the Yatesmeter to the Laptop.
Carrying cases for the Yatesmeter, and Laptop
Motor Monitor Data Cable Extension.
Borehole Temperature Probes and Pressure Sensors.

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Flowmeter Calibration Methodology

4 TAPPING ARRANGEMENTS
All the tappings are fitted with gate valves, which will take BSP T-pieces. This is
illustrated in the Appendices, in section 7.1.
Tappings need to be positioned in different ways according to the pump arrangement.

4.1 CONVENTIONAL SURFACE MOUNTED PUMPS

The figure in section 7.2 of the appendices shows a drawing of a typical centrifugal pump
with delivery and suction pipework connected to it by two flanges.
Two BSP tappings are installed a minimum of two pipe diameters from the flanges. It
is important to install the delivery tapping upstream of the isolating valve so that the pump
can be throttled during testing.

4.2 SUBMERSIBLE PUMPS

The figure in section 7.3 of the appendices shows a drawing of a typical submersible
pump. In this case two tappings are (" BSP) are made in the delivery pipework. Both
probes are inserted into the pipework and the offset is calculated only using a single tenminute calibration period.

4.3 SUSPENDED BOWL PUMPS.

The figure in section 7.4 of the appendices shows a typical suspended bowl pump with its
suction inlet held well below the water level of the sump.
In this case only one tapping needs to be made in the delivery pipework, as shown. For a
pump test the suction pressure transducer and temperature probe are lowered into the
sump next to the pump inlet.

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Flowmeter Calibration Methodology

5 METHODOLOGY
5.1 CALIBRATION
The probes and transducers can be installed while the pump is running. Once in place, a
calibration of the temperature probes is performed. This requires a minimum of 20
minutes running the pump at a constant speed.
For the first 10 minutes the suction temperature probe is put in the delivery pipework, and
the delivery temperature probe is put in the suction pipework. For the second ten minutes
the probes are reversed, subsequently, an offset is calculated by the Yatesmeter.

5.2 TEST POINT

Values for the following parameters are measured at each test point:

suction pressure

delivery pressure

absolute water temperature

difference in water temperature across the pump

motor input power

From these, the Yatesmeter calculates the following parameters:

pump efficiency

flow rate

suction head

delivery head

velocity head

pump head

motor efficiency

5.2.1 Power Monitoring

Monitoring the input power to the pump motors in an integral part of the Yatesmeter testing
procedure.
High Voltage
AEMS High Voltage Power monitoring is done by one of two methods, by calculation
through the Yatesmeter or manually.
Method 1:
The power monitor is connected to a secondary circuit test block. The
power is then recorded via the Yatesmeter

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Flowmeter Calibration Methodology

Method 2:
In the HV switch-room, a single revolution of the Ferraris wheel is timed
using a stop-watch. This is done at each test point, and the power is calculated each time.
Medium Voltage
On medium voltage systems monitoring equipment is attached the starter panel and a
data lead run from the power monitor to the Yatesmeter.
The power equipment consists of:

power monitor

fused voltage connector 3

clip on current transformer 3

earth/neutral connector.

Once the monitor is connected and the panel door closed there is usually no need to
access the starter panel again until the end of the test.
5.2.2 Connection Arrangement for 3 Phase Power Measurement

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Flowmeter Calibration Methodology

6 GENERIC METHOD STATEMENT

6.1 INTRODUCTION
This section describes the methodology used for the flowmeter calibration work.
The work consist of two parts:
1. Measurement of flow rate using the Yatesmeter
2. Calibration of the 4-20 mA signal from the flowmeter.

6.2 SUMMARY OF TESTING PROGRAMME

The flow rate of water through a particular pump is measured using the Yatesmeter
equipment using the following test programme:
Procedure
Number

Operation

Time
(mins)

1
2
3
4
5
6
7
8
9
10
11
12
13
14

Set up Yatesmeter on Pump

Connect 3 phase power meter to starter panel
Install 4-20 mA logger on flowmeter output signal
Isolate pump for zero flow measurement
Run pump and calibrate Yatesmeter
Measure normal flow rate
Reduce flow rate
Record data
Reduce flow rate
Record data
Disconnect power meter
Disconnect 4-20 mA logger
Return plant to normal operation
Disconnect Yatesmeter

30
5
5
10
30
15
5
15
5
15
5
5
30
30
3 hrs

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Disruption
(mins)
0
5
5
10
0
15
5
15
5
15
5
5
30
0
2 hrs

Flowmeter Calibration Methodology

6.3 DESCRIPTION OF PROCEDURES

1. Set up Yatesmeter on Pump
As previously shown the Yatesmeter comprises of two sets of monitoring equipment.

Pump Efficiency Meter (Hydraulic monitor)

Power Meter (Electrical monitor)

The pump Efficiency monitor uses two temperature probes and two pressure
transducers to monitor and measure the pump efficiency in real time. The probes are
inserted into the pipework via the T-pieces, and the following information is recorded:

