Influence of flow disturbances on the performance of industry-standard LNG flow meters

In the last decade significant progress has been achieved in the development of measurement traceability for LNG inline metering technologies such as Coriolis and ultrasonic flow meters. In 2019, the world's first LNG research and calibration facility has been realised thus enabling calibration and performance testing of small and mid-scale LNG flow meters under realistic cryogenic conditions at a maximum flow rate of 200 m³/h and provisional mass flow measurement uncertainty of 0.30% (k = 2) using liquid nitrogen as the calibration fluid. This facility enabled, for the first time, an extensive test programme of LNG flow meters under cryogenic conditions to be carried out to achieve three main objectives; the first is to reduce the onsite flow measurement uncertainty for small and mid-scale LNG applications to meet a target measurement uncertainty of 0.50% (k = 2), the second is to systematically assess the impact of upstream flow disturbances and meter insulation on meter performance and the third is to assess transferability of meter calibrations with water at ambient conditions to cryogenic conditions. SI-traceable flow calibration results from testing six LNG flow meters (four Coriolis and two ultrasonic, see acknowledgment section) with water in a water calibration facility and liquid nitrogen (LIN) in the LNG research and calibration facility under various test conditions are fully described in this paper. Water and LIN calibration data were compared and it was observed that the influence of removing the meter insulation on mass flow rate measurement accuracy can be more significant (meter error > ±0.50%) than the influence of many typical upstream disturbances when the meter is preceded by a straight piping length equal to twenty pipe diameters (20D) with no additional flow conditioning devices, in particular for ultrasonic meters. The results indicate that the correction models used to transfer the water calibration to cryogenic conditions (using LIN) can potentially result in mass flow rate measurement errors below ±0.5%, however, the correction models are specific to the meter type and manufacturer. This work shows that the target measurement uncertainty of 0.50% can be achieved if the expanded standard error of the mean value measured by the meter is smaller than 0.40% (k = 2). It is planned to repeat these tests with LNG in order to compare the results with the LIN tests presented in this paper. This may reveal that testing with an explosion safe and environmentally friendly fluid such as LIN produces representative results for testing LNG flow meters.     

Uncertainty analysis of the high pressure closed loop gas flow standard facility in NIM

High pressure air flow standard facilities, including the pVTt facility, sonic nozzle facility and closed loop facility were built in NIM at the end of 2014. The high pressure closed loop gas flow facility was the first closed loop facility in China. The system has 4 sets of 100 mm diameter turbine meters for the reference meters with a flow range of (40–1300) m³/h and a pressure range of (190–2500) kPa. To avoid uncertainties introduced during installation, the reference meters were designed to be calibrated in situ using the sonic nozzle facility. The uncertainty in the pressure measurement was reduced by installing an absolute pressure transducer in the manifold upstream of the reference meters, with differential pressure transducers used to measure the pressure drops across the reference flow meter and the test flow meter. The relative expanded uncertainty for the test meter can reach 0.20% (k = 2) as verified by comparison the sonic nozzle facility and the closed loop facility measurements.     

Design and development for amelioration of primary water flow standard and calibration systems

The present study outlines the efforts made to improve national primary water flow standards and calibration systems through design and development. The facility has been designed and developed in accordance with ISO 4185 standard in the flow range 0.03 m³/h to 650 m³/h to calibrate various types of flow meters up to DN200 (Nominal diameter) using 12 kg, 300 kg, 3000 kg, and 6000 kg weighing systems. In the flow range up to 530 m³/h, the expanded uncertainty in flow meter calibration in totalized mode is found to be ±0.01% to ±0.025% (k = 2), whereas it is ±(0.03–0.05) % (k = 2) up to DN200 size (test rigs) for mass flow rate (MFR) and volume flow rate (VFR) in the flow range 0.1 m³/h to 650 m³/h. The measurement uncertainty achieved is comparable to that of state-of-the-art water flow measurement capabilities available at numerous National Metrology Institutes (NMIs). Thus, the present designed and developed system at CSIR-National Physical Laboratory (CSIR-NPL) is a solution to maintain traceability to the users and industries.     

