White Paper

Solve Steam Measurement

Challenges with Versatile Vortex
Flow Metering
Technology advances achieve better control and
improve efficiency in steam-flow applications
Solve Steam Measurement Challenges White Paper

Introduction
The ability to handle the most challenging flow applications combined with ease
of use make the Rosemount™ MultiVariable Vortex technology a first choice for
many applications.

Of all the challenges an instrumentation engineer is likely to fear, this one might be
foremost: “We want to improve measurement of steam flow through our distribution
system. This will include saturated and superheated steam across a wide range of flows
and temperatures. Oh, and it has to be accurate enough for custody transfer.”

This daunting challenge is very common because many plants and facilities — both
commercial and industrial — have many uses for steam as a mechanism to deliver power,
pressure, and heat. Yet steam systems are expensive to operate since they are highly
energy intensive, and if steam is allowed to cool, its energy and value vanishes.

For engineers who may have to deal with other types of flow measurement challenges,
working through steam applications can be highly instructive since an instrument
capable of measuring steam can measure just about anything. Vortex flow meters
provide a number of advantages for steam and other challenging measurements,
as explained below.

Steam systems are everywhere

Steam systems can provide power by driving a turbine, but many more applications
apply it as a heat delivery mechanism for countless uses, including:
ƒ Gas and liquid heat exchangers.
ƒ Distillation column reboilers.
ƒ Jacketed cooking vessels for food and beverage plants.
ƒ Spray driers.
ƒ Large-scale industrial and commercial HVAC systems.

If a distribution system is well designed and maintained to minimize heat loss and
recapture condensate effectively, it can be highly efficient and cover large areas across
a sprawling industrial facility, or a campus with many buildings.

Heat is transferred during phase transition as latent heat, so the temperature can
be fixed. This allows heating to be carefully controlled by managing pressure and
temperature, but these characteristics also make it difficult to measure.

Power applications call for superheated steam because it can deliver more energy
to a turbine and is better for distribution over a long distance. On the other hand,
heating applications call for saturated steam thanks to its high heat-transfer capabilities.
Superheated steam coming through a distribution system can be de-superheated
as necessary for specific heating applications.

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The importance of accurate measurement

Steam flow measurement is critical because it is the basis for evaluating the
effectiveness and efficiency of an entire generation and distribution system, and
of course for custody transfer applications. Measurements are used for many different
purposes, including:

ƒ Steam output, which must reflect balanced boiler combustion control to reduce
excess O2.
ƒ Determining energy consumption by use point for analysis and billing.
ƒ Loading balance throughout the distribution system.
ƒ Determining energy loss due to poor insulation, ineffective steam traps,
and other factors.

The main measurement challenge emerges because steam has far more complex
characteristics than conventional liquids and gases, and those characteristics influence
how it must be measured. Boilers are usually rated in pounds of steam per hour,
reflecting the number of pounds of water that can be converted to steam. However,
this requires additional qualification of the steam conditions. A boiler can also be rated
by kBtu/hour, which is the amount of heat it can deliver, or by horsepower.

Measuring steam flow can be equally complex. The ultimate common denominator
is that steam flow must be a mass flow reading rather than volume.

When a mass flow measurement is needed, the first thought is often Coriolis technology
since it can handle virtually any fluid type and it natively provides a mass flow reading.
However, Coriolis flow meters are rarely used in steam applications for several reasons.
Steam is often too hot or too wet, and steam lines are often relatively large, which calls
for a bulky and expensive Coriolis flow meter. Moreover, this technology struggles with
two-phase flow, which can often be the case with steam.

Ultrasonic flow meters are another technology which come readily to mind for
measuring mass flow. Due to the high process temperatures in the steam flow,
Ultrasonic flow meters are not a great solution because the transducers can overheat
and fail.

Some flow metering technologies must convert a native fluid velocity or volume
measurement into a mass reading. This is a very common practice in many types
of applications. The volume calculation is multiplied by the fluid density to calculate
the mass, but this requires additional considerations. Since density is a function
of temperature and pressure, the calculation has to include those factors. This is
the reason some types of flow meters include a temperature and pressure
measurement. Getting an accurate mass flow reading requires a combination of all
three factors: flow, temperature, and pressure. The main question when designing
an application is, what is the best way to measure flow, given the wide range of options?

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Differential pressure and other flow technologies

With its many variations, differential pressure (DP) flow meter technology in all its forms
remains the most common measurement technology. It is suitable for steam but has
some significant drawbacks. Primarily among those are:
ƒ A large pressure drop may be necessary, especially when a wide turndown range
is needed.
ƒ Installations tend to be complex (Figure 1) and maintenance-intensive with multiple
impulse lines, shut-off valves, etc.
ƒ Multiple process penetrations are necessary to capture all the temperature and
pressure measurements to calculate a mass flow reading.
ƒ Long straight pipe sections are required up- and down-stream to deliver stability.

