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Methods of Placement and Installation of UFM to Extend the Linearity Range of

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Article · October 2013

DOI: 10.26634/jic.1.4.2600

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 RESEARCH PAPERS

METHODS OF PLACEMENT AND INSTALLATION OF UFM TO

EXTEND THE LINEARITY RANGE OF MEASUREMENT
By
SHEIKH RAFIK MANIHAR AHMED
Control System Engineer, Fluor Daniel India Private Limited, Gurgaon, New Delhi, India.
ABSTRACT
This paper explains the different Methods of Placement and Installation of Ultrasonic Flow Measuring Instrument on the Pipe
of different configuration to extend the linearity range of measurement up to maximum of the input range. Accurate flow
measurement is an essential requirement both from qualitative and economic points of view. Among the non contact type
of flow measurement, Ultrasonic Flow Measurement (UFM) is widely used to measure flow, because of its advantage like high
resolution and less interference of noise on output. However, non linear characteristics of Ultrasonic flow meters have
restricted its use [1-2]. But the different arrangement and Installation method helps us to understand, how to linearise the
overall system to maximise its full scale range and to make it adaptive to variations in pipe diameter, liquid density, and liquid
temperature [3-4]. A flowmeter installed in such a pipeline should indicate the volumetric flowrate correctly and
independently of the flow profile. The ultrasonic flowmeter integrates, or averages, the velocity along its measuring paths [8-
11]. Clamp-on transducers eliminate in-line installation, allowing one meter to be used at many locations. For easy
installation, no moving parts and no contact between transducer and Fluid is required. Exterior installation eliminates
pressure losses and prevents leaking that can be associated with in-line meter installations [15].
Keywords: Clamp-on Transducer, In-line Meter, Ultrasonic Transreceiver, Transit time, Doppler Shift, Ultrasonic Flow Meter,
Calibration Scale (CS), Full Scale (FS), Absolute Error, Sonic Coupling, Laminar, Turbulent, Direct Mode, Reflecting Mode.

INTRODUCTION
liquids with many impurities.
Flow measurement is the quantification of bulk fluid
movement. Flow can be measured in a variety of ways, Ultrasonic flow meters are one of the most interesting types

may be by contact type or non-contact type of sensor. of meters used to measure flow in pipes. There are two

Positive-displacement flow meters accumulate a fixed types of Ultrasonic techniques available in the Market used

volume of fluid and then count the number of times the for the measurement of the Flow in pipes which are follows.

volume is filled to measure flow. Other indirect flow
measurement methods rely on forces produced by the
flowing stream as it overcomes a known constriction [7-9].
Flow may be measured by measuring the velocity of fluid
over a known area.
1. Ultrasonic Flow Meter
1.1 Doppler Method
This method needs reflectors in the process. Due to
malfunctioning, and incorrect application, there is feeling
of uncertainty, in ultrasonic flow measurement. Instead of
tracking the time it takes to cross the other side, it relies on
having the signal deflected by particles in the flowstream.

Ultrasonic flow meters have gained a lot of attention over These particles are traveling at the same speed of the flow

the past years, primarily because of their ability for [10]. Therefore, as the signal passes through the stream, its

measuring custody transfer of natural gas. They are frequency shifts in proportion to the mean velocity of the

replacing differential pressure and turbine flow meters in fluid. A receiver detects the reflected signal and measures

many natural gas applications. Ultrasonic Flowmeters are its frequency as shown in Figure 1. The meter calculates

also widely used to measure liquid flow. This is not limited to flow by comparing the generated and detected

clean liquids either [5-6]. A special type of Ultrasonic frequencies.

Flowmeter can accurately measure the flow of slurries and Doppler method relies on reflectors in the flowing liquid. To

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To overcome the restriction faced due to nonlinear

