2022 International Conference on Industry 4.

0 Technology (I4Tech)
Vishwakarma Institute of Technology, Pune, India. Sep 23-24, 2022

Process Control and Automation for Flow meter

Calibration Rig
Mr. Sanket Deshpande Mr. Akshay Ghadge
Department of Instrumentation and Control Engineering Technical Manager
College of Engineering, Pune SBEM Flow Laboratory
Pune, India - 411002 SBEM Pvt. Ltd. Pune
Email: deshpandesm20.instru@coep.ac.in Pune, India - 412205
Email: akshay.ghadge@sbem.co.in

Abstract—In flow meter calibration, measurements taken while mentation is required which includes the field instruments
2022 International Conference on Industry 4.0 Technology (I4Tech) | 978-1-6654-7196-1/22/$31.00 ©2022 IEEE | DOI: 10.1109/I4TECH55392.2022.9952957

it is in use are compared to measurements taken by a standard such as control valves, level switches, temperature sensor,
flow measuring device under the same circumstances. The flow pressure sensor, prover tank etc for the construction of a
meter scale is then modified until it nearly resembles the bench-
mark. The large volumetric flow calibration test rig is designed better flow calibration rig. Development and integration of
and developed in which the closed conduit flow meters like Elec- control strategies for PID control loop, Tower calibration and
tromagnetic / Ultrasonic are calibrated by flowing water through Flow meter calibration. To obtain calibration measurement
UUT (unit under test) with direct volume comparison with capability (CMC) of ± 0.2 percent or better, create a control
reference standard. The higher accuracy and lower uncertainty scheme that is controlled and monitored by PLC and SCADA.
is required because flow meter is used for commercial metering
purpose, so calibration process needs to be precise to get accurate
metering results. Conventional comparative methods will not give
better accuracy results, as meter readings are commutative and III. M ETHODOLOGY
possibility that error becomes twice. To overcome this problem
M/S SBEM employs a volumetric primary calibration method in The amount of liquid collected is measured volumetrically
accordance with ISO 8316, which reduces calibration uncertainty.
in the flow meter calibration setup. The standard vessel in the
Index Terms—Electromagnetic flow meter, Volumetric calibra- volumetric method is a container with a calibrated volume.
tion, PLC and SCADA, Process Control, Field Instruments. The method’s basic idea is to guide the water passing through
the flow meter into a tank with precise measurements. When
I. I NTRODUCTION the water is passing through the flow meter, the collected
Calibration is an essential aspect of Instrumentation in a volume is measured. The tower has 22 level switches, each of
broad range of industries that require high-accuracy measure- which location is precisely regulated, and the volume between
ments with a negligible percentage of error. Increased trust the switches is precalibrated using a Transfer Standard Meter
in the reading from the flow meter in use is the goal of of high precision. To reach the appropriate volume, switches
calibration. The viscosity of the fluid, installation effects from can be used in conjunction. Control valves over PID loops
bends and fittings, temperature, and pressure are factors that are used to identify and control the velocity. For adjusting
need to be taken into consideration. The standard should also flow rate, the PID loop makes advantage of the reference flow
have a defined traceability and uncertainty chosen to match meter’s 4-20 mA output. The specific level switch indicates the
the expectation of the final measurement. Standards may be level of the tower when the flow rate stabilises, and from that
static or dynamic, and this choice is made on the basis of the level switch the calibration cycle is initiated. The calibration
output and end use of the flow meter. Some flow meters are cycle is paused and the volume between the level switches is
used to measure quantity and have a fast response time; others measured once the flow rate starts to decrease at that specific
are designed to measure flow rate and have a slow response level switch. This cycle is repeated until the flow rate is stable.
time. Calibration of a flow meter should cover a significant The test rig is set up to calibrate lines with diameters ranging
flow-rate range for the flow meter and establish a performance from DN 350 to DN 1600 and flow rates ranging from 250
across that range. In this flow calibration rig Electromagnetic m3/hr to 4000 m3/hr. Sensors with sizes ranging from 350
flow meter are calibrated with very precise and accurate mm to 750 mm are mounted on Line B, while those with sizes
Instrumentation which is controlled and monitored by PLC ranging from 800 mm to 1600 mm are installed on Line A.
and SCADA to achieve CMC of ± 0.2 percent or better as per The flow laboratory consists of an underground sump of 120m³
the standard ISO 8316:1987 (Volumetric method). capacities to store the required water. The test rig is supplied
with water from Reference Tower with total volume capacity
II. S COPE AND O BJECTIVE 50m³ and useable calibration volume is (Tower 1= 5m³ to
A dedicated calibration and testing facility is necessary to 35m³). The uncertainty depends on volumetric tank calibration
enhance/improve calibration also selection of precise Instru- uncertainty, temperature uncertainty and timing uncertainty.

