Instrumentation Books and Notes: March 2012

Thursday 29 March 2012

Cross-Correlation Flow Metering

Current Applications
Pumped paper pulp, pneumatically conveyed coal dust, cement, grain, plastic granules,
chalk, water flow in nuclear and industrial plants, and animal foodstuffs
Sizes
Practically unlimited
Cost
A 4-in 150 # mass flowmeter with epoxy-resin-lined, enameled steel pipe costs $6000.
If the sensor costs are not considered, the electronic detector alone is around $2000.
Nuclear power plant flow metering installations range from $25,000 to $50,000.
Partial List of Suppliers
Analysis and Measurement Services Corp. (www.ams-corp.com)
Endress
+
Hauser Inc. (www.us.endress.com)
Kajaani Electronics Ltd. (Finland)

The oldest and simplest methods of flow measurement are
the various tagging techniques. Here, a portion of the flowstream
is tagged at some upstream point, and the flow rate
is determined as a measurement of transit time. Variations of
this technique include particle tracking, pulse tracking, and
dye or chemical tracing, including radioactive types. The
advantages of tagging techniques include the ability to measure
the velocity of only one component in a multicomponent
flowstream without requiring calibration or pipeline penetration.
For example, electromagnetic tagging of gas-entrained
particles allows for the determination of their speed through
the detection of their time of passage between two points that
are a fixed distance from each other.
Flow metering based on correlation techniques
is similar
in concept to the tagging or tracing techniques, because
it also detects transit time. As illustrated in Figure 2.5a, any
measurable process variable that is noisy (displays localized

variations in its value) can be used to build a correlation
flowmeter. The only requirement is that the noise pattern must
persist long enough to be seen by both detectors
A
and
B
as
the flowing stream travels down the pipe. Flow velocity is
obtained by dividing the distance (between the identical pair
of detectors) by the transit time. In recent years, the required
electronic computing hardware, with fast pattern recognition
capability, has become available. Consequently, it is feasible
to build on-line flowmeters using this technique.
3
The following process variables display persistent enough
noise patterns (or local fluctuations) that correlation flowmeters
can be built by using an identical pair of these sensors:
Density
Pressure
Temperature

Ultrasonics
Gamma radiation
Capacitive density
Conductivity

Several of the above process variables (such as temperature,
4,5
gamma radiation, and capacitive density
6
) have
been investigated as potential sensors for correlation flowmeters.
One instrument has been developed that uses the
principle of ultrasonic cross-correlation to measure heavywater
flow.
3
Others are available for paper pulp applications
using photometric sensors and for solids flow measurement
utilizing capacitance detectors (Figure 2.23v). For crosscorrelation
flowmeters applied in solids flow applications,
refer to Section 2.23.
When fully developed, correlation flow metering can
extend the ability to measure flow not only into the most
hostile process environments but also into areas of multiphase
flow and into three-dimensional flow vectoring.

BTU Flowmeters for Gaseous Fuels

Sensors Required
Conventional head-type flowmeter, calorimeter, or wobble index detector plus pressure
and temperature measurements
Process Fluids
Gaseous fuels
Applications
Combustion processes are optimized by measuring and controlling fuel gas flow on
the basis of the heat flow (BTU/h) requirement of the process
BTU Flow Range
From 100 BTU/min to very large heat flow rates; limited only by pipe sizes
Inaccuracy
±1.0 to± 2.0% of full scale, depending on the accuracy of the head type flowmeter used
Costs
for the costs of the different types of calorimeters. The cost of
a general-purpose wobble index detector is $10,000 to $12,000. Explosion-proof
designs cost $5000 to $6000 more. For flow, temperature, and pressure transmitter
costs, refer to Chapters 2, 4, and
5.
Partial List of Suppliers
ABB Process Automation—Analytical Div. (www.abb.com/us)
The Foxboro Co. (www.foxboro.com)
Honeywell Industrial Control (www.honeywell.com/acs/cp)
ICS (www.icsadvent.com)
Thermo Onix Process Analyzers (formerly Fluid Data/Amscor) (www.thermoonix.com).

The heat flow rate provided by the burning of a fuel gas can
be measured by detecting its mass flow rate and multiplying
it by its heating value, which can be detected by wobble index
sensors or calorimeters . The burning
of waste gases from a variety of process sources .
and the accurate control of regular fuel gases made it necessary
to measure their heat flows on line and continuously.
In the past, only the volumetric flow of the fuel gas was
measured, and the heating value and the specific gravity of
the gas were assumed to be constants. This approach is not
acceptable for applications involving the burning of waste
gases, because both their composition and heating values are
variable.
In the past, in hazardous areas, the heating value of fuel
gases could not be continuously measured, so specific gravity
measurements were used to estimate their heating value and
to control the combustion process. Today, continuous and
explosion-proof calorimeters are available for
the measurement of the heating value of any fuel gas. These
optimized combustion controls are automatically adjusted for
variations in either the specific gravity or the heating value
of the fuel gas.

The heat flow rate provided by the burning of a fuel gas can
be measured by detecting its mass flow rate and multiplying
it by its heating value, which can be detected by wobble index
sensors or calorimeters. The burning
of waste gases from a variety of process sources
and the accurate control of regular fuel gases made it necessary
to measure their heat flows on line and continuously.
In the past, only the volumetric flow of the fuel gas was
measured, and the heating value and the specific gravity of
the gas were assumed to be constants. This approach is not
acceptable for applications involving the burning of waste
gases, because both their composition and heating values are
variable.
In the past, in hazardous areas, the heating value of fuel
gases could not be continuously measured, so specific gravity
measurements were used to estimate their heating value and
to control the combustion process. Today, continuous and
explosion-proof calorimeters are availablefor
the measurement of the heating value of any fuel gas. These
optimized combustion controls are automatically adjusted for
variations in either the specific gravity or the heating value
of the fuel gas.