REPORT

ON

IN-PLANT TRAINING
AT

FLUID CONTROL RESEARCH

INSTITUTE (FCRI)
KANJIKODE WEST
PALAKKAD

SUBMITTED BY

SIBI-B.
ASTS TECHNICAL DIVISION
SOUTH KALAMASSERY
ERNAKULAM

ACKNOWLEDGEMENT
iam pleased to submit this in-plant training report at the esteemed organization
FLUID CONTROL RESEARCH INSTITUTE (FCRI). I deeply indebted to each and every
one who helped me to make my training a successful one.
At the very outset, I express my sincere thanks to our respected Director and Head of
Training G. Sundaravadivel for giving me an opportunity to attend the in-plant training.
I hereby express my sincere gratitude to Mr. Achuthanathan P. and Mr. Madhu V.
from the Department of Training for the arrangement and guidance provided throughout the
endeavor.
I also express my special thanks to all the lab experts for sharing the knowledge and
information about all the divisions of the prestigious institution FCRI.

CONTENTS
INTRODUCTION
FLOW CHART
PHYSICAL STANDARD LAB
WATER FLOW LAB
CWM (CENTER FOR WATER MANAGEMENT)
LWFL (LARGE WATER FLOW LAB)
OIL FLOW LAB
ENVIRONMENTAL QUALIFICATION & TESTING LAB

CLOSED LOOP AIR TEST FACILITY

AIR FLOW LAB
CNG (COMPRESSED NATURAL GAS)
CONCLUSION

INTRODUCTION
FLUID CONTROL RESEARCH INSTITUTE (FCRI), an esteemed organization
dedicated to design and development of flow products and its calibration techniques was
established in the year 1989. FCRI has been, established by Govt. of India with techno-economic
inputs from the UNITED NATIONS DEVELOPMENT PROGRAMME (UNDP). The institute
has grown into a fully fledged quality assurance centre for the core sector industry and is on par
with similar establishments in developed countries.
FCRI is authorized by Department of Weights & Measures to conduct model approval
tests on flow meters. FCRI is accomplished of NABL accredited laboratories for the calibration
of flow meters in water, oil, and air media. The accurate and highly reliable services of FCRI are
rendered to the major companies including GAIL, BPCL, BHEL, HPCL, ONGC, water supply
boards etc.
Besides the fluid laboratories, FCRI also has three supporting labs. The Physical Standard
Lab deals with the calibration of mass, volume, density, viscosity, material testing and pressure
metrology, Electronics and Instrumentation Lab is for the calibration of electrical parameters and
time and Noise & Vibration Lab undertakes noise evaluation of control valves, generator sets,
pumps etc.

FLOW CHART

PHYSICAL STANDARDS
LABORATORY (PSL)
The Physical Standard Laboratory maintains the primary standards of length, mass, time,
temperature, pressure/vacuum, volume, relative humidity and hardness. It also provides
calibration services in the field of dimensional metrology. The laboratory is equipped with the
most reliable and sophisticated reference instruments, operated under controlled environmental
conditions of 20 degree Celsius and 50 Rh. The master equipments are traceable to National
Physical Laboratory at New Delhi.
The laboratory is also equipped with reference instruments for force and torque.
Calibration activities are carried out with established procedures in conformance with standard
specifications.

MASTER INSTRUMENTS AVAILABLE FOR CALIBRATION:

Parameter Equipment
Range
Accuracy
slip gauges
0.5 - 100mm
00 grade
gauge blocks
125 - 500mm
0 grade
slip gauge calibrator
0 - 100mm
< 0.1 micron
universal length measuring machine
0 - 610mm
0.46 micrometer
Length
Surface Finish, Profile projector, Micro checker, Mu checker, Height master, Vernier Calipers

Mass

volume

pressure
Force
Density
Viscosity

Standard Weights
0.001g - 50kg
Micro Balance
0 - 50g
Micro Balance
0 - 210g
Mass comparator
0 - 5kg
Electronic Balance
64kg
Electronic Balance
600kg
Standard volume jar
5L/20L
Specific gravity bottle
50ml
Oil dead weight tester
1 - 1200 bar
Oil dead weight tester
1 - 600 bar
Air dead weight tester
-1000 to 1000mbar
Air dead weight tester
-1 to 7 bar
Absolute dead weight tester
30 mbar -20bar(abs)
Very low pressure pneumatic dead weight test
0.2mbar -160mbar
High pressure pneumatic dead weight tester
1bar - 160 bar
Multi function pressure indicator
0 - 20 bar(abs)
Liquid column manometer, Portable calibrator(400bar), precision pressure gauge

