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FLOW INSTRUMENTATION DESIGN GUIDE

SR.NOPROPERTIES ORIFICE PLATE VENTURI ROTAMETER PITOT TUBE MAG. FLOWMETER VORTEX MASS FLOWMETER ULTRASONIC
Doppler Type : 1. Under no flow condition, the frenquencies of the ultrasonic beams and its reflrction Coriolis mass flowmeters measure are the same. the force resulting from the 2.With the flow in the pipe acceleration caused by mass moving difference between the frequencies towards ( oe away from) a center of the Ultrasonic beam and its rotation..This effect can be reflection increses propotional to experienced when ridinga merry-go- flow velocity. round,where moving toward the Transit Time : 1.Transit time center will cause aperson to have to " ultrasonic flowmeter alternately lean into" the rotation so as to transmit ultrasonic energy into the fluid in the direction and against the maintain balance. As related to flowmeters, the effect can be direction of flow. demonstrated by flowing water in 2.The time difference between aloop of flexible hose that is "swung" ultrasonic energy moving upstream back & forth in front of the body with to downstream in the fluid is used both hands.Becasue the water is to determine the fluid velocity. flowing toward & away from the 3.Undergo flow condition time for hands oppsite forces are generated ultrasonic energy to travel upstream and cause the hose to twist. & downstream are same. 4.With flow in pipe time for ultrasonic energy to travel upstream will be greater than the downstream time. 1.Measures the acceleration caused by vibration by moving fluids towards centers. 2.Amount of twist is proportional to the massflowrate of fluid passing through tubes.

1 Working

As the flowing fluid passes through the orifice plate, the restricted cross section are causes an increase in velocity & decrease in pressure. The pressure difference before & after the orifice plate is used to calculte the f,ow velocity.

Similar to pitot tubes but with multiple openings, averaging Pitot tubes take flow profile into consideration to provide better overall accuracy in pipe flows.

1.An obstruction (Bluff body or strut) located in the flow stream. Operates on Faraday's low of Low-low : Fluid flow around Electromagnetic obstruction. Induction.Conducting material High-Flow: Alternating vortices are passes through the magnetic field formed.(No. of vortices formed are produces avolatge perpendicular to proportional to fluid velocity. magnetic field & velocity of fluids. 2.These vibrations senses by E=BLV where E = EMF, B= piezoelectric crystals which convert Magnetic Field, L = Length of it into elctric pulses. Conductor, V= Velocity of 3.Vortex meter can not measure Conductor . Therefore zero since it works on fluid velocity E=4.B.L.Q/Pie d principle.It required some flow to work.

2 Flowrate

Medium

High Flow

Low Flow rate

Wide range of flows

Electric conductivity greater than 5 Measurement with flow velocities mS/cm. ( Re < 4000) not possible.

3 Pressure Drop 4 Application

Changes

Permanent Pressure drop & good recovery. Not handles viscous slurries only Suitable for most of gases & liquids solids fluids. Predictable Accurate over long range. 3.5 : 1 1% of Full scale 1.Low differential press.compensation.

Constant Pressure drop Handle almost corrosive services

Negligible pressure drop Utility services where accuracy is not necessary. 1.Conductive liquids such as water,acids, caustic and slurries 2.Custody transfer application. Bi-directional flow and large size available. 10:1, 30:1 0.5% typically

Confirm allowable pressure drop loss while selecting meter size. Much higher for gases/vapors. Accuracy degraded during low range flow application. 20:01 0.2 typically 2% typically 1.Direct mass flow measurement of any liquid flow. 1.Wide flow range.

5 Characteristics 6 Rangeability 7 Accuracy

Accurate over small or short range Wide range flows & pipe sizes. 10:01 2% 3:01 0.5 % to 1.5 %

3.5:1 2% ~ 4% of full scale 1.Low Cost

10:01 1% of measurement 1.Low installtion cost & calibration not required.

1.Relatively low in cost. 2.Can 1.Available from 1/2 to 150 inches 1.Large pipe sizes & capacities. handles wide variety of corrosives. of pipe size.

2.Available in wide range of sizes & 2. Can be used for slurries & dirty construction. fluids. 8 Advantages 3.No moving parts 3.Can be welded into pipe lines.

3.Especially suited for low flow metereing. 4.Linear output

2.Long term measurement stability.

2.Can handles slurries & greasy materials 3.Very small erros in flow measurement.Measurement in both directions. 4.No pressure drop. 5.No obstruction in pipe. 6.Good Linearity over widerange. 7.Unaffeceted by fluid properties such as density,viscosity & temperature.

2.Good accuracy of fluids can be as good as 0.75% of rate for gases & 1% of rate for liquids. 3.Wide 2.Wide rangeability. range ( 1/2 " to 12" : 18" on request. 4.Wide temp. range (-200 to 400C). 5.Can be used for steam, gases or liquids. 6.Linearity is independent of density, viscosity & pressure.

3.Can be used for highly corrosive fluids.

5.Can be easily equipped with 3. Can be placed in service under magnetic,electronic,induction or pressure. mercury switch alarms, or transmitting devices. 6.Glass tube version capable of 4.Negligible permanent pressure measuring low flow rates. 7. drop. Can be installed immediately 5.Minimum lengths of straight downstream of control valve. piping runs.