Development of the PVTt system for very low gas flow rates

A new $PVTt$ system (pressure–volume–temperature–time system) has been constructed to establish a standard for a gas flow rate of less than 5 mg/min. This system has two unique aspects for the calibration of gas flow meters. First, this $PVTt$ system can calibrate any type of flow meter by introducing an automatic pressure controller to keep the downstream pressure of a flow meter constant, although most $PVTt$ systems can calibrate only flow meters whose output is not influenced by the change of the differential pressure working on them. Secondly, this system does not need a mass correction in the dead volume in most cases, because the difference of the mass of gas in the dead volume between the final condition and the initial condition would be negligibly small as the initial pressure is used as a trigger to stop the measurement. It is presented in this paper that a mass of gas gathered in the constant volume tank (CVT) is the most important parameter on an uncertainty analysis of a $PVTt$ system and the uncertainty of a flow rate must be described with the collection time. In this $PVTt$ system, a realistic relative standard uncertainty of a flow rate of 0.01 mg/min is 0.21% when the collection time is 40 h and a realistic relative standard uncertainty is 0.0001% at a flow rate of 5 mg/min with the collection time of one hour.     

Constant pressure primary flow standard for gas flows from 0.01 cm3/min to 100 cm3/min (0.007–74 μmol/s)

We describe a flow standard for gas flows in the range from 0.01 sccm to 100 sccm with a relative standard uncertainty (68% confidence) of 0.03% at 1 sccm (1 sccm≡1 cm³/min of an ideal gas at 101325 Pa and 0 °C ≈ 0.74358 μmol/s). The flow standard calibrates a secondary meter by withdrawing a piston from a cylinder held at constant pressure P while gas flows from the secondary meter into the cylinder. The flow standard can operate anywhere in the range 10 kPa<P<300 kPa, and it can act as a flow source as well as a flow receiver. The flow standard incorporated features that improved its convenience and lowered its cost without sacrificing accuracy, specifically (1) dry sliding seals made with commercially available, easily replaced, o-rings, (2) a compact design based on a commercially available, hollow piston, and (3) a linear encoder with a small Abbe error.     

Calibration procedures and uncertainty analysis for a thermal mass gas flowmeter of a new generation

This paper deals with the differences between traditional and new technology gas meters, and focuses specifically on the calibration procedure and uncertainty evaluation of CTTMFs (Capillary Type Thermal Mass Flow Meter). In particular, measurements performed on a sample set of commercial CTTMFs for natural gas in domestic/residential (G4) applications allowed to evaluate the modifications to calibration procedures required by the new generation, digital, gas flow meters. Indeed, traditionally natural gas is metered by means of volumetric measurement techniques, while the modern, static gas flow meters (thermal and ultrasonic ones) are based on electronic flow sensors. This implies that the gas volume through the meter is measured by sampling the flow rate at selected time points and integrating the flow rate in time. The measurement time becomes therefore an important parameter, thus requiring a thorough rethinking of the calibration procedure. In order to analyse the effects of the various parameters, a series of ad-hoc calibrations were performed. Specifically, one set of calibrations was performed with constant totalized volume, while the other required a constant measurement time. In order to highlight the novelties that will have to be implemented in ordinary calibration procedures to get the best of the new technologies, the two procedures as performed on a sample set CTTMFs will be compared; the theoretical (generic) evaluation of the associated uncertainty will also be presented. Measurements were carried out at the test facility of INRIM, the Italian National Metrology Institute.     

An experimental intercomparison of gas meter calibrations

This paper presents four calibrations carried out in four different, independent, metrological accredited laboratories, on six diaphragm gas meters for domestic use (G4). The aim of this study is to evaluate the degree of metrological agreement among different calibration results, by means of the assessment of suitable factors (compatibility index, also known as normalized error). This application study is quite interesting in the field of “legal metrology”, when often conformity assessment are requested in order to assure the adequate behavior of a domestic gas meter. The six gas meters were calibrated in four different laboratories, each of them characterized by different values of the calibration uncertainty (also called CMC = Calibration and Measurement Capability, or BMC = Best Measurement Capability, or Minimum Uncertainty). Two alternative approaches about the metrological compatibility are introduced: a quantitative approach and a qualitative approach. The calibration results show that for diaphragm gas meters for domestic use, the metrological agreement should be preferable by means of the qualitative approach.     