Class E1, E2, F1

1g
0.01mg
0.001g
0.001g
0.1g
0.02%
0.02%
0.025%
0.04%
0.02%
0.015%
0.025%
0.03%
0.03%
0.025%

Proving rings (tension & compression)

Hydrometer
Falling ball, capillary viscometer, std liquids etc

Class A
L 50
0.50%

1000kgf, 50000kgf
0.6 - 1.6g/ml
0.5 - 10^5mPas/cSt

WATER FLOW LABORATORY

(WFL)
The Water Flow Laboratory has specialized test rigs for the precise calibration of flow
meters, testing of valves, pipe fittings and other flow products. The whole laboratory system is
designed to handle a maximum flow rate of 5000m3/hr. and pipeline sizes are classified into two
categories namely 100 to 600mm and 15 to 100mm. The measurement of flow rate is done as per
the static ISO 4185 static gravimetric method. The two weighing tanks are of the capacities 2T
and 20T. The water is collected in the weighing tanks by diverter system for an accurately
measured period of time. Electromagnetic flow meters are
Connected to the end of the pipe lines. The mass measurement is by load cells. The online
density acquired by a precision online densitometer and mass readings after correction for air
buoyancy enables the mass to be converted into volume.
These volumes and respective diversion time can provide an accurate measurement of flow rate.

FCRI is actively involved in testing of water meter of various water board authorities,
local municipalities, corporation office for bulk purchase of water meters. It is involved from the
stage of preparation of tendering specifications to evaluation of competent suppliers of large
flow measurements needs. FCRI is identified as testing agency for performance evaluation of
water meters. An advanced, highly sophisticated and accurate water flow laboratory
accommodating meter sizes up to 100mm and flow rate of 300m3/hr has been set up and was
commissioned on October 2005.
Both laboratories are accredited by NABL for testing & calibration and also by W&M
for the model approval of flow meters.

CENTRE FOR WATER

MANAGEMENT (CWM)
Centre for water management offers services like in-house flow product assessment, on site
measurement/calibrations, analysis/design and consultancy service related to flow problems
especially in water distribution networks, surge etc, A brief description of the activities are given
below.
A laboratory equipped with state of the art equipments facilitates in-house evaluation of flow
product. In this facility, accurate measurement of flow in terms of volume is determined by
gravimetric system. A flow rate up to 300 cu.m/hr through 150mm pipeline can be achieved in
the laboratory with overall uncertainty in volume better than 0.04%.
The flow sources are a constant head tank located at a height of 15m and at set centrifugal pumps
of different capacity. Water passing through the test line is collected in a tank kept on a weighing
scale, 300kg and 3000kg weighing systems serves this purpose. In order to maintain the water
quality, stainless steel pipes and fixtures are used. A bank of reference magnetic flow meters is
used to set the derived focus through the test line.

Testing of water meters

FCRI is involved in testing of different types and sizes of water meters for the last two decades.
Around 3000 water meters of various sizes are tested every year. The test facility is accredited by
NABL and recognized by Bureau of Indian Standards. Routine tests (initial verification tests)
and Pattern approval tests are normally conducted on meters. Routine test of water meters
include hydrostatic pressure test, accuracy tests at different flow rates and pressure loss tests.
Adequate facilities are available for carrying out various tests specified in different water meter
standards like IS, ISO, EEC, and OIML etc. Endurance testing of water meters as per IS/ISO are
conducted for different water boards in India during their bulk purchase.

This has ensured reasonable life for meters in the field and has yielded substantial increase in
revenue for water boards.
A model approval program (MAP) is launched by FCRI, based on suggestion from several major
water boards. This is intended mainly to help the consumers and Water boards for quick
purchase of meters, while ensuring the quality of meters.
Details of models passed the endurance test will be made available in FCRI website. This is
expected to help water boards to verify the models submitted by suppliers and proceed with
quick purchase with acceptance tests on randomly sampled meters and applying the prescribed
acceptance criteria. Special concessions on testing charges are applicable for water boards
carrying out acceptance tests as per national/international norms during their bulk purchase. This
quality assurance practice followed by various water boards in India has yielded substantial
improvement in their revenue and reduction in UFW.
Most of the water boards in India and manufacturers in India and abroad are availing various
services offered by FCRI. FCRI encourage the customers to witness the tests along with any
person they permit, which makes the testing completely transparent.