Figure 1

Figure 1. DP flow metering can be accurate in steam service, but impulse lines can be a maintenance headache.

When these drawbacks are mitigated, DP flow installations can provide reliable and
accurate compensated mass flow readings for steam systems. However, problems with
impulse lines and the large number of components necessary to install a system can be
difficult to overcome over time. In areas where winter temperatures fall below freezing,
condensate in impulse lines can freeze, creating blockages and even damaging the lines.
This calls for insulation, heat tracing, and other high-maintenance solutions to maintain
reliable readings.

Other more primitive flow measuring methods (Figure 2) can be used, but these also
have serious limitations.

ƒ Variable-area flow meters (“rotameters”) use a floating cone pushing against a

spring to indicate flow. They work but are hugely affected by pressure, such that any
reading on the scale must be corrected if the pressure is higher or lower than the
calibration value.
ƒ Turbine flow meters use a bladed rotor that spins in response to fluid movement.
These respond to fluid velocity, so when measuring steam they are affected by
pressure. Since these are mechanical devices with moving parts, they require
maintenance, and can get jammed by contaminants in the stream.

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ƒ Target flow meters insert a paddle into the fluid stream and calculate flow based on
the force against the paddle.

Figure 2

Figure 2. Three other technologies (left to right) include variable-area, turbine, and target flow meters.

While these might help determine some relative level of steam consumption for
a specific piece of equipment or part of a distribution branch, there is no way they can
deliver an accurate compensated mass flow reading based on their own capabilities.

Vortex flow meters

Another flow metering technology that is growing in steam applications is vortex flow
metering. This has been in use for a long time, but it is not as well-known as DP, and its
growth has been hampered by some design problems early on that we will discuss in
a moment.

When a bar, called a shedder bar (Figure 3), is inserted across the inside of a pipe, such
that it is centered and perpendicular to the fluid flow, the fluid has to go around the bar
on both sides. This creates alternating vortices, described as the von Kármán effect,
the frequency of which is proportional to fluid velocity.

Flow is calculated using this formula:

Flow rate (volume/second) = vortex frequency (pulses/second) / K-factor (pulses/volume)

The K-factor is a calibration constant determined in a flow lab by measuring the pulses
generated divided by one unit of volumetric flow. With a well-designed unit, this
K-factor constant is accurate over a large operating range of flows.

Figure 3

Figure 3. Vortex flow technology measures the frequency of vortices formed by fluid flowing around an obstruction.

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This simple technological concept has several critical benefits:

ƒ It can measure any fluid type — including liquids, gases, and steam — with no
concerns about fluid characteristics, such as conductivity.
ƒ The design is highly scalable, suitable for small and large installations, so it adapts
well to large steam pipes.
ƒ The meter body is compact and there is no need for long straight pipe runs, making
installation easy even in tight quarters.

The long-standing problem with traditional vortex designs is the moving mechanical
sensor extending out of the back of the shedder bar into the fluid to capture the vortices
(Figure 4).

Figure 4

Figure 4. Traditional vortex flow meter designs were often prone to plugging and leakage problems.

Construction of the sensor and its placement on the shedder bar, plus the mechanism
to count the movement frequency, made for a complex and potentially leak-prone
installation. Debris could foul the mechanical sensor causing inaccuracy or a complete
loss of the measurement. If the sensor needed to be repaired or replaced, the seal had
to be broken, requiring a process shutdown.

Improvements in vortex performance

Emerson’s Rosemount 8800 Series Vortex Flow Meters and Rosemount 8800
MultiVariable Vortex Flow Meters (Figure 5) use a shedder bar design that eliminates
the mechanical sensor and its problems. The shedder bar profile optimizes vortices
formation for consistency and predictability.

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Figure 5

Figure 5. The two versions of the Rosemount 8800 differ by inclusion of an integral temperature sensor in the MultiVariable
version (right).

The vortex sensor is integrated with the shedder bar (Figure 6) and it detects and
quantifies the vortex pulses, sending a signal to the transmitter.

Figure 6

Figure 6. Rosemount 8800 Vortex Flow Meters use a shedder bar design with an integral sensor to eliminate plugging
and leak points.

Rosemount 8800 Series Vortex Flow Meters add new capabilities to solve earlier
problems:
ƒ The meter body can be cast and welded together as a single, fully sealed piece,
eliminating gaskets and potential leak points; there are no impulse lines to leak
or clog.
ƒ The MultiVariable configuration includes a temperature sensor built into the shedder
bar, so the reading is available directly to the transmitter without an additional
process penetration.
ƒ Since the meter body is fabricated as a single piece, it adapts well to construction
in special materials for severe applications.
ƒ With no gaskets or seals, the sensor body can withstand very high temperatures
and pressures, typical of superheated steam service.
ƒ Since the body is sealed, it is possible to remove all the electronic components,
including the full transmitter and temperature sensor, while the process is operating;
everything can be reassembled in-situ, simplifying maintenance.