Gas Oil Piston Prover,primary reference values for Gas-Volume

The paper describes the design, measurement results and uncertainty analyses of the hydraulic driven piston-prover system which has been in operation at VSL since 2008. The 12-meter long, 0.6 m bore piston-prover is used for the realization of Reference Values for Gas-Volume at pressures between 1 and 65 bar(a) at several gases. The principle is based on the displacement of a piston acting as a Gas–Oil separator. The standard has a flow-rate range from 5 to 230 m³/h. The system is designed to calibrate reference meters. The Calibration and Measurement Capability (CMC) of the system is proven to be smaller than 0.1% (k=2). The paper also explains the coherence between the Gas–Oil piston-prover and other traceability generators and ‘flow rate bootstrapper systems’.     

Uncertainty estimation of a liquid flow standard system with small flow rates

A liquid flow standard system is used to calibrate liquid volume of fuel–oil flow meters at small flow rates between 50 L/h and 700 L/h. However, the system has not been used to calibrate volume flow rate because the system is only operated with the standing-start-and-finish mode. In this study, the liquid flow standard system was rebuilt to provide a calibration service of volume flow rate by attaching two flow diverters, which can operate the system with the flying-start-and-finish mode. To evaluate its performance for volume flow metering, several techniques were introduced. First, diverter timing errors were estimated by linear regression. Second, covariance between buoyancy correction factor and water density was obtained to consider interdependency between the two measurands. Third, calibration and measurement capability (CMC) was evaluated by setting a fixed value of collected weight or elapsed time for flow diversion. Finally, several CMCs were compared to find the best measurement condition. As a result of the above approach, the CMC of the liquid flow standard system was found to be (0.10–0.52)% (k = 2) for (50–700) L/h with a minimum collected weight at 10 kg.     

Development and evaluation of the calibration facility for high-pressure hydrogen gas flow meters

The calibration facility with the multi-nozzle calibrator was developed for the calibration of flow meters to be used with high-pressure, high-flow-rate hydrogen gas. The critical nozzles installed in the multi-nozzle calibrator were calibrated with traceability to the national standard. The relative standard uncertainty of the mass flow rates produced from the calibration facility is 0.09% when the flow rate is between 150 g/min and 550 g/min. In this study, the Coriolis flow meter was calibrated for a pressure range of 15–35 MPa. The relative standard uncertainty of the flow rates obtained from the Coriolis flow meter was 0.44% for the case of the worst fluctuations in the output of the flow meter; based on the calibration curve, this is 0.91%. The present result shows that there is a maximum 3% difference between the output of the Coriolis flow meter and the mass flow rates of the multi-nozzle calibrator, even though the Coriolis flow meter was calibrated using water. Therefore, for the development of a calibration facility that can calibrate a flow meter under the same conditions as those encountered in actual use, it will be important to develop a new flow meter.     

Refined reconstruction of liquid–gas interface structures for stratified two-phase flow using wire-mesh sensor

Wire-mesh sensors (WMS), developed at HZDR [4], [13], are widely used to visualize two-phase flows and measure flow parameters, such as phase fraction distributions or gas phase velocities quantitatively and with a very high temporal resolution. They have been extensively applied to a wide range of two-phase gas–liquid flow problems with conducting and non-conducting liquids. However, for very low liquid loadings, the state of the art data analysis algorithms for WMS data suffer from the comparably low spatial resolution of measurements and from boundary effects, caused by e.g. flange rings – especially in the case of capacitance type WMS. In the recent past, diverse studies have been performed on two-phase liquid–gas stratified flow with low liquid loading conditions in horizontal pipes at the University of Tulsa. These tests cover oil–air flow in a 6-inch ID pipe and water–air flow in a 3-inch ID pipe employing dual WMS with 32×32 and 16×16 wires, respectively. For oil–air flow experiments, the superficial liquid and gas velocities vary between 9.2 m/s≤ν_SG≤15 m/s and 0.01 m/s≤ν_SL≤0.02 m/s, respectively [2]. In water–air experiments, the superficial liquid and gas velocities vary between 9.1 m/s≤ν_SG≤33.5 m/s and 0.03 m/s≤ν_SL≤0.2 m/s, respectively [17], [18]. In order to understand the stratified wavy structure of the flow, the reconstruction of the liquid–gas interface is essential. Due to the relatively low spatial resolution in the WMS measurements of approximately 5 mm, the liquid–gas interface recognition has always an unknown uncertainty level. In this work, a novel algorithm for refined liquid–gas interface reconstruction is introduced for flow conditions where entrainment is negligible.     