response characteristics of the ultrasonic flow meter,
several techniques have been suggested [19-20]. But
some of these are tedious and time consuming. Further,
the process of calibration needs to be repeated or
calibration circuit needs to be replaced/ tuned every time
there is a change in pipe diameter or liquid density. The
problem of nonlinear response characteristics of an
Ultrasonic Flowmeter further aggravates when there is a
change in liquid temperature, since the output of an
Ultrasonic Flowmeter is dependent on temperature also.
Figure 1. Doppler Method
From Figure 2, we have
obtain reliable measurements, therefore, attention must
be given to the lower limits for concentrations and sizes of Tup = (1)
solids or bubbles [12-13]. The flow must also be rapid Tdown= (2)
enough to keep these materials in suspension. ΔT = Tup – Tdown (3)
1.2 Transit-Time Method Frequency, FIN = 1/ΔT
The most common used, transit time method; have both a Where
sending and a receiving transducer. Figure 2 shows the
M – No of times ultrasonic signal travels in forward/
arrangement of one such Ultrasonic Flowmeter. Both
backward direction
sending and receiving transducers are mounted on either
Co – Velocity of ultrasonic signal in static fluid
side of the flow meter, or the pipe wall. The sending
transducer sends an ultrasonic signal at an angle from one D – Pipe diameter
side of the pipe which is received by the receiving V – Velocity of fluid
transducer. The flow meter measures the time that the The velocity of ultrasonic signal depends on [13] density of
ultrasonic signal takes to travel across the pipe in forward liquid as shown in Figure 3
and reverse direction. When the signal travels along the
(4)
direction of the flow, it travels more quickly compared to
With k – bulk modulus and
the condition of no flow. On the other hand, when the signal
travels against the direction of flow, it slows down. The ρ – Density of liquid
difference between the “transit times” of the two signals is Effect of temperature on density [14-15] can be given by
proportional to flow rate [5, 10-13]. (5)
Where:-
ρ1 – specific density of liquid at temperature t1
ρ0 - specific density of liquid at temperature t0
Pt1 – pressure at temperature t1
Pt0 – pressure at temperature t0
E– Modulus of elasticity of the liquid
α – temperature coefficient of liquid
2. Ultrasonic Flowmeter Characteristics

Figure 2. Transit-Time Method Meters are chosen for their application by their

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performance characteristics. The Ultrasonic Flowmeter is a

high accuracy (custody transfer quality), wide flow range
meter capable of high accuracy at high or low flow rates.
Ultrasonic Flowmeters are large capacity meters for their
diametric size. They are calibrated meters and commonly
replace multiple parallel orifice meters with only one
Ultrasonic Flowmeter. They are more tolerant to tube wall
build-up than most meters. They are full-bore with no
restriction. Flowmeters measure very low flow rates or rates
as fast as you would operate a line without causing
Figure 3. Direct Mode or Z-Method
component erosion [14]. The meter's wet-gas performance
is excellent compared to conventional high accuracy
metering technologies. Ultrasonic meters operate well at
high pressures. They are in operation in gas injection
applications up to 10,000 PSI. The characteristics alone
offer a wide choice of applications; however, it is interesting
that only a few meter tube design configurations are
necessary to accomplish the entire range of applications
[16-18]. There are numerous site configurations possible.
Designers should plan site tie-ins carefully.
3. Methodology Figure 4. Reflecting Mode or V-Method

3.1 Methods of Ultrasonic Sensor Installation
There are three methods by which Ultrasonic Flow
measuring instrument can be installed in the pipe
according to the condition of the Fluids, which are as
follows.
1. Direct Mode (Z-Method) Installation
In this Direct Mode or Z-Method of Installation, Ultrasonic
flow measuring Sensor or Transreceiver can be installed
opposite to each other as shown in Figure 3.
Sensor or Transreceiver can be installed in the Same Line at
predefined distance to each other, which is slightly more
than V-Method as shown in Figure 6, because to extend the
linearity range of measurement up to maximum of the
input range and make W- shape.
3.2 Clamp on Flow Meter
For liquid flow measurements on pipelines DN 15 to 5000,
·Where the flow rate only needs to be checked from
time to time, e.g. pump delivery capacities,

2. Reflecting Mode Installation or V-Method

In this Reflecting mode or V-Method of Installation,
Ultrasonic flow measuring Sensor or Transreceiver can be
installed in the Same Line at predefined distance to each
other as shown in Figure 4.
Ultrasonic sound wave reflects from wall of the Pipe and
makes V-shape. The graph shown in Figure 5, gives the
difference between ultrasonic waves along the flow of fluid
(T1-T2) and opposite to the flow of fluid (T2-T1).
W-Methods
In this W-Method of Installation, Ultrasonic flow measuring Figure 5. Graph between T1-T2 and T2-T1.