3.Because of the mass flow is measured,hence the measurement is 4.Immune to liquid chemistry and not affected by fluid-density , physics property. viscosity, pressurechanges.

FLOW INSTRUMENTATION DESIGN GUIDE

SR.NOPROPERTIES ORIFICE PLATE
1.Square root relationship.

VENTURI
1.high Cost.

ROTAMETER
1.must be mounted vertically.

PITOT TUBE
1.Not applicable for dirty & sticky services.

MAG. FLOWMETER
1.Relatively high cost.

VORTEX
1.Not suitable for dirty arabrasice fluid as well as for high viscous liquids.

MASS FLOWMETER
1.Pressure drop may be high.

ULTRASONIC
1. Susceptible to noise.

2.Low accuracy.

2.Relatively low temperature limitations. 3.Limited to small pipe sizes and 2. Square root v/s flow relationship. capacities unless put in bypass.

2.Operating data still limited.

2.Fluid measured must be atleast slightly conductive.Not Suitable for gas service.

9 Disadvantages 3.Accuracy affected by density & flow profile. 4.May be used only with relatively clean fluids. 3.Pitot tube doesn't work very well at low velocities because at low 3.Complex elctronic circuitary velocity differential press. Is very neede. low. 4.If support not required then tube 4.Temperature limit may be depend strengths calculation & resonance on insulation materials (usually less frequency vibration for all services than 200C) including liquids to be checked. 1.For Reliable measurement fluid must enter the primary element free of Turbulence.This can be achieved Really not required. by providing suitable lengths of straight pipe ( Refer Annexure -A).

2.Measurement with low flow velocities ( Re < 4000) not possible.Vortex frequency remains 2.cannot measure gas flow with low 2.Straight run upstream piping is constant & independent of press., pipeline pressure. required. temp, density in the range of Re> 20,000 that is utilized for measuring volume flow. 3.Confirm allowable pressure drop 3.Can be costly & should be taken loss while selecting meter size. into consideration. 4.Vortex meter is used for steam water , light hydrocarbons and any gases where large turndown is required. 3.Integral linners(Rubber,Cement,Glass etc.) must be intimately bonded to pipe material.

3. Big & heavy in larger pipe size.

4.Viscosity affects the flowmeters.

10

Straight Run Requirement

1.For Reliable measurement fluid must enter the primary element free of Turbulence.This can be achieved by providing suitable lengths of straight pipe ( Refer Annexure -A).

No Straight Run Requirements.

Long staright lengths necessary depending on the type of fitting upstreams.

No straight meter run requirement.

Straight Run requirement to be maintained.

When flow is obstructed it creates 1.Liner material - hard Rubber,PTFE vortices across shredder bar which etc. in turn creates vibrations flow.

Dopper Equation: Vf=K*Df where K = Constant; Vf= Velocity of fluids where ultrasonic energy is reflected; Df=Diff. between transmitted & reflected frequencies. Transmit Time Equation: Vp=K(Tu-Td)/Tu*Td Where Vp= Average Velocity ib=n fluid path,K=Constant;Tu=Upstream Transit Time, Td= Downstream transit time.

11

General Requirements

2.Electrode material -SS 316,Hestalloy c, titanium,Platinum etc. grounding : Done by Rings on eithrside or Times grounding by electrode in order to go around spurious voltages.

FIELD INSTRUMENTATION DESIGN GUIDE Orifice Plate Assembly Plates : Orifice Tappings

Venturi Meter

Rotameter

Pitot Tubes

Magnetic Flowmeter

Vortex Flowmeter

Mass Flowmeter

Ultrasonic Flowmeter Transit-Time Doppler Type

Flow Instruments Comparision Sheet

Sl.No.

Sensor

Rangeability1

Accuracy2

Dynamics (s) -low cost

Advantages

Disadvantages -high pressure loss -plugging with slurries -high cost -line under 15 cm -higher cost than orifice plate -limited pipe sizes -very poor accuracy -poor performance with dirty or sticky fluids - straight run requirement

Applications / Remarks

orifice

3.5:1

2-4% of full span

-extensive industrial practice -lower pressure loss than orifice

venturi

3.5:1

1% of full span

-slurries do not plug -good for slurry service

3 4

flow nozzle elbow meter

3.5:1 3:1

2% full span 5-10% of full span

-intermediate pressure loss -low pressure loss -low pressure loss

annubar

3:1

0.5-1.5% of full span

-large pipe diameters -wide rangeability

rotameter

10:1

2%

-linear output

A higher-cost flowmeter, used mainly for water applications. They are limited to conductive fluids. They operate on a voltage generator.