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ƒ Low power consumption makes these meters two-wire devices, with no separate
power wiring required.

Of course, every technology has its tradeoffs, and this is no exception:

ƒ Operation does require some pressure loss around the shedder bar, but generally
far less than is necessary for a comparable DP flow meter. Free passage is also greater
than with a comparable DP flow meter.
ƒ Reliable readings of vortex formation require a minimum fluid velocity, so the
turndown ratio falls off at the low end, however there is still a practical turndown
ratio of at least 30:1 for most sizes. If fluid velocity is low for the pipe size, a reducer
version is available to increase fluid velocity.
ƒ Vortex designs can experience interference caused by stray vibrations coming
through the piping, but Emerson’s exclusive Adaptive Digital Signal Processing filters
out noise and reads only the fluid-induced pulsations.
ƒ While a vortex flow meter can handle any type of fluid, mixed phases are a problem.
Emerson’s Smart Fluid Diagnostics alert users when the flowing fluid changes from
liquid to gas.

Rosemount 8800 Series Vortex Flow Meters provide most of what is required for
a compensated mass flow reading, but a pressure reading from an external device
is required, which can be provided by an elegant means as described in the Sidebar.

Vortex advantages for steam service

A vortex flow meter can be used for any type of fluid, and it is particularly well suited
to steam service thanks to several specialized capabilities which have not been discussed
fully, so far. These types of applications do require a pressure measurement to deliver
full MultiVariable capability. Advantages of vortex flow technology include the ability to:
ƒ Compensate for changing fluid density in steam and liquid applications automatically
without the need for a separate flow computer.
ƒ Detect superheated steam degradation where the process temperature falls below
the superheat threshold at the operating conditions.
ƒ Measure integral temperature with a sensor that covers a range of -40 to 800 °F
(-40 to 427 °C), so it can cover most typical steam applications.

Versatility for a host of applications

Process manufacturing plants use steam as a heat source and to drive turbines, but use
of steam also extends into a wide range of other areas, including:
ƒ Steam injection enhances oil recovery, when steam is forced into the oil reservoir
in the ground it reduces crude oil viscosity, making it easier to pump out.
ƒ Injecting steam into a liquid line can provide a driving force to push the liquid along
without the need for a pump. The steam’s heat also tends to reduce viscosity.
ƒ Steam injected into flare gas improves combustion, reducing ugly black smoke.
ƒ Steam can atomize liquids using a two-phase nozzle in place of compressed air.
This is especially useful for hydrocarbons and viscous products where the heat assists
in breaking up difficult liquids.

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ƒ Steam is a powerful cleaning agent thanks to its heat and blasting force. It is used
frequently for tough applications such as removing coke deposits from the inside
of furnace tubes.
ƒ Steam can serve multiple uses in the same location. For example, in a paper mill,
the Fourdrinier machine can be driven by a steam turbine, with the exhaust pumped
to rollers to provide heat for drying. Steam can also maintain desirable humidity
levels.

Here are some brief examples of companies that have realized the advantages of
Emerson’s Rosemount 8800 MultiVariable Vortex Flow Meters in steam monitoring
applications:

A producer of paper for wallboard, wallboard tape, and joint compound was looking
to optimize plant productivity. Steam use for each department for both process and
house heat, as well as steam production at the powerhouse, is carefully measured
and totalized, with each department billed accordingly. Some plant sections used
mechanical flow meters that had to be read manually and were in difficult-to-reach
locations, and these devices required frequent maintenance. The plant replaced the
old mechanical meter with a Rosemount 8800 MultiVariable Vortex Flow Meter on
the steam line for house heat.

With no moving parts and no ports or crevices to clog, the vortex meter provides
a cost-effective, reliable, low-maintenance solution. Since the MultiVariable vortex
meter has an integrated temperature sensor that compensates for changes in saturated
steam applications, it is able to provide significantly higher accuracy in steam flow
measurement, with an output of flow rate, temperature, and compensated mass flow.

A Midwestern power company operates a boiler plant to provide district heating in

an urban area. In order to maintain saturated steam operational availability for its
customers, it needed a flow meter that could easily verify user consumption without
requiring a process shutdown for sensor verification or replacement, while not requiring
recalibration.

After struggling with a variety of measuring solutions, the company now uses
Rosemount 8800 MultiVariable Vortex Flow Meters to provide a compensated mass
flow reading suitable for billing. Since these flow meters do not require annual
calibration, the company has reduced maintenance costs substantially. The integral
temperature ensures the meter provides an accurate mass flow measurement,
even with steam density fluctuations.