LARGE WATER FLOW LAB

(LWFL)
One of the Largest & Unique Calibration/ Testing facilities of the Country is commissioned at
FCRI. The facility is a Large Water Flow Laboratory which is designed for a pipe diameter of
2000mm with a max flow rate of 15000m3/ hr.

The facility consists of an underground water sump of capacity 3000 m3 on which five Vertical
Turbine pumps are erected.
The major specifications of this facility are as under:
1. Flow Medium: Water
2. Maximum discharge: 15000 m3/hr
3. Pipe Line Size: 2000mm (Design) & Ready to Use 1200mm
4. Maximum velocity : 1.4m/sin 2000mm dia. & 3.4 m/sin 1200mm dia.
5. Max Line Size Possible: 3000mm
6. Sump Dimensions: 50m long x 8 m wide x 7.5 m deep
7. Type of Flow: Direct Pumping
8. Pump Type: Vertical turbine
9. Discharge: 5000 m3/hr, 4000 m^3/hr.,3000m^3/hr, 2000 m^3/hr., 1000 m^3/hr.
10. Head: 20m of Water Column
11. Type of Drive: Electrical Motor
12. Power: DG Sets, 1250 KVA 2 Nos
13. Uncertainty: +/- 0.5%
Important Flow Products which can be Calibrated / Tested in this facility include Large Size (
600mm 2000mm ) EMF , Ultrasonic Flow Meters , all types of Insertion flow meters , Orifice
Plates , Mass flow Meters and all types of Valves. The added advantage of this facility is Pump
Testing also can be performed here within a flow range of 2500m^3/HR.

OIL FLOW LABORATORY (OFL)

The Oil Flow Laboratory has the ability to calibrate any type of flow meter and is used
for the bulk flow measurements viz positive displacement flow meters, turbine flow meters, and
mass flow meters etc. which are used to determine the total quantity of fluid. The Oil Flow
Laboratory was commissioned in 1995. The calibration of OFL has been accredited by NABL.
Legal Metrology, Weights & Measures unit, Department of Consumer Affairs has recognized
FCRI for conducting Model Approval Test on flow measuring instruments and volume
measuring instruments.
The Oil Flow Laboratory makes use of static gravimetric calibration system for
measurement and calibration is done by Standing start and stop method.
Turbine flow meters are connected at the end to get the pulse output. The diversion method used
in WFL is not used here as it might cause back pressure problems in the pipeline. A maximum
line size of 200mm and of maximum flow rate of 650m3/h is also maintained in the lab. The
medium of flow is EXXSOL D80 with kinematic viscosity of 2.06 Centistokes at 250C and a
specific gravity of 0.78. For a flow rate up to 100m3/h (450GPM) it is possible to change the
medium of calibration to Hydrol 100 or Hydrol 220.
Calibration of composite probes used in petroleum retail outlets for level, density and
temperature measurement is carried out at this Oil Flow Laboratory. The performance evaluation
of fuel pumps used in automobile sector, industrial applications, and P.D pumps is conducted as
per relevant standards.
The calibration of flow products at the Oil Flow Laboratory are carried out with
reference to API, ISO, ASTM and OIML standards.

ENVIRONMENTAL
QUALIFICATION & TESTING
LABORATORY (EQL & ETL)
Environmental Qualification Laboratory of FCRI is well equipped for in-plant/site studies
with the state of the art equipments/instruments. The following capabilities and services are
offered by the Environmental Qualification Laboratory.
Industrial / Environmental / Traffic Noise surveys
Valve noise measurement and its abatement
Determination of noise emission values of
various equipment
Machine vibration monitoring
Strain Measurements
Dynamic response of structures

Measured Parameter

Acoustic Pressure

Vibration - Acceleration
Vibration - Velocity
Vibration - Displacement
Accelerometer
Sound Power
Speed

Range
94 dB @ 1 KHz
114dB @1 KHz
124dB @ 250 KHz
94, 104 & 114dB @ 31.5Hz
to 8 KHz Octave
1 to 100 m/s2 (0.1 to 10 g)
5 Hz to 5 KHz
10 to 1000 mm/s
5 Hz to 5 KHz
0.01 to 10 mm
5 Hz to 1 KHz
10g @ 160 Hz
25 to 140dB@125Hz to 16 KHz
Source volume 0.7 m3
100 rpm to 10,000 rpm
10000 rpm to 25000 rpm