Magnetic flowmeter

10:1

0.5% typically 0.5% of measurement

-bidirectional flow & large size available -temperature limit may depend on insulation material (usually less than -No straight meter run required 200C) -high reangeability -high pressure drop -damaged by flow surge or solids -high cost -strainer needed, especially for slurries

positive displacement

10:1 or greater

-good accuracy -wide rangeability

turbine

20:1

0.25% of measurement

-good accuracy -wide rangeability -insensitive to variations in density, temperature, pressure, and viscosity -for high viscous flow such as tars,asphalt etc -wide rangeability

These are used as an alternative to differential pressure flowmeters. They operate best with clean, low-viscosity, medium to high speed fluids. -expensive These twisting meters measure mass flow as opposed to volumetric flow. They are known for their accuracy but their size is limiting. They carry an initial high cost, but a low maintenance cost. They are used for clean liquids and gases flowing at medium to high velocity, in pipes six inches and under. These flowmeters are growing exponentially in popularity, mainly due to their effectiveness in use for measuring natural gasses. They are non-intrusive and have no pressure drop. It is essential that they operate on clean fluids.

10 11

vortex shedding Target flowmeter

10:1 -

1% of measurement Typically 2%

12 13

Coriolis mass flomwmete Ultrasonic Flowmeters

20:1

0.2% typically Typically 2%

-no straight meter run required

FLOWMETER SELECTION GUIDE

TERMINOLOGY G = GOOD
Corrosive / Errosive Liquid

L = LIMITED APPLICATION
Accuracy Reynolds Nos. Typical or other Rangeability limitations

X = NOT RECOMMENDED
Sensitivity to Installation effects

Sr No.

Instrument

Clean Liquid

Dirty Liquid

Slurry

Viscous Liquid

Clean Gas

Dirty Gas

Steam

Viscosity Effect

Full Bore Size Availability

Type of Measurement

(%)

Straight Piping Requirements

Typical ancillary Equipments

Other Considerations

Preferred Meter Orientation

Initial Cost

Installation Cost

maintenance Cost

Operation Cost

Performance Stability

Standard or Recommended Practise.

Concentric Orifice Plate (Square edge)

High

> 1" > 25mm

Square 2 to 4 root of full scale Volumetric ( 0.5% to 3% )

3:1 to 5:1 >10,000

High

10D to 40D- Up 2D to 6D Down

Drain, Vent Blow -off & S/D Valves

Pressure and/or Temp. Compensation May be required Same as Orifice Plate

Pressure Tap orientation Depends on the Pipe orientation & Fluid Being Metered

Low to High

Medium to Medium to High High

* AGA3 Performanc * ANSI/API 2530 Medium to e affected * ANSI/ASME MFC 3M High by Edge & * ISO 5167 ASME Fluid Tap Wear Meters Low to Medium

Segmental Wedge

Low

> 1/2"> 15 mm

Square root Volumetric

0.5 to 2 of full scale (0.5% to 5%)

3:1 to 5:1 > 500

Low

5D to 10D - Up None with Remote Seal 2D to 5D Version Down

No Limitations on Remote Seal High Elements

Low

Low

GOOD

Venturi Tube

High

> 2" > 50 mm

Square root Volumetric

1of full scale 3:1 to 5:1 >10,000 (0.5% to 1.5%)

Low

Upsteram Runs shorter than Same as orifice plate,air Same as Orifice Plate by purge & vent cleanners on Orifice Plate Factor 2-9 Dirty liquids times

Same as Orifice Medium Plate to High

Medium

Low

Low

GOOD

* AGA3 * ANSI/API 2530 * ANSI/ASME MFC 3M * ISO 5167 ASME Fluid Meters * AGA3 * ANSI/API 2530 * ANSI/ASME MFC 3M * ISO 5167 ASME Fluid Meters -

Flow Nozzle

High

> 2" > 50 mm

Square root Volumetric Square root Volumetric Square root Volumetric

1 to 2 of full scale (1% to 2%)

3:1 to 5:1 > 75,000

Mod

Same as Orifice Same as Orifice plate plate

Same as Orifice plate

Same as Orifice Medium plate to High

Medium

Low

Medium

GOOD

V-cone

1 to 16"( 25mm to 400 mm)

0.5% to 2%

3:1 to 5:1 > 4000

Low

5 to 10D - Up

Same as Orifice plate

Same as Orifice plate Viscosity Affetcs performace below critical Rd

Medium

Medium to Medium High

Medium

GOOD

Target

> 1/2 " Medium > 15 mm

1 to 2 of full scale (0.5% to 5%) 1 to 10 of full scale (0.5% to 5%)

3:1 to 20:1 > 1000

High

Same as Orifice plate

Zero May need adjustment in vertical installtion

Low to High

Low

Medium to Medium High

Performanc e affected by Wear of Target

Variable Area

< 3" < Medium 75mm

Linear Volumetric

10:01

Fluids under 3 Cp

None

None

Magnetic

None

> 1/16" > Linear 1mm Volumetric

0.5 of rate (0.2 to 2%)

30:1 to 100:1

None

Low

5 to 10D - Up 3D - Down

Block valve may be required to Isolate Meter for Servicing

Cn only beinstalled Low to Vertical pipe with Medium Flow up Electrodees must be in AC Design may Horizonatal give better plane.Flow Medium Performance should be to High ON some Upwards in Slurries vertical installation. Indicates Zero Flow below cut- off

Low

Low

Medium

GOOD

Low to Medium

Low to Medium

Low

GOOD

ISO 6817

Vortex

1/2" to 12" Linear 15 to Volumetric 300mm

1 of rate (0.5% to 1.5%)

10:1 to 20:1

> 20,000

High

Same as Orifice Block valve may be plate with 0.70 required to Isolate Meter for Servicing Beta