Station name

Flowmeter name

Height of suction pressure transducer above datum

Height of delivery pressure transducer above datum

Diameter of suction pipework at tapping location

Diameter of delivery pipework at tapping location

Motor power

Motor speed

Test equipment serial numbers

2. Connect 3 phase power meter to starter panel

This is the first disruption to the plant. To connect the power meter the pump must
be stopped and electrically isolated. Once isolated the panel can be accessed and
the power meter connected. The power meter is then connected, the panel closed
and the pump is ready to be returned to service.
3. Install 4-20 mA logger
A digital multimeter is connected to the 4-20 mA loop to record/measure the
generated 4-20 mA signal from the flowmeter.
4. Isolate pump for zero flow measurement
5. Run pump and calibrate Yatesmeter
The pump is started and allowed to stabilise. Once the pump has stabilised the
Yatesmeter is calibrated to correct for any variation between the home base
calibration and the site conditions.

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Flowmeter Calibration Methodology

6. Measure normal flow rate

With the Yatesmeter calibrated, the non-running pumps on the system are isolated
(to prevent any re-circulation through faulty NRVs), the 1st test point is obtained.
7. Reduce flow rate
8. Record data
Collect data for 2nd test point
9. Reduce flow rate
10. Record data
Collect data for 3rd test point
11. Disconnect power meter
The delivery valve is opened to return the pump back to its normal operating
position. Once the system has stabilised, the pump is stopped and the power
meter is disconnected.
12. Disconnect 4-20 mA logger
13. Return plant to normal operation
All valves that have been isolated for the duration of the test are returned to the
condition found.
14. Disconnect Yatesmeter

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Flowmeter Calibration Methodology

6.4 CALIBRATION OF 4-20 MA SIGNAL FROM FLOWMETER

Calibration Errors
The error values consist of:

Offset Error: the constant error throughout the range. It is expressed as a flow rate
(units MLD, m3/hr, l/s etc), and

Range Error: expressed as a percentage; calculated by subtracting the gradient of

the non-calibrated flow figures from the ideal (i.e. grad. = 1)

Station Flow

Reference line
(grad.= 1)

Line drawn from

test data.
(let grad.= 0.8)

Offset Error
Yatesflow
The diagram above shows a hypothetical flowmeter comparison. The red line represents
the reference line (i.e. Station Flow = Yatesflow) and the blue line shows the line drawn
through the test data. Therefore, using these results the range error may be calculated as
follows,
= (1 0.8)/1 100 %

range error
ER

= 20 %.

To calculate the actual flow through the flowmeter using the data collected, the following
method is used:
Using the form of a general linear equation, y = m x + c,
Let

m = (1 ER )
c = offset error (EO)
x = The actual flow rate (Q)

then

y = The flow rate that the meter is seeing (Ql)

therefore, the actual flow rate,

Q = (Ql E0)/(1 ER).

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Flowmeter Calibration Methodology

A comparison of meters will be made at zero flow. If the meter is not recording zero flow
when flow is stationary (i.e. The pump is off and isolated) then an adjustment is made.
This adjustment is made by making the signal from the flowmeters converter unit equal 4
mA which corresponds to zero flow. The magnitude of this adjustment represents the
offset error.
The station is returned to normal operating conditions, and as stated previously, three
further test points are taken. These points give a linear representation of how the stations
flow varies with the reference flow (i.e. flow calculated by the Yatesmeter). Any remaining
error will be removed by adjusting the velocity range setting on the meter. This error is the
range error.
Below is a worked example of the calculation involved in finding the actual flow rate, given
the flow rate seen by the station flow meter. Using data from a tested flowmeter, the
following values have been calculated,
Offset error, EO

= -4.58 m3/hr

Range error, ER

= -0.99%

At open valve, the stations flowmeter recorded a flow, Ql = 144.6 m3/hr. Therefore, the
actual flow,
Q

= (Ql EO)/(1 ER) m3/hr

= (144.6 + 4.58)/(1 0.0099) m3/hr
= 147.72 m3/hr.

This flow corresponds to the flow recorded by the Yatesmeter, at the same open valve
conditions.

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Flowmeter Calibration Methodology

7 APPENDICES
7.1 APPENDIX 1: TYPICAL TAPPING ARRANGEMENT

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Flowmeter Calibration Methodology

7.2 APPENDIX 2: CONVENTIONAL SPLIT-CASE PUMP

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7.3 APPENDIX 3: SUBMERSIBLE PUMP

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7.4 APPENDIX 4: SUSPENDED BOWL PUMP

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7.5 APPENDIX 5: RISK ASSESSMENT FORM FOR PIPE-WORK TAPPINGS

HAZARD

RISK

LEVEL

CONTROL
MEASURE

LEVEL

Working
Machinery

Entanglement
Crushing

Medium

Machinery Guards
Area Cordoned off

Low

Working below
1.2 metres

Flooded
chamber
Gas

High

Pump out chamber

Lower gas detector
Tripod/safety
harness

Low

Working above
2 metres

Falling

Medium

Fixed ladder
Tower
Safety line

Low

Portable Tools

Electrocution

Medium

Tested 110V
equipment

Low

Noise

Chronic hearing
damage

High

Ear defenders

Low

Manual handling

Sprains, strains,
fractures etc.