Best Measurement Capability

(+/-)
0.3 dB
0.3 dB
0.3 dB
0.3 dB
4%
4%
4%
4%
2 dB
2.0 rpm
4.0 rpm

The Environmental Test Facility (ETF) at FCRI caters to environmental testing needs for
almost all types of manufacturing and R&D industry. ETF facilitates a wide range of products
including temperature/humidity and HVAC equipment, electrical/electronic measuring &
indicating instruments, electrical switch-gear/control gear enclosures, telemetry/wireless
communication equipment, audio visual equipment, products for space/aerospace, military and
outdoor applications. It also includes water spray, water jet test, dust spray test, etc.
The environmental chamber, spray water chamber, dust test unit are provided in this lab
to check the ability of customer product to withstand corresponding parameters. The
environmental chamber tests the humidity and temperature withstanding capability of the
products like control panel, switch board, gas regulators etc. The spray water chamber detects the
water proof ability of the products. The example includes water proof watches. The dust test unit
checks the dust withstand capability of products like water meters. The talcum powder is used as
dust. The two modes of operation include vacuum mode and non-vacuum mode. 80% of material
volume dust is blown to the product to check the dust withstand ability at blow pressure 20mbar.

NOISE AND VIBRATION LAB

Noise and vibration laboratory of FCRI is well equipped for in-plant/site studies with the
state

of

art

equipment/instruments.

It

is

used

to

conduct

noise

and

vibration

measurement/calibration. The laboratory caters to calibration of rpm indicators, tachometers,

vibration pick-ups, sound level meters, accelerometers, measurement of valve noise, torque
machine vibration monitoring, impact testing of specimens as per ASTM E 23, stress analysis of
valve body, fatigue testing of engine valves and seismic testing.
The products calibrated at this lab include rotors, radial fans, wiper motor, compressors,
automobiles, valves, engines, medical equipment, crackers, for shipping purposes, etc.
The

services

offered

by

noise

and

vibration

laboratory

include

industrial/environmental/traffic noise surveys, valve noise measurements, machine vibration

monitoring, strain measurements and dynamic response of structures.

FCRI has a Hemi Anechoic Chamber in accordance with ISO standards to cater the needs
like determination of sound power level of noise sources, noise emission values and
measurement of aerodynamic noise generated by control valves. Hemi Anechoic Chamber is a
cubic room consisting of glass wools arranged in sacs to absorb the sound. This acoustic
environment can be used for determination of sound power levels of noise sources by precision
method as per the standard ISO 3745 or by engineering method as per the Standard ISO 3744.
Test objects of maximum dimension of 1 m x 1 m x 1 m can be tested inside the Hemi Anechoic
Chamber by precision method. The air from the Closed Loop Air Testing Facility (CLATF) is
given through a pressure transducer according to the consumer product requirements to detect
the sound range. The sound is detected in decibels using a microphone and sound level meter.
The vibration testing facility has found its applications in the areas including
environmental testing of objects and structures, fatigue testing of specimens, resonance
searching, calibration of accelerometers etc. Tachometers are used for rpm measurements and
calibration of customer products. Calibration of contact and non-contact (blinking led) type
tachometers are available here. The shaker system available is of the frequency range 5Hz to 2.5
kHz.

CLOSED LOOP AIR TEST

FACILITY (CLATF)
It is the type of flow test meters for high pressure calibration of industrial flow meters. It
can with stand an air pressure of 2-20bar that is stored in different vessels. These vessels consist
of safety valves. If the pressure exceed 20bar then the safety valves opens and eject the excess
pressure outside and maintain required pressure level. A temporary vessel with low pressure is
used to achieve air flow from high pressure area to low pressure area. As all other calibration,
pressure calibration can also be done by two methods, primary and secondary.