978-1-6654-7196-1/22/$31.00 ©2022 IEEE 1

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 IV. EXISTING CONDITION/PREREQUISITE once the water level reaches to bottom level switch. The
• The flow meter under test and associated measuring deviation between the reference volume and Meter measured
equipment’s should be switched on for warm-up period volume is calculated and recorded in the test report. Repeat the
of 15 min under steady state environmental conditions. measurements on the same point and average reading shall be
Program the parameters in Master meter according to computed for calculation of sensor factor (Calibration factor)
Meter line size. value to be programmed in Meter under calibration. In order to
• SBEM Laboratory monitor, control and record the en- evaluate the performance of instrument for a specified range,
vironmental conditions as per NABL. Standard Environ- test point should be taken at 90 percent (V1) ,60 percent
mental Condition for the SBEM Laboratory shall be as (V2)and 30 percent (V3) velocities / flow rate mentioned
Temperature 25 deg C ± 3 deg C and RH 45 percent to in standard requirement request form. During calibration, the
75 percent. water is continuously flow under gravity out. The command
• Record the temperature and humidity inside the control is send over PID loop to control valve for 30 percent closing.
room. Environmental conditions will be monitored and The control valve adjusts the flow rate to V1 velocity and
recorded by using calibrated equipment and if the above calibration starts when the velocity is achieved and stabilizes.
stated limit will exceed then calibration will immediately Measurement procedure is same as above.
stop.
• A calibrated temperature monitoring device is available SBEM  


Air

LS101 VOLUMETRIC  

for measuring the temperature of Calibration fluid. Effec- LS103

LS105
 Start
Release!+!# 
LABOARTORY/153UFM03S

tive separation between neigh boring areas is provided Tower50m LS107

Stabilization$*
Velocity *


V1
0.00
V2
0.00
V3
0.00
Volume LS109 Relay/O
Calibration'   
to avoid incompatible activities and prevent the cross LS111
to, 
PLC

A
B
Calibration' ! 
Meter!"#$
0.000
LS113 Start!"#$:0.000 Difference

contamination. RV102

VolumePulse
150Liter End!"#$:0.000 0.000
LS115 Pulse!# 
Reset
123456789 RS485Modbus 420mAControl# # 
The water in the calibration tower and pipe work should
Top *" LS117

•
Pulse# PID
Switch
LS119 Stop 3Nos,#" Controller1
Counters !&#
Temp'!  End!+!#  System
TS102 Stop LS120 RS485Modbus PID

be fully filled and stabilize.Ensure all the air is remove Counting

Meter)  Line Controller2 %Degree!+

420mAInput

420 
RV101 800to1600mm
1200Liter
Test Feedback(  FCV500
FBM500
Temp'! 

from pipe work.

TS103
Bottom *"
Switch
  RS485Modbus
Feedback( 
Start FBM350 

• Only authorized personnel or customer (on request)

Temp'!  
TS104
Counting

Line %Degree!+
350mm !750mm
FCV350
should be allowed to enter into the laboratory area to BFV53 Reference"!
1.002 BFV51
Drain"*
BFV101
Drain"*
BFV202 BFV201

BFV102

maintain customer confidentiality. Also access to the lab-

Volume,#"

15D-!% $ 20D) $

Straight #750 Straight # PT101 BFV125 BFV80
mm 1000mm
Pump+

oratory is limited to authorized personnel and approved

START STOP
Pressure Motor
FCV50 Transfer'   Transmitter Underground'#$ M101 M102
Meter'(101(50mm) PT101 TK403100m3 210m3/hr 80m3/hr