Flares are important safety devices used by refineries to prevent over-pressuring in

pipes and reactors by safely burning unrecoverable hydrocarbon. During flaring, excess
gases are combined with steam, producing water vapor and carbon dioxide. The U.S.
EPA has strict rules on flare gas composition, which requires efficient combustion.
Injecting steam helps mix the gas and atomizes any liquid droplets, so everything burns

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completely. Adding just the right amount of steam at all times is critical for maintaining
compliance.

One North American refinery uses multiple Rosemount flow metering technologies
to achieve steam measurement accuracy of ±5% of mass flow over a turndown range
of 100:1 required by regulators. For measuring steam atomization in the low flow range,
Emerson’s Rosemount 8800 Vortex meter with temperature compensation are used
to calculate mass flow and meet turndown requirements. A Rosemount 8800 Vortex
meter is also used for mass measurement of the center steam injector affecting flame
shape and stability.

Versatility and ease-of-use

Steam and a variety of other difficult flow measurement challenges can be addressed
by vortex technology, with Emerson’s Rosemount 8800 MultiVariable Vortex Flow Meter
as a prime example. The ability to integrate flow, temperature, and pressure presents
a picture of the process with exceptional accuracy and detail. When combined with the
technology’s operational durability and simplicity, it is difficult to find a more effective
approach offering comparable low lifecycle costs.

Sidebar: Installation and Communication

Sidebar:
Protocols for
MultiVariable Operation
The standard configuration for Rosemount 8800 MultiVariable Flow Meters is a flanged
spool section with the integral temperature sensor mounted directly opposite the main
transmitter housing. Full multivariable performance requires a pressure reading which
calls for its own transmitter, such as a Rosemount 3051 In-Line Pressure Transmitter,
which should be mounted four straight pipe diameters downstream (Figure S1) from
the flow meter for optimal performance.

Figure S1

A. Pressure transmitter
B. Four straight pipe diameters downstream
C. Temperature transmitter
D. Six straight pipe diameters downstream
Figure S1. A pressure transmitter should be located downstream from the vortex flow meter sensor. If a separate temperature
sensor must be added, it should be slightly farther downstream.

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Since two transmitters are now involved in the measurement, they must be
interconnected (Figure S2), and there are multiple options for the wiring. The question
to be answered to select the right option is how much information is needed for the
automation host system, including all the elements of the multivariable measurement.

Figure S2

Figure S2. Since the pressure reading is necessary to calculate a compensated mass flow reading, the two transmitters must be
interconnected.

The simplest approach is to wire the two transmitters together using a fixed analog
configuration (Figure S3).

Figure S3

A. Vortex transmitter
B. Pressure transmitter
C. Power supply
Figure S3. The simplest method for connecting the two transmitters delivers all readings via the local displays only.

This method powers both transmitters but has no provision for sending data to a host
system. Operators simply read the values for flow, temperature, and pressure off the
transmitters’ local displays. Configuring both devices with different non-zero HART®
addresses results in a fixed output of 4 mA. This is an excellent approach for measuring
flow at distant parts of a distribution system where there is no need for an analog output
for control or totalizing applications.

When an analog output back to the host system is required, there are two possible
approaches, both using Emerson’s HART® Communication Bridge (Figure S4). This
DIN-rail device captures data from both transmitters, allows them to communicate
with each other, and has two options for interfacing with the host system.

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Figure S4

Figure S4. The HART® Communication Bridge is a compact, convenient device that easily enables communication from a HART®
pressure transmitter to the Rosemount 8800 MultiVariable Vortex flow meter.

Figure S5

A. Vortex transmitter
B. Pressure transmitter
C. HART® Communication Bridge
D. DCS with analog input (AI) card and integral DC power supply
E. Load resistor
Figure S5. Dual and single analog wiring configurations enable the vortex meter to receive the pressure input from a HART® pressure
transmitter while maintaining the ability for independent 4–20 mA outputs from the pressure transmitter and/or vortex meter.

The dual analog configuration (Figure S5 left) connects both transmitters to the
communication bridge. The two transmitters exchange data locally, and there are two
separate 4–20 mA analog signals which can both be landed at the host system, as if
the two transmitters are totally independent. Both transmitters retain all their native
capabilities, but this approach does require two inputs at the host system. Additional
variables are available via the HART® signal, provided HART®-enabled I/O is in use.

The single analog configuration (Figure S5 right) also uses the communication bridge,
but only one 4-20 mA analog signal, the primary flow measurement, is sent back to the
host system. The individual secondary measurements (pressure, temperature, etc.)
are available via the HART® signal, provided HART®-enabled I/O is in use. This approach
is especially important when I/O slots are at a premium.

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WP-002535, April 2021