PRIMARY STANDARD GALVIMETRIC SYSTEM (PSGS)

This type of calibration is performed by using the primary standard as the reference. It is
an open loop system consisting of a huge spherical weighing vessel into which the compressed
air is passed. Time rate of mass of air collecting in that vessel calculated which gives the mass
flow rate. Finally air is emptied from the spherical weighing vessel to atmosphere. Maximum
measurable unit of PSGS is 1000m3/h.
APPLICATION OF PSGS
1. Primary calibration by mass and time measurement using air under following conditions

Pressure : 20 bar
Temperature : Ambient
Flow rate : 4-1000kg/h
Expanded uncertainty : 0.1%

2. Primary calibration of turbine meters, positive displacement meters, coriolis mass flow
meters, critical flow venturi nozzle etc.
3. Evaluation of flow meters for custody transfer application of natural gas, Hydrogen etc.
4. Round robin test program to establish the dynamic traceability of PSGS.
5. Establishment of traceability of high pressure flow measurements carried out at CLATF to
National/International standards.
6. Training of personnel in calibration of flow meters using primary standard techniques.

CLOSED LOOP AIR TEST FACILITY (CLATF)

It is the secondary type of pressure calibration method. As the name indicates it is the
closed loop method. Initially the compressed air is passed through the blower to adjust the speed
of flow and in turn to the heat exchanger. The heat exchanger is provided with a chiller plant
parallel to maintain the temperature of 25 degree Celsius. A filter is also provided for filtering
purpose. Unlike the primary or open loop method, it has three reference line with turbine meters
and two test line
where the test meters are connected. The air is then passed through the pre-filters and it is again
channeled to the blowers. Hence maintain the closed loop.
APPLICATION OF CLATF
v Secondary calibration technique using master turbine meter as per AGA7/ISO 9951 under
following conditions.

Pressure : 20 bar
Temperature : 25+/-1 degree Celsius
Flow rate : 10-4000m3/h
Expanded uncertainty : 0.3%

2. High pressure calibration of industrial flow meters such as turbine, ultrasonic, Positive

Displacement, vortex, orifice, coriolis, thermal, averaging pitut static tubes etc.
3. Evaluation of custody transfer flow meters for naturals gases etc.
4. Model approval of custody transfers flow meters as per OIML/BE EN/ANSI/IS standards.
5. Testing of products such as butterfly and ball valves, flow straightness, filters etc.
6. Training of personnel in calibration /testing of flow products.
7. Design/Development of flow control/measuring elements and reliability studies.

AIR FLOW LABORATORY (AFL)

FCRI has established Air Flow facilities covering areas related to industrial gases. This
lab has the low pressure calibration facility operating at near atmospheric pressure with flow rate
up to 10000m3/hr . According to the calibration methods there are again Primary Air Flow
Laboratory (PAFL) and Secondary Air Flow Laboratory (SAFL).

PRIMARY AIR FLOW LABORATORY

Primary Air Flow Laboratory is called so because here we are taking the primary
reference standard volume for calibration. The flow rate calibration in PAFL ranges up to
40m3/hr. This section is maintained at an ambient temperature range of 20+/-1 degree Celsius,
humidity 55+/-5. The conditioned atmosphere of PAFL maintains the metrological qualities of
the master flow meters and there by provides high reliability of calibration and operating
performance. Calibration is performed under Compression mode operation. This instrument has
a 3point reproducibility and 5point repeatability.
PAFL consist of three major low pressure measurement instruments.
1. BELL PROVER

Here the air flow is measured with displacement of bell and the volume is calculated by
the equation
Area * length = volume

; where the bell area remains constant.

Hence volume flow rate can be determined in the unit of litter/minute, and then
converted to m3/hr.

2. PISTON PROVER
This is mainly used to calibrate the instruments where the flow rate is low about
3m3/hr. By using this instrument pulse rate can also be counted, hence k factor is calculated.
The equation to determine the volume rate is
Volume rate = [(pulses / time) / k factor] * 3600
There is a higher piston and lower piston that are automatically selected by the
instrument itself according to the flow rate.
3. VOLUME METER
This is very rarely used equipment where the flow rate is very low about 250ml/min.
the measurement is taken out according to the level beams provided by the LEDs are cut.
There is another portable air flow measuring device. It consists of four channels of
thermal mass flow meter for different temperature level. The temperature difference of air input
and output of the thermal mass flow meter is calculated which gives the flow rate up to 400L/hr
is converted into m3/hr.

SECONDARY AIR FLOW LABORATORY

Secondary air flow lab is called so because here we take secondary reference output from
the lab. Here sonic nozzles are used as reference standard for calibration purpose where the
velocity of flow becomes equal to velocity of sound that is known as sonic level. It is designed as
per ISO 9300 reference standard. There are three different sonic levels with specific mach
numbers. They are:
Subsonic <1
Sonic =1
Supersonic >1
12 sonic nozzles arranged in parallel having different flow rate can be calibrated, the
combination of these values can also be calibrated according to the test meter specification. This
lab maintained at temperature 25 +/- 1 degree, and humidity about 55+/-5 degree. Here the

Calibration is performed under suction mode operation. Three blowers are provided for sucking
air. The range of flow rate calibration is 22.50 to 10000m3/hr. The standard flow rates calibrated
by using sonic nozzles are given below.