Volume
visitors. BFV52

Drain 

Description: SBEM  !"#$ "!%"&  ! &!  !  Doc!: GA1530302R01

V. SYSTEM DESCRIPTION Prepared : Mr   Date:04/02/2022 Page1of1

A. Calibration of Flow meter by Using Volumetric Tower

Fig. 1. Schematic layout of Volumetric flow calibration rig.
The test rig is supplied with water from Reference Tower
with Calibration volume capacity Tower 1 – (5m³ to 35m³).
Initially the calibration tower and pipe work has been fully B. Calibration of Flow meter by Using Comparison Method
filled and allowed to stabilize before the calibration starts. Flow meters are used in laboratory as Master for compar-
Close the downstream valve and remove the air cavity present ative calibration having enhanced uncertainty. Procedure is
in the pipeline and tower by using air vent and adjust the flow same as Volumetric flow calibration but in this two Master
zero of meter. The regulator and control valve opens at desired meter of size 350mm and 500mm are facilitated in calibration
percentage and water flows under gravity out of the tower and rig depending upon MUT size and flow rate requirements.
through the MUT. The velocity is identified and achieved by Calibration by comparative method is done by comparing the
control valve over PID loop .The PID loop uses the reference flow rate of standard master meter and meter under test in
flow meter 4-20mA output for flow rate controlling. The tower terms of pulse count measured during collection time. Both
consist different level switch whose position is accurately ad- the meters are connected on the same measuring line and
justed and volume between the switch is precalibrated by using calibration can be performed, the flow meter to be calibrated
high accuracy Transfer Standard Meter. Switches can be used is installed in a pipeline upstream of reference or master flow
in combination to achieve required volume. Triggering pulse is meter. The flow measurements of meters are simultaneously
not activated through level switch from the reference Tower till started and stopped to achieve the accurate measurement.
the calibration velocity of upstream flow is not achieved and When the flow of water through the flow meter is stable, a
stabilized. Once’s the velocity is achieved and the water passes timer is started and simultaneously the outputs of both flow
the top level switch, the pulse counter is activated. The meter meter in calibration and reference meter are recorded. In order
volume get measured and registered on Pulse Counter. Note to evaluate the performance of instrument for specified range,
down the temp indicator reading installed on measuring line at least three/five measurement readings are taken at each
during the calibration cycle which is further used for density point. This deviation between true and MUT values can be
calculation and volume correction. The counter is deactivated expressed in percentage of measured flow. After calibration

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cycle is over all the readings are saved in SCADA database Friction factor of straight line is 0.009
or MS-Office with secured path with limited access. Velocity for line A is,

VI. SYSTEM DESIGN FEASIBILITY 2 ∗ 9.81 ∗ 16.5
V = (11)
Design calculations for determining velocity by considering 1.5 + 4∗0.009∗22.5
0.5
the friction losses in the pipe with the help of Bernoulli’s
equation. V = 10.86m/s (12)
1 1 Velocity for line B is,
p1 + ρv12 + ρgh1 = p2 + ρv22 + ρgh2 (1)
2 2 
2 ∗ 9.81 ∗ 16.5
Where, V = (13)
1.5 + 4∗0.009∗17
0.35
P is pressure exerted by fluid
V is velocity of fluid V = 9.98m/s (14)
ρisdensityof f luid Calculation of flow rate,
H is height of tower For line A is
For calculating the velocity, V= 10.86 m/s and D= 0.5m
p1 v1 π 2
H = Z1 + + (2) A= (d )
ρg 2g 4
(15)

p1 v2 p2 v2 3.14
Z1 + + 1 = Z2 + + 2 (3) A= ∗ 0.52 (16)
ρg 2g ρg 2g 4
Add friction loss at output side
A = 0.1962m2 (17)
p1 v12
p2 v22
Z1 + + = Z2 + + + h i + hf (4)
ρg 2g ρg 2g
Q=V ∗A (18)
We have to calculate velocity by considering friction loss

v22 Q = 10.18 ∗ 0.1962 (19)

Z1 = hi + hf + (5)
2g
Friction loss formula Q = 1.9978m3 /s (20)
L v22 Convert into m³/hr
h1 = 4 ∗ F ∗ ∗ (6)
D 2g
Where, Q = 1.9978 ∗ 3600 (21)

F is friction factor Q = 7192.17m3 /hr (22)

h1 isf rictionloss
L is length of pipe For line B is
D is diameter of pipe V= 9.98 m/s and D= 0.35m
V is velocity of liquid π 2
G is gravitational constant A= (d ) (23)
4
v22 L v2 v2 3.14
Z1 = 0.5 +4∗F ∗ ∗ + 2 (7) A= ∗ 0.352 (24)
2g D 2g 2g 4
v22 4∗F ∗L
Z1 = (0.5 + + 1) (8) A = 0.0961m2 (25)
2g D
Z1 = h
Q=V ∗A (26)
v2 4∗F ∗L
h = 2 (1.5 + ) (9)
2g D
Q = 9.98 ∗ 0.0961 (27)