Medium

Low to Medium

Low to Medium

Medium

GOOD

ANSI / ASME MFC 6M * AGA7 * API 2534 * ISO 2715 ASME Fluid meter * API Manual for Petroleum Measurement Standards

10

Turbine

> 1/4" > 6 Linear 0.25% of rate 10:1 to mm Volumetric (0.1% to 1%) 50:1

Fluids under 10 CST

High

Similar to Orifice Plate

Strainers, Filters, Air Eliminators, steam taps may be required

Viscosity can affects Performance

Some design Low to must be oriented High as Calibrated

Medium to Medium to Medium High High

Performanc e affected by wear of bearing & other parameters

11

Ultrasonic - Doppler Type

None

> 1/2 " > 15 mm

Linear 5 of full scale Mass > 10:1 (1% to 5%) Volumetric Linear Mass Volumetric 1 to 5 of full scale (1% to 5%)

Fluids Must Have High Suspensoi ds Fluids must be clean

Similar to Orifice Plate

May have problems on concentrated slurries May have problems on Dirty Fluids

Transducers Low to must bein High horizontal plane Transducers Low to must bein High horizontal plane

Low to Medium

Low

Low

GOOD

12

Ultrasonic - Transit Time

None

> 1/2 " > 15 mm

> 10:1

High

Similar to Orifice Plate

Low to Medium

Low

Low

GOOD

ANSI / ASME MFC - YY

FLOWMETER SELECTION GUIDE

TERMINOLOGY G = GOOD
Corrosive / Errosive Liquid

L = LIMITED APPLICATION
Accuracy Reynolds Nos. Typical or other Rangeability limitations

X = NOT RECOMMENDED
Sensitivity to Installation effects

Sr No.

Instrument

Clean Liquid

Dirty Liquid

Slurry

Viscous Liquid

Clean Gas

Dirty Gas

Steam

Viscosity Effect

Full Bore Size Availability

Type of Measurement

(%)

Straight Piping Requirements

Typical ancillary Equipments

Other Considerations

Preferred Meter Orientation

Initial Cost

Installation Cost

maintenance Cost

Operation Cost

Performance Stability

Standard or Recommended Practise.

13

Coriolis Type

None

Linear < 6" Mass < 150 mm Volumetric

0.4 of rate 40:1 to (0.15% to 2%) 100:1

None

None

None

Special supports may be required for meters

Entrained air may cause problem

Specific orientations vary High with meter designs

Low to Medium

Low

Low to High GOOD

*ANSI / ASME MFC-11M California weights & standards

14

Thermal Dispersion

< 3" < 75 mm

Logirithmic Mass

1% to 5%

Upto 100:1

None

Mod to High 10 to 20D - UP

May need to provide comensation for wide TEMP. ranges

Some types require same Low to orientation as in High calibration

Low to Medium

Low

Low to Medium

Performanc e affeccted by severe Build up on sensor for immersion types

Level Instruments Design Guide

Sl.No. Characteristics DP Cell Displacement type Displacer LT Float type Ultrasonic LT Radar LT
Radar Technology is a time flight measurement 1. Microwave energy is transmitted by the radar. 2.The Mircowave energy is reflected off the product surface. 3.The Radar Sensor receives the microwave energy. 4.The time from transmitting to receving the microwave energy is measured. 5. The time is converted to a distance measurement and then eventuallly a level Radar Wavelength = Speed of Light / Frequency

Guided Wave Radar LT Guided Wave Radar level measurement 1.Time of Flight , 2.Top Mounted 3.Solids & liquids applications. 4.Contact Management. 5.GWR is virtually unaffected by Temperature,Pressure & vacuum,Conductivity,Dielectric constant,Specific Gravity,Vapor steam or Dust air movement, Build ups & Foam. Principle of Operation: A microwave pulse (2 GHz) is guided along a cable or rod in a 20 diameter or inside a coaxial system. The pulse is then reflected from the solid or liquid, back to the head of the unit. The travel time of the pulse is measured and then converted to distance.

The difference in pressures between to points in a vessel depends on the fluids between these two points. If the 1.By Archimedes principle, a body immersed in a liquid is buoyed by a difference in densities between the fluids is significant, which is certainly true for a vapor and liquid and can be force equal to the weight of the liquid displaced by the body. ( Thus, a body true for two different liquids, the difference in pressure can that is more dense than the liquid can be placed in the vessel, and the amount of liquid displaced by the body, measured by the weight of the body when in the be used to determine the interface level between the fluids. Usually, a seal liquid is used in the two connecting liquid, can be used to determine the level. ) pipes (legs) to prevent plugging at the sensing points.
1 Working

Perhaps the most frequently used device for the measurement of level is a differential pressure transmitter. 2.Displacers work on the Archimedes Using DP for level is really an inferential measurement. A Principle, when a body is immersed in a DP is used to transmit the head pressure that the fluid it loses weight equal to that of the perhaps attached to a rod, can be diaphragm senses due to the height of the material in the fluid displaced. determined to measure the level. vessel multiplied by a density variable.