SONIC NOZZLES

FLOW RATE(m3/hr)

SN 1

22.50

SN 2

45

SN 3

90

SN 4

180

SN 5

180

SN 6

720

SN 7

1440

SN 8

2880

SN 9

2880

SN 10

360

SN 11

1440

COMPRESSED NATURAL
GAS(CNG)
Increased concern on the environmental pollution caused by conventional auto fuels such as
diesel/petrol, Compressed Natural Gas (CNG), an environmental friendly and clean fuel is opted
as an alternate fuel. Auto fuel Policy introduced during 2003 by MOPNG aims at to address the
issues of vehicle emission, vehicle technology and auto fuel quality. And also it aims at optimal
utilization of oil & gas infrastructure. The use of CNG and LPG would be increased in pollution
effected cities.
CNG Vehicles are in use in major states in Maharashtra, Gujarat, Delhi, Andhrapradesh, Bengal,
UP, MP etc. In recent future, it is likely that most Southern cities will also go on CNG. GAIL
(India) Ltd is planning to expand its CNG distribution network to 46 cities in the country to meet
the automobile industry demand. CNG is dispensed using specialized dispensing equipment to
the vehicle. Domestic Natural Gas consumption is about 100 mmscmd of which Auto and
Industrial consumption stands at about 20%. To augment the gas supply position, LNG regasification capacity is to be enhancing to 25mtpa by 2010. Deposits of Coal Bed Methane
(CBM) that could yield 1.2 trillion m3 of gas and Methane Gas Hydrates that can produce 7.5
trillion m3 of gas in about 80000 km2 areas have been found in India. In the Automobile sector,
there is a continuous growth of CNG stations totaling more than 600 catering to about 700000
vehicles.
Indian automotive sector contributes about 4% to GDP. Automotive Mission Plan (AMP) 200616 envisages an investment of $40 billion to help transform India into a global automobile player
accounting for 10 per cent of the GDP.

Cost of Metering Errors

The cost of the fuel is charged based on mass measurements made by Coriolis mass flow meters
installed in each dispenser. OIML recommendations stipulate an error of 1.5% on the dispensed

quantity, which is in the range 10 100 kg. Small errors in CNG measurement will result in
large revenue losses. For example, consider a typical fleet consisting of 30 vehicles in which
individual vehicles travel 80 km per day. At an average fuel efficiency of 20 km per kg, the fleet
will consume a total of 43800 kg per year. At an average price of Rs.20 per kg, the fuel cost for
one year is Rs.8,76,000. An error of about 1.5% could produce a revenue loss or gain of Rs.
13140 per year for the fleet. 5% could result in an annual loss in revenue of Rs.43800. 15%
could provide a revenue loss of Rs.131400.

250 bar Natural Gas Calibration and Test Laboratory

The new 250 bar facility is capable of evaluating high-pressure storage cylinder, natural gas
storage tanks and testing metering technologies for high pressure compressed natural gas
applications and type test dispensers. The facility consists off major components such as booster
compressor, piping components, control components, storage cascades, weigh and buffer tanks
and precision electronic mass comparator.

Features of the facility

Test Line size : Up to 1.5
Medium : Compressed Natural Gas
Storage volume : 18 m3
Reference :Gravimetric method
Pressure : Up to 200 bar
Weight Flow rate : 4500 kg/h
Vessel : 985l
Buffer Tank: 900
Flow Rate Uncertainty : 0.1 %
Clean dry gas filled in cascades is used as test media. Gas drawn from Weigh/buffer tanks
(pressure variation 180-25 bar) by booster type reciprocating compressor is compressed to the
operating pressure of 250 bar and stored in cascades. The high-pressure storage system has
sufficient internal volume to cater to a maximum flow rate of 4500 kg/h at 200 bar. The system
will ensure flexibility in discharge and adequate supply of gas to the set up. The pressure to the