2∗g∗h
V = (10)
(1.5 + 4∗FD∗L ) Q = 0.9597m3 /s (28)

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 Convert into m³/hr C. PID Implementation
The feedback meter’s 4-20 mA output current is coupled to
Q = 0.9597 ∗ 3600 (29) a PID controller, and the real line flow rate is calculated using
this current value. In order to manage the flow and reach the
desired set point, the PID controller will continuously monitor
Q = 3454.92m3 /hr (30)
the actual line flow rate and produce a 4-20 mA control output.
The motorised valve positioner or VFD is also provided with
this controlled 4-20 mA output in order to manage the valve
position and maintain a constant flow rate.

VIII. SYSTEM FLOW CHART

Fig. 2. Tower Design Specfications

VII. PROPOSED IMPROVEMENTS

A. Enhanced Uncertainty
To achieve better uncertainty, analysis and necessary im-
provements are accomplished such as 5D straight piping at
upstream of flow meter and 3 D straight piping at downstream Fig. 3. Volumetric tower calibration strategy
of flow meter, also for proper flow profile correction concentric
expander and concentric reducer are installed which increases
the velocity and helps to maintain a regular steady flow. IX. APPLICATION
M/s SBEM Flow Laboratory is established to provide cal-
B. Automation System ibration services in fluid flow discipline to calibrate closed
To get precise and exact outcomes, automation systems conduit flow measuring devices. The facility is accredited
like PLC and SCADA are used to increase production rates, by NABL (National Accreditation Board for Testing and
boost productivity, cut down on time, improve quality, and Calibration Laboratories) as per standard ISO 17025:2017 and
concentrate on your main goals. Report creation that automat- calibration results are traceable to National and International
ically captures data from measuring devices to prevent user standard. Laboratory is provided calibration services for flow
manipulation Additionally, the real-time data base, which is meters manufactured by M/s SBEM. Additionally Laboratory
a built-in part of the SCADA system used for the automated to be calibrate flow meters of external customer under NABL
operation of the test field, offers unique capabilities that are scope. Calibration of flow measuring devices is being run auto-
necessary in order to carry out the flow calibration procedure. matically, with the capabilities of the computer-based SCADA

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system being utilized for automatic process control operations, XIII. DELIVERABLES
data communications and acquisition, mathematical calcula- • Consistently delivering quality results as per commitment
tions and report generations of flow meter calibration. and in conformance to the regulatory requirements
• Consistently comply with field specific requirements for
X. ADVANTAGES fluid flow discipline to deliver accurate and precise results
with enhanced uncertainty.
• For Fluid flow measuring devices with liquid volume
flow rate by using Electromagnetic Flow meter within
measurement range of 500m³/hr to 3500m³/hr with the
calibration measurement capability (CMC) of ± 0.2 per-
cent
XIV. ACKNOWLEDGEMENT
The author is thankful to M/s SBEM Flow Laboratory,
SBEM Pvt. Ltd, Pune for helping throughout the project and
providing this opportunity and facilities to carry out this work.
R EFERENCES
[1] Abbas, Ali, Nitin Kumar Jhankal, and Arun Kumar. ”Calibration of
Electromagnetic Flowmeter Using Advanced SCADA System.”
[2] Seierstad, Johanne. ”Design system for primary calibration of flow.”
Master’s thesis, Institutt for energi-og prosessteknikk, 2013.
[3] ISO 8316, Measurement of liquid flow in closed conduits - Method by
collection of the liquid in a Volumetric tank
XI. RESULT [4] IS0 5168, Measurement of fluid flow - Estimation of uncertainty of a
flow-rate measurement

Fig. 4. Flow Meter Calibration Report

XII. CONCLUSION
These unique capabilities are a requirement to carry out
the flow calibration procedure and are provided by the PLC
and SCADA system used for the automated operation of the
test field. The calibration report generated is as expected and
accuracy of flow meter is found within limits. The calibration
measurement capability (CMC) of ± 0.2 percent is found
within measurement range of 500m³/hr to 3500m³/hr.

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