1.Ultrasonic transmitters work on the principle of sending a sound wave from a peizo electric transducer to the contents of the vessel. The device measures the length of time it takes for the reflected sound wave to return to the transducer. A successful measurement depends on reflection from the process material in a straight line back to the transducer. Also 2.Time of Flight Technilogy. 3. Short ultrasonic impulses emitted from transducer. 4.Bursts are created from electrical energy applied to piezo electric crystal inside the transducer. 5.The transducer creates sound wave ( mechanical energy). 6.With longer measuring ranges a lower frequency The float of material that is lighter than and higher amplitude are needed to produce sound waves that can travel further. the fluid follows the movement of the 7.The longer the measuring range the larger the liquid level. The position of the float, transducer nust be

=c / f
Frequency 6.3 GHz wavelength = 47.5 mm

Frequency 26 GHz wavelength = 11.5 mm

Arrangement

Level Instruments Design Guide

Sl.No. Characteristics
3 Accuracy

DP Cell

Displacement type Displacer LT Float type

Ultrasonic LT
Typical accuray 5~ 10 mm.

Radar LT
1 Typical Accuracy for High Frequency(26Ghz " K " Band) - 3~ 5 mm. 2.Typical Accuracy for Low Frequency ( 6.3 Ghz - "C" Band 10 mm.

Guided Wave Radar LT

1.Both floats and displacers work well with clean liquids and are accurate and 1.The primary benefit of DPs is that it can be externally adaptable to wide variations in fluid densities installed or retrofitted to an existing vessel. It can also be isolated safely from the process using block valves for maintenance and testing.
4 Advantages

1.the transducer does not come into contact with the process material

2.No Moving Parts in this level measurement techniques.

1.This non-contact technology produces highly accurate measurements in storage tanks and some process vessels. Radar is an excellent, but fairly expensive technology (1k to 5k per measurement) for continuous level measurements. 2.radar can be highly accurate, is immune to most vapours / physical characteristics of the measured media, other than, in some cases, dielectric constant. 1.Its primary disadvantage is cost. 2.The pressure ratings on radar antenna are limited and these devices cannot measure interfaces.

2.There are certain measurements such as total level in separator vessels that due to wide variations in material composition of the upper phase DP is the only viable if not ideal option.
1.D/P transmitters are subject to errors due to changes in liquid density. Density variations are caused by temperature changes or change of product.

2.the process fluid measured must maintain its density if repeatability is required, this is particularly true of displacers

3.a single top of vessel entry makes leaks less probable than fully wetted techniques There are various influences that affect the return signal. Things such as powders, heavy vapors, surface turbulence, foam and even ambient noise can affect the returning signal. Temperature can also be a limiting factor in many process applications. Ultrasonic devices will not operate on vacuum or high pressure applications.

Displacers are affected by changes in product density since the displacement of the body (its weight loss) is equal to the weight of the fluid displaced. eg. If the specific gravity changes, then the weight of the displaced material changes, thus changing the calibration.

Disadvantages

2.These variations must always be compensated for if accurate measurements are to be made. 3.DPs are mainly intended for clean liquids and require two vessel penetrations. One is near the bottom of the vessel where leak paths are the cause of the majority of problems. D/Ps should not be used with liquids that solidify as their concentrations increase. An example is paper pulp stock. Refer Annexure - 1 Fluid density must be stable if readings are to be accurate. If liquid density is subject to change a second d/p transmitter is required to measure density and then used to compensate for any changes. To accommodate the measurement of light slurries, differential pressure transmitters are available with extended diaphragms that fit flush to the side of the vessel. However, if the d/p transmitter diaphragm becomes coated, it may require recalibration, which can be impractical and will add to the "cost of ownership". Frequently, the measuring device is only one consideration in the total installation of the job. Although a D/P transmitter is often less expensive than other types of level sensors, there is usually considerable additional hardware and labour required to make a practical installation. The implementation of a stable, lowpressure leg and 3 / 5 valve manifolds will add considerable cost to the installation.

This is especially problematic in interface measurements, where both liquids increase or decrease density, while the signal is proportional to the density difference. Because the displacer is emersed in the process fluid it will be vulnerable to particulate deposition. This will change the displacer mass and the effective displacement causing a calibration shift.

3.Pulse radar has difficulty making accurate measurement when the media is in close proximity to the antenna because the time difference between send and return signals is too fast to measure accurately.

Application

Refer Annexure - 1

Refer Annexure - 1

Refer Annexure - 1 Successful measurement depends on the transmitter being mounted in the correct position so that the internal structure of the vessel will not interfere with the signal path. To ignore obstructions in the vessel, tank mapping has been developed. Tank mapping lets the operator take a "sonic snapshot" of an empty vessel. The transducer transmits a sound burst and the echo is recorded as a signature of the tank. Any obstructions in the vessel will send an echo and create a profile. Later on, this signature or profile is locked into the ultrasonic units memory so it will not respond to echoes created by these obstructions.