test loop can be regulated to the required levels. Multiple sets of pressure regulators are
incorporated for maximum flexibility while testing 2-3 bank dispensers. Mass flow rates are
monitored using coriolis meters connected ahead of test line. A set of 7 critical flow venturi
nozzles of different capacities controls the mass flow rates. Actual mass flow rates are
determined using electronic balance. Pressures are measured at upstream/downstream of nozzles
and also at the inlet of the compressor.
Meters up to 1 1/2 shall be accommodated in the loop. The facility is extensively instrumented
and remotely operated valves will be controlled by an online real time PC based GE Fanuc
SCADA System.
The facility is designed as per relevant ASME/NGV/CCOE Pressure Vessel Codes. Complete
test loop is constructed using stainless steel considering the safety and extended life of the loop
components eliminating the problem associated with rust and ageing effects.

Calibration Process in the laboratory

Before the test begins, the gas flow through the system is bypassed into buffer tank and the
weighing balance along with weigh tank above is tarred. This minimizes error in final mass
totals due to gas in the piping upstream from the meter. During the test, the data acquisition
system records the time-based variations of the gas pressure, the mass of the gas
delivered/stored. Gas flow rates can be automatically controlled to simulate vehicle-fueling
scenarios as in 2/3 bank filling system. The flow is directed through the meter and into highpressure weigh cylinders mounted on the precision balance. At the end of the test, the gas
collected at weigh tank is pumped back into the storage cascades.

Applications
This facility will facilitate dynamic testing capable of testing CNG systems at large scale in
realistic gas dispensing conditions and consequently. This facility will extend services in the area
of Testing and evaluation
Flow capacity evaluation of fills systems as per AGA/CGA NGV1 CNG norms.

 Characteristics of temperature variation at inlet of receiving tank.

Characteristics of temperature variation at the downstream of fill system.
Pressure rise characteristics of receiver tank.
Fill time characteristics.
Performance testing of components such as check valves, relief valves, filters, fittings, fuel
pipelines
To undertake the calibration of mass flow meters used in the CNG dispensers.
To carry out high Pressure calibration of Industrial Custody Transfer Gas Flow Meters such as
hydrogen, Oxygen etc.
To conduct the model approval tests on CNG dispensers as per OIML recommendations.

CONCLUSION
Fluid Control Research Institute is the leading fluid research institute in South East Asia.
It is a pride to our country and works for the development of the industries. The Test, Research
and Calibration facilities are continually upgraded, updated and expanded to ensure they are
among the best in the World. Regular Inter-comparison exercises, International Certifications
and validations, stringent Quality Audits, skilled and trained manpower and overall
professionalism have contributed to our high levels of reputation and credibility.
FCRI has also undertaken projects in the area of software development related to
analytical techniques, selection, estimation of requirement of flow meters etc. These softwares
are also used by valve manufacturers, fertilizer industries and petrochemical plants. NEWTON,
VAP 1.0, AUTOVALV, SAFEVALV etc are the software developed by FCRI.
The in-plant training at FCRI has given us ideas about the calibration and testing of flow
products. We were introduced to the following labs:

Physical Standards Lab

Water Flow Lab & Oil Flow Lab
Environmental Qualification & testing Lab
Closed Loop Air Test Facility & Primary Standard Gravimetric System
Air Flow Laboratory

The major facilities at FCRI to undertake testing and calibration are air flow, water flow,
oil flow, noise and vibration etc.
This in-plant training helped us to perceive knowledge about the calibration techniques
and we were able to observe the practical applications of theoretical classes we have undergone.

APPENDIX
Specifications of the Water Flow Laboratory

Max. Flow

Max. Size

Measurement Uncertainty

Rate (m3/h)

4500

900mm

15000

2000mm

In Mass
Flow rate

In Volume
Flow rate

In Total
Volume

0.04%(Upto 250 T/h)

0.10%(300 to 1800 T/h)

0.05% (Upto 250 m3/h)

0.10% (300 to 1800 m3/h)
0.25% (1800 to 4500 m3/h)

0.04%
(Upto 20 m3)

In Total mass
0.01% (0 to
2000 kg)
0.025% (2000 to
20000 kg)

0.5% (4500- 15000 m3/hr)

Specifications of the Air Flow Laboratory

Laboratory

Max. Flow
Rate(m3/h)

Air Flow (1bar abs)

10000

Closed Loop Air Test

Facility (20 bar)

400
50

Uncertainty in Flow Rate

(% reading)

Uncertainty volume
(% reading)