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Figure 6. W-Method of Installation

·or where installation of a flowmeter in an existing

pipeline is not possible. Figure 7. Sonic coupling in clamp-on ultrasonic flowmeters
·Special ultrasonic flowmeters are available that can
3.3 Independence from the Reynolds number (flow
be clamped on to the pipeline.
profile)
Such clamp-on devices are available in two versions:
A laminar and a turbulent flow profile at the same
·Portable devices for check measurements volumetric flow rate.
·Permanently installed industrial measuring devices. Some petrochemical products have very high viscosities,
The following points need to be borne in mind when so laminar flow can also occur in large-diameter pipelines.
selecting the mounting location:- If a low-viscosity product is involved, the flow can in turn be
·Straight inlet run > 10 D (for details, refer to turbulent. A flowmeter installed in such a pipeline should
manufacturer's details) indicate the volumetric flowrate correctly and independently
of the flow profile. The ultrasonic flowmeter integrates, or
·Reynolds number > 10,000
averages, the velocity along its measuring paths. In laminar
Parameters such as:-
flow conditions, and with only one ultrasonic beam passing
· Type of process product (or its sound velocity), through the tube centerline, it averages by way of the peak of
· Thickness and material of the pipe wall, and the parabolic flow profile. In turbulent flow conditions, it
· Diameter of the pipeline averages by way of the much flatter profile. Measurement
results are inevitably different. For accurate flow
Affect the beam's angle of incidence as shown in Figure 7
measurement independent of the Reynolds number,
the path length of the sound waves, and hence the transit
ultrasonic flowmeters are available with a number of
times and the necessary sensor distance is achieved. For
that reason, the signal converter polls these parameters in
dialog, computes the sensor distance for setting the two
sensor assemblies, and includes this data in the flow
computation. Measuring-point data can be stored and
used for subsequent measurements. The portable signal
converter has an internal data logger to allow recording of
the flowrate. This data can then be transmitted via an
interface to a PC at a later date. For continuous process
flow measurements with high accuracy requirements,
absolutely no maintenance, and the greatest possible
independence from the Reynolds number and other
process conditions this is used. Figure 8. Typical Piping & Meter Configuration

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 RESEARCH PAPERS
measuring channels adapted to the task in hand. Figure 8
shows the Typical Piping and Meter Configuration.
Versions of ultrasonic flowmeters are available today in
which the measuring beam is reflected from the tube wall
several times in order to reduce the effect of the flow profile
and to extend the linearity range of measurement up to
maximum of the input range. This method does have its
advantages:-
·The measuring beam is lengthened compared to the
direct transmission methods.
·Accordingly, above all with small meter sizes, the time
resolution of signal processing need not be particularly
high,
·The beams cross the flow profile several times, thereby
achieving the independence from the Reynolds
number.
However, this design also involves risks:-
·If the tube walls are soiled, the measuring beam fans
out more at every reflection so that, given heavier
deposits on the walls; the ultrasonic pulse may not be
strong enough when it arrives at the receiver.
·In addition, the square shape of the tube can cause
heavier deposits in the corners. The resultant changes
in cross-sectional area then presumably lead to errors
of measurement.
Conclusion
The proposed method of placement and installation of
Ultrasonic Flow Measuring Instrument has gained
intelligence in addition to increase in the linearity range.
The output is somehow made adaptive to variations in pipe
diameter and liquid density. Thus, if the liquid is changed by
another liquid of different density, and/or the pipe is
replaced by another pipe of different diameter, and/or
liquid temperature is changed then the calibration process
need not be repeated. These different methods of
Installation of Ultrasonic Flow Measuring Instrument on the
Pipe of different Configuration, extend the linearity range of
measurement up to maximum of the input range. Clamp-
on transducers eliminate in-line installation, allowing one
meter to be used at many locations. For Easy installation,
no moving parts and no contact between transducer and
10 i-manager’s Journal on Instrumentation & Control Engineering, Vol. 1 l
Fluid is required. Exterior installation eliminates pressure
losses and prevents leaking that can be associated with in-
line meter installations.
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ABOUT THE AUTHOR

Sheikh Rafik Manihar Ahmed is currently working as an Associate Design Engineer in Control System in Fluor Daniel India Private
Limited. He received his Bachelor of Engineering from Chhattisgarh Swami Vivekananda Technical University, Bhilai,
Chhattisgarh. He has published many Books and Research paper in International and National Journals in the field of
Electronics, Robotics & Automation. He also got many Awards related to Research Projects like NIT, Kozhikode National Award for
Best B.Tech Project given by ISTE (Indian Society for Technical Education), Best Innovative Idea Award given by IIT Roorkee; Best
Innovative Project Certificate of Merit Awarded by O.P Jindal College.

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