Refer Annexure - 1

Refer Annexure - 1

Practical Limitation

1. Displacers and floats should only be used for relatively non-viscous, clean fluids and provide optimal performance in switch applications and over for short spans. 2 .Spans of up to 12m are possible, but they become prohibitively expensive. 3.Cost of installation for displacers is high and many refineries are now replacing them due to the inaccuracies experienced under process density changes especially on interface duties. 4. High quality float switches still provide reliable and repeatable performance. Even with todays array of level technologies, if a 100% process seal is required under fail conditions for a Cryogenic application the only technique available, other than nucleonic, is a magnetically coupled float switch

In the case of hydrocarbons, an accurate water Interface Measurement bottoms measurement must be made for precise inventory control. Typically, another technology, such as RF Admittance is used to make the interface measurement between water and hydrocarbons. Some installations, such as floating roof tanks, require the installation of a stillpipe. Inconsistencies on the internal surface of the stillpipe can cause erroneous echoes, these can have an adverse effect on the accuracy of some vendor's equipment. High frequency shorter wavelength narrower beam angle more focused signal ability to measure smaller vesselswith more flexible mounting Low frequency longer wavelength wider beam angle less focused signal ability to measure smaller vessels with difficult application variables.

Level Instruments Design Guide

Sl.No. Characteristics Nuclear LT Capacitance LT RF Admittance The theory of operation for an RF Admittance level transmitter is similar to that of Capacitance transmitters, but with two important circuit additions. The oscillator buffer and chopper drive circuits permit separate measurement of resistance and capacitance. Since the resistance and capacitance of any coating are of equal magnitude (by physical laws), the error generated by a coating can be measured and subtracted from the total output. The result is an accurate measurement regardless of the amount of coating on the probe.

Working

1.Nucleonic level controls are used for point and continuous measurements, typically A capacitance probe can be immersed in the liquid of the tank, where most other technologies are unsuccessful. 2.The and the capacitance between the probe and the vessel wall radioisotopes used for level measurement emit energy at a fairly constant rate but in depends on the level. By measuring the capacitance of the random bursts. Gamma radiation, the source generally used for nucleonic level liquid, the level of the tank can be .As the level rises and gauging is similar to microwaves or even light (these are also electromagnetic material begins to cover the sensing element the capacitance radiation, but of lower energy and longer wavelength). The short wavelength and higher within the circuit between the probe and the media (conductive energy of gamma radiation penetrates the vessel wall and process media. applications) or the probe and the vessel wall (insulating 3.A detector on the other side of the vessel measures the radiation field strength and applications) increases. This causes a bridge misbalance, the infers the level in the vessel. Different radioisotopes are used, based on the penetrating signal is demodulated (rectified), amplified and the output is increased. power needed to "see" the process within the vessel. With single point gauges the radiation provides a simple on/off switching function, whereas with continuous level measurement the percentage of transmission decreases as the level increases.

Arrangement
Capacitance Type

RF Ad mittance Type

Accuracy

Level Instruments Design Guide

Sl.No. Characteristics Nuclear LT 1.As no penetration of the vessel is needed there are a number of situations that cause nucleonic transmitters to be considered over other technologies. Capacitance LT RF Admittance

Advantages

RF Admittance is next generation capacitance as such it is by far the most versatile technology for continuous level measurement. It can handle a wide range of process conditions anywhere from Capacitance techniques are capable of operation at extremes of cryogenics to approximately 850 o C and from vacuum to 10,000 2.These applications generally involve high temperatures / pressures or where toxic or psi pressure. Aside from the electronic circuit technology, sensing temperature and pressure. They work well for materials that corrosive materials are within the vessel. Placing the source and / or detector in wells wont leave a coating. Usually only a single tank penetration is element design is very important to handle these process within the vessel can reduce source sizes. conditions. There are no moving parts to wear, plug, or jam. As with required. capacitance systems there is only a single tank penetration, usually 3.An extension of this is to use a moving source within the vessel; this facilitates the at the top of the tank, above the actual process level. unique ability to combine density profiling with accurate tracking of a moving interface. It would appear that nucleonic gauges provide a truly universal "fit and forget" level RF admittance is intrusive. Insulating granular measurements measurement technology. Although when the "cost of ownership" is calculated nuclear require special considerations, such as the moisture range and level measurement is often more expensive than conventional systems. Hidden costs location of the sensing element to minimize errors caused by probe include initial licensing and periodic surveying. These services are usually provided by movement. external authorities or by the equipment supplier, assuming they have appropriately Capacitance systems are intrusive. Have problems with varying qualified staff. If no longer required, the nucleonic gauge must be disposed of through dielectric materials and those medias, that coat the sensing appropriately licensed, external organizations, which again can be a costly exercise. element. Thus users are normally limited to water-like media. Even acids and caustics that dont appear to coat the sensing element are so conductive that the thin film they leave can cause serious errors in measurement.

Disadvantages

Application From a psychological standpoint, the radiation symbol found on these controls is frequently the cause of unfounded concern with uninitiated plant personnel. Plant Management is usually required to ensure that appropriate education is given to any staff likely to be involved with this measurement technology. Source size regulations can often be met in difficult applications by placing the source and / or detector in wells within the vessel if necessary. Most users realise the limitations of Capacitance level Admittance technology and nucleonic measurement provide the measurement, such as the large errors caused by coatings. This only practical methods for level measurement in coating has led to a decrease in the number of these systems in applications. For insulating materials with changing dielectric operation. Other technologies such as FMCW radar and in constants, the measurement can only be made reliably if the particular RF Admittance have now gained acceptance due to material being measured is homogeneous. A reference sensor is high levels of reliability and accuracy. added to monitor the dielectric constant and then compensate the calibration based on this information. Smart RF transmitters are available providing superior levels of stability and accuracy as well as remote communication. Knowledge of the approximate electrical character of the process material is key to optimum system selection and performance.