400mm

0-40 m3/hr : +/- 0.2% > 40

m3/hr : +/- 0.25%

0 - 0.5 m3 : +/- 0.1%

100mm
50mm

+/-0.27%
+/-0.12%

Max. Line Size

Specifications of the Oil Flow Laboratory

Max. Flow
Rate(m3/h)
650

Max. Line Size

200mm

Uncertainty in Flow Rate (% reading)

0 - 100 m3/hr : +/-0.075%100 650m3/hr : +/- 0.1%

Uncertainty volume(% reading)

0 - 9 m3 : +/- 0.05%

Specifications of the vibration shaker

M/s Unholtz
Dickie
Corporation
USA

: Sine 2040 kgf a) Seismic qualification tests as per

(PK)
the standard IEEE-244
: Random 2040 kgf b) Vibration tests as per OIML R
Force rating
(RMS)
185/1993
: Shock 4080 kgf c) Exploratory vibration test as per
(PK)
ANSI B 16.41/ ASME QME 1
Frequency range
5 Hz to 5 kHz
d) Shock testing as per IS 9001 Part
17
Max. Bare table
95 g Peak
sec 1/1985
acceleration
e) Vibration testing as per QM 333
: 1.8 m/s (sine)
and QM-351
Max. velocity
Peak
f)Vibration testing as per JSS 55555
: 2.4 m/s (shock)
g) Vibration tests for automobile
Max. displacement : 51 mm Peak to
parts as per JIS D1601/1995
Peak
h) Vibration testing as per various
Max. static pay
454 kg
MIL/IEC and other
load (Vertical
National/International standards
Axis)
Table diameter
335 mm
Horizontal Slip
Table size
Vertical Head
expander size

915 x 915 mm
610 x 610 mm

Electronic & Instrumentation Laboratory testing facilities

Parameter

Instrument used
for testing

Range

% Uncertainty

Voltage

Multifunction calibrator

1 V to 1000V AC &
DC

+/- 0.0002 to +/- 0.4

Multifunction calibrator 1 A to 11A AC & DC

Current

Transconductance

0.2mA to 100A

+/-0.02 % O/P to

Amplifier

AC & DC

+/- 0.02% of range

1 Ohm to 100M Ohm

1 Pf to 100 m F
100 m H to 10H
1MHz to 20 MHz

+/- 0.007 to 0.0109

0.1
0.1

Resistance Multifunction calibrator

Capacitance
LCR Meter
Inductance
LCR Meter
Frequency
Function generator
Water Bath
Oil Bath

Temperature

Time

+/-0.0042 to +/-0.9

Fluid Bath

Stability +/-0.1 deg.C

+10 to +100 deg.C

Stability +/-0.01 deg.C

-30 to +150 deg.C
Stability +/- 0.2 deg.C

+30 to +700 deg.C

+/- 0.01 deg.C(Dead bed)

High temperature
calibration system

+5 to +1100 deg.C

Universal Counter

1 nS to 105 S

Stability +/-0.25 deg.c

0.00001% to 0.007%

Technologies developed by FCRI are :

1. Automatic level controller- An Automatic level controller to maintain fluid levels
in reservoirs has been developed.
2. Averaging Pitut Probe- Design, development, testing and supply of Averaging
pitut tubes used for flow measurement in Large pipelines have been completed.
3. Cone Flow meter- This flow meter was indigenously developed at FCRI. It is a
differential pressure type flow meter operating on the same principle as
conventional orifice meter, venture meter, nozzle etc.

4. Development of Non Intrusive diagnostic techniques for check valves- A non

Intrusive technique for Check valve diagnostics has been developed.
5. Five hole Probe- Special purpose probes called Five hole probes used for
boundary layer flow measurement has been designed, developed tested and
supplied by the Institute.
6. Frequency to Current Converter- A unique Frequency to Current Converter
finding a wide variety of applications was developed in-house.
7. Multiphase Flow meter (Transient) - A flow meter to measure transient steam water flow mixtures with good accuracy levels is being attempted in the Institute.
8. Nozzles for steam flow measurement- Special purpose Nozzles for Steam flow
measurement have been designed, fabricated, tested and supplied by the Institute.
9. Special Probes for oscillating flow measurement- Design, development, testing
and supply of a probe for measurement of time variant flow (oscillating flow) was
completed at the Institute.
10. Thermal Mass flow meter- Design, development, testing and supply of Thermal
mass flow meters have been completed.