Low

Trained personnel
Lifting aids

Low

General Working

Trips; slips; falls;

cuts; bruises etc

Medium

Working practice
Personal safety
equipment

Low

Raw water;
sewage; oils;
greases;
additives

Ingestion
Internal damage
Illness

High

Protective clothing
Safe working
practice

Low

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7.6 APPENDIX 6: RISK ASSESSMENT FORM

TESTING AND FLOWMETER ASSESSMENT

FOR

HAZARD

RISK

LEVEL

CONTROL
MEASURE

LEVEL

Working
Machinery

Entanglement
Crushing

Medium

Machinery Guards
Area Cordoned off

Low

Working below
1.2 metres

Flooded
chamber
Gas

High

Pump out chamber

Lower gas detector
Tripod/safety
harness

Low

Working above
2 metres

Falling

Medium

Fixed ladder
Tower
Safety line

Low

Connecting
Power
monitoring equip

Electrocution

Medium

Safe working
practice; isolation;
insulated connectors

Low

Portable Tools

Electrocution

Medium

Tested 110V
equipment

Low

Noise

Chronic hearing
damage

High

Ear defenders

Low

Manual handling

Sprains, strains,
fractures etc.

Low

Trained personnel
Lifting aids

Low

General Working

Trips; slips; falls;

cuts; bruises etc

Medium

Working practice
Personal safety
equipment

Low

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PUMP PERFORMANCE

7.7 APPENDIX 7: EXAMPLE OF FLOWMETER CONFORMITY CERTIFICATE

ADVANCED ENERGY MONITORING SYSTEMS LTD.
THE ENERGY CENTRE, FINNIMORE INDUSTRIAL ESTATE,
OTTERY ST MARY, DEVON. EX11 1NR
TELEPHONE +44 (0) 1404 812294 & 815470
FAX +44 (0) 1404 812603
E-MAIL info@yatesmeter.co.uk
WEBSITE www.yatesmeter.co.uk

CERTIFICATE OF CONFORMITY
EXAMPLE
Client:

Flowmeter:

Southern Water Services Ltd.

Southern House
Lewes Rd.
Falmer
East Sussex
BN1 9PY

Flow From Borehole

KA0096
1075424
5467
25-Jan-2001
J Whittaker

Meter Asset#:
Certificate#:
Date Tested:
Tested By:

FLOWMETER DETAILS
Manufacturer:
Device:
Type:
Serial #:
Output Signal:
Transducer:

ABB Kent Taylor

Electromagnetic
Veriflux VKB
00035BHG
4-20 mA
Electromagnetic Converter

Display:
Range:
Normal Flow:
% Scale of Flow:
Flowmeter Bore:
Zero Flow:

LCD
7 MLD
2.8 MLD
40%
200 mm
4.000 mA

ACCREDITATION OF CALIBRATION DEVICES

Ammeter
Thurlby
F2365
2005688
20/09/2001

Manufacturer:
Serial #
Certificate #:
Calibration Expires:

Dead weights
Budenburg
3094
2015
12/02/2004

Pressure Tester
Budenburg
24093
2015
12/02/2004

FLOWMETER TEST RESULTS

Test Point

Yatesmeter
Flow Rate

Time
11:50 to 12:05
0:0 to 0:15
12:0 to 12:15

l/s
32.13
32.13
-0.60

12:05 to 12:20
12:22 to 12:37
12:45 to 13:00

32.25
26.89
21.13

COMMENTS:

Yatesmeter
Flow Rate
MLD
2.78
2.78
-0.05
Adjustment
2.79
2.32
1.83

Station
Signal

Calc'd
Offset Error
Station Flow

mA
9.01
9.01
4.00
Performed
10.35
9.34
8.19

MLD
2.19
2.19

2.78
2.34
1.83

Adjustment successfully performed. Flowmet er within tolerance.

Signed:
On Behalf of: Advanced Energy Monitoring Systems Ltd.
Issue #: 1
Registered in England Registration No. 1589111

Test Date: 25-Jan-2001

VAT Registration No. 365 7075 32

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Range Error

MLD

0.04

22.52

0.04

1.51

EXAMPLE - Flow From Borehole

FLOWMETER COMPARISON
Testers: J Whittaker Test Date: 25/1/2001

OFFSET ERROR: 0.04 MLD

RANGE ERROR: 1.51 %

15
Pre Calibration

Post Calibration

Reference

14

13

12
4:47:42 PM
4:47:42 PM

11

4:47:42 PM

10

Station Flow

1
T/N: 5467

0
0

5
6
Yatesmeter Flow

[ ALL UNITS IN MLD ]

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10