Practical Limitation

In other words

Control Valve Comparision Sheet for Reference

SR.NO Properties Globe Body Valves Single Seated
1. Minimum leakage in close position.

Rotary Valves Angle Valve Cage guided

1.Leakage rate is like as Single seat.

Double Seated
1.Higher leakage rate than Singale seated valve

3-Way valve

Butterfly valve
1. For High capacity and low pressure drop services.

Ball Valve

Eccentric spherical plug valve

1.Three pipeline connections provide 1.For high pressure general converging (flow mixing0 or services diverging(flow-splitting) services. 2.Usually single port type only.

1.Suitable for erosive and viscous fluids 1.Usually less costly than conventional or slurries containing entrained solids or globe valves and adaptable to ordinary fiber control requirements. 2.V-Notch produces an equal % flow characteristicn,and used for control of above fluids and application where very high rangeability is required.

2.Require large actuator force,particulrly 2.Required less actuato forces due to large sizes. balancing feature of plug.

2.Balanced Plud design 2.Conventional discs provide permits operation with throttling control for up to 60disc smaller actuators. rotation.

3.Most common body atype & simple in Construction

3.Noise attenuation or 3.Low torque requirements can permit 3.Typical wafer body design , a lug anti-cavitation type trim ball valves to be used inQuick manual or wafer design and flanged design. available. automatic operation. 4.Full Ball : 1.A complete sphere as the flow controlling member. 2.Rotary shaft design and include aflow passage. 3.Trunion mounted with a Single piece ball & shaft to reduce torque requirements & last motion. V-Port Ball Valve:1. V -Port ball valve utilizes a partial sphere that has a Vshaped notch in it. 2.Notch permits wide range of service & produces an equal % flow charcteristics. 3.Straight forward flow design produces very little pressure drop & the valve is suited to the control of erosion & viscous fluids. 4.V-port ball reduces the clogging when it comes in contact with seal which produces shearing effect.

WORKING 1

Applicable Codes BEST SUITED CONTROL Quick opening,Linear ; offer full flow with Exhibits approximately equal % flow Linear flow characteristics through 90 of minimum turbulence and can balance or disk rotation. characterics. throttle fluids.Best suited for On-off . Interchangeability o ftrim permits 1.Actuator selection demands careful choice of several flow characteristics consideration,particularly for or noise attenuation or anti-cavitation construction with unbalanced valve components. plug. 1.Reduced unbalance permits operation of valves with smaller actuators than those necessary of single ported valves. 2.Higher capacity than the Single ported valves. 3.Many double seated bodies reverse, so the plug can be installed either push-down-to -open or pushdown-to-close. 1.Will not provide same "Shut-off " as the Single Seated do. 1.High performance butterfly valve should be sized to control within 15 to 75 range of disk opening. 1.Low cost and Maintenance. 2.High Capacity 3.Good flow control.

Linear and Equal %

DESIGN INFORMATION

Valve shall be designed to meet the design pressure and temperature.

1.Efiicient throttling

1.Low cost.

2.High Capacity. 1.Erosion resistance.

ADVANTAGES

2.Accurate flow control

3.Low leakage and maintenance

3.Available in Multiple ports

4.Low pressure drop.

4.Tight sealing with low torque.

1.High Pressure drop 5 DISADVANTAGES 2.More expensive than other valve

1.High torque required for control.

1.Poor throttling characteristics.

2.Prone to Caviation at lower flows. 2.Prone to Cavitation. 1.Throttling service/flow regulation but not generally recommended because of their maintenance cost and leakage. 1. Can be used for throttling midtravel position control either converging or diverging fluids. 1.Fully open/closed at throttling services & on-off valve.

1.Throttling service/flow regulation 6 RECOMMENDED USED 2.Frequent operation

1.Fully open/closed, limited -throttling

2.Frequent operation. 3.Minimal fluid trapping inline. 4.Big 2.Higher temperature fluids. lines(Liquid service upto 96").

Control Valve Comparision Sheet for Reference

SR.NO Properties Globe Body Valves Single Seated Double Seated
1.Typically used in refineries on highly viscous fluids ( dirt,contaminants, or process deposits on trim) concern

Rotary Valves Angle Valve

1.Coking service. 2.Solids carried in supsension. 3.Severe flashing services. 4.Cavitaion services. 5.High pressure drops.

3-Way valve

Cage guided

Butterfly valve

Ball Valve

Eccentric spherical plug valve

APPLICATION

1.Liquids,vapors,gases,corrosive sustances,slurries

1.Lquid,gases ,slurries,liquids with suspended solids.

1.Most liquids, high temperatures, slurries.

2.Specified for application stringent shut- 2.Often used for on-off or low off requirements. pressure throttling device. 8 CONNECTION RATING (Typical upto ANSI 2500) As per Piping Specifications.(H-103) Standard end connections (Flanged,screwed,butt weld etc.)Can As per Piping be specified to mate with piping Specifications.(H-103) design specs. Variations include trim materials As per Piping selected for high temperature service. Specifications.(H-103) As per Piping Std. Raised faced piping Specifications.(H-103) flanges.Typical ANSI 600. As per Piping Specifications.(H-103) As per Piping Specifications.(H103).Typical upto ANSI 900. As per Piping Specifications.(H-103)

MATERAIL

As per Piping Specifications.(H-103) PTFE( Polytetrafluro ethylene widely used because of its inert and has low coefficient of friction. Can be applied to 400F.

As per Piping Specifications.(H-103)

As per Piping Specifications.(H-103)

As per Piping Specifications.(H-103)

10

PACKING

11

Metal-to-Metal seating usually Metal-to- Metal saeting surfaces pr soft provides only Class II shut-off SEAT LEAKAGE seating with PTFE.Tight shut-off capability,although Class III achievable. capability is also possible.

Tight-off can be achieved.

Tight shut-off achievable.

Quick Opening:Provides a maximum change in flowrate at lower valve tarvel with fairly linear relationship and lesser flow increase as the plug further opens.( Normally not used for throttling) TRIM CHARACTERISTICS Linear: Provides equal increase in CV for equal increment in stem travel. Linear one often specified for liquid level control and application requiring constant gain Pressure drop is Constant) ( Equal %:Provides equal% increase in CV for equal increament of stem travel.This characteristic provides throttling control valve at valve close position and rapidly increaasing capacity as the plug is near the open position. Equal% is suitable for pressure control application, or on application where highly varying pressure drop can be expected and pressure drop at the control valve is relatively small against the system pressure drop. 13 14 SIZING Flow Capacity Moderate The shear Safety factor should be a minimum 150% at the specied Shutoff pressure drop condition. High High

12

WIRE CONVERSION CHART

Wire Number (Gauge) S.W.G. (Inches) 0.3 0.276 0.252 0.232 0.212 0.192 0.176 0.16 0.144 0.128 0.116 0.104 0.092 0.08 0.072 0.064 0.056 0.048 0.04 0.036 0.032 0.028 0.024 0.022 0.02 0.018 0.0164 0.0148 0.0136 0.0124 0.0116 0.0108 0.01 0.0092 0.0084 0.0076 0.0068 0.006 0.0052 0.0048 (MM) 7.62 7.01 6.401 5.893 5.385 4.877 4.47 4.064 3.658 3.251 2.946 2.642 2.337 2.032 1.829 1.626 1.422 1.219 1.016 0.9144 0.8128 0.7112 0.6096 0.55.88 0.508 0.4572 0.4166 0.3759 0.3454 0.315 0.2946 0.2743 0.254 0.2337 0.2138 0.193 0.1727 0.1524 0.1321 0.121 American Wire Gauges (AWG) Metric (Inches) 0.289 0.258 0.229 0.204 0.182 0.162 0.144 0.128 0.114 0.102 0.091 0.081 0.072 0.064 0.057 0.051 0.045 0.04 0.036 0.032 0.028 0.025 0.023 0.02 0.018 0.016 0.014 0.013 0.011 0.01 0.009 0.008 0.007 0.0063 0.0056 0.005 0.0044 0.004 0.0035 0.0031 (MM) 7,348 6,543 5,827 5,189 4,621 4,115 3,665 3,264 2,906 2,588 2,304 2,052 1,829 1,628 1,450 1,291 1,150 1,024 0,9119 0,8128 0,7239 0,6426 0,5740 0,5106 0,4547 0,4038 0,3606 0,3200 0,2870 0,2540 0,2261 0,2032 0,1803 0,1601 0,1422 0,1270 0,1143 0,1016 0,0889 0,0787 (MM2) 42.429 33.592 26.694 21.155 16.763 13.267 10.52 8.346 6.605 5.268 4.154 3.3 2.63 2.086 1.651 1.306 1.038 0.817 0.65 0.515 0.407 0.321 0.255 0.204 0.159 0.125 0.101 0.08 0.066 0.049 0.041 0.032 0.024 0.02 0.015 0.012 0.009 0.008 0.006 0.005

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

American Wire Gauge (AWG) 0 0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Diameter (inches) 0.46 0.4096 0.3648 0.3249 0.2893 0.2576 0.2294 0.2043 0.1819 0.162 0.1443 0.1285 0.1144 0.1019 0.0907 0.0808 0.072 0.0641 0.0571 0.0508 0.0453 0.0403 0.0359 0.032 0.0285 0.0254 0.0226 0.0201 0.0179 0.0159

Diameter (mm) 11.68 10.4 9.27 8.25 7.35 6.54 5.83 5.19 4.62 4.11 3.67 3.26 2.91 2.59 2.3 2.05 1.83 1.63 1.45 1.29 1.15 1.02 0.91 0.81 0.72 0.65 0.57 0.51 0.45 0.4

Cross Sectional Area (mm2) 107.16 84.97 67.4 53.46 42.39 33.61 26.65 21.14 16.76 13.29 10.55 8.36 6.63 5.26 4.17 3.31 2.63 2.08 1.65 1.31 1.04 0.82 0.65 0.52 0.41 0.33 0.26 0.2 0.16 0.13

Remarks