Study on the parallel pressure differential type gas laminar flow sensing technique

Parallel pressure differential (PPD) type laminar flow sensing technique was invented several years ago to reduce nonlinear effect in a traditional laminar flow element (LFE). In this paper, the internal flow of each branch in a PPD LFE is numerically simulated for gas flow. The results show that the relative deviation of the pressure drops of the two branches in a PPD LFE is within ±0.05% as inlet mass flow being the same, indicating that the flow resistance characteristics of the two branches are consistent, which means that the hypothesis of a same flow rate for the two branches in a real PPD LFE is tenable. There is little difference, ±0.01%, in the local pressure losses of the two upstream capillaries outlet flows, which can be ignored in a real measurement, further verifying that the theoretical analysis of the PPD principle is reliable. Capillary length effect in a PPD LFE is also examined. The bigger capillary length, the higher measurement precision can be achieved for a certain length range. For instance, it is suggested that the length of the short components should not be shorter than the laminar flow dimensionless entrance length defined by X_e (L_e/d/Re, where L_e is the entrance length) = 0.035, for flow measurement uncertainty within ±1.0%. The simulation and experiment results of gas flow show that the suitable value of K_exp is 1, and in the flow range of (0.0256–5.2985) m³/h measurement error of a PPD LFE is within ±0.8% only with expansion correction, indicating that the PPD laminar flow measurement technique is suitable for the gas flow.     

In-situ calibration of permanent magnet flow meters in PFBR using noise analysis technique

In Fast Breeder Reactor sodium circuits, permanent magnet flow meters (PMFM) are extensively used to measure the liquid sodium flow rate. The performance of PMFM can degrade with respect to time due to various reasons. This degradation results in reduction in output voltage and affects flow meter stability. The distortion of the magnetic field in the large diameter flow meters makes its characteristics nonlinear. Further, the performance of the flow meter is also affected by vibrations, shocks, temperature and change of reluctance within the magnetic circuit. Hence, it is desirable to calibrate the PMFM at periodic time intervals for ensuring accuracy and stability. However, it is very difficult and almost impossible to calibrate large size flow meters once installed in the system under actual flow conditions in a sodium test loop. Therefore, it is necessary to calibrate the flow meter in-situ without disturbing its normal operating conditions.Experiments were carried out in different sodium loops in Fast Reactor Technology Group (FRTG) and Fast Breeder Test Reactor (FBTR) with permanent magnet flow meters of different sizes to develop an in-situ calibration procedure. Cross-correlation technique is studied and the flow rate is estimated from the transit time with a deviation of ±5.5%, which is comparable with that of calibration of the flow meter in actual sodium test loop. In this paper, in-situ calibration of PMFM is discussed with experimental details, data acquisition, cross-correlation technique and the results obtained.     

Performance model evaluation of turbine flow meter in vertical gas-liquid two-phase flows

Aiming at the need for flow measurement of gas-liquid flows in domestic gas well production, this paper proposes a measurement method based on the combination of the turbine flow meter (TFM) and a rotating electric field conductance sensor (REFCS). In experiments, the REFCS is used for the measurement of the gas holdup. To verify the applicability of the TFM models investigated in the previous study, for the modeling part, the mass, momentum and torque models are evaluated in vertical upward gas-liquid two-phase flows. In our model test, the meter factor model of TFM considers the effects of the slip ratio between the gas and liquid phases and flow patterns. In particular, the gas holdup involved in calculating the slip ratio in the model evaluation is obtained from the REFCS measurements. Model test results show the torque model has better volumetric flow rate prediction accuracy than the mass and momentum models. In the present study, the ranges of the liquid and gas phases are Q_w = 2–30 m³/d and Q_g = 1–16 m³/d, it was found that the average absolute deviation (AAD) in the predicted volume flow rate is equal to 1.23 m³/d and the average absolute percentage deviation (AAPD) is equal to 7.69%. The evaluated results presented in this paper will allow better estimates of the volumetric flow rates of gas-liquid flows based on the combined TMF and REFCS measurements during the monitoring of gas well production.     

Development and validation of a dynamic primary standard for unsteady liquid flow calibration

LNE-CETIAT liquid flow laboratory is the French Designated Institute for liquid water flow rate from 1 g h⁻¹ to 50 t h⁻¹. Historically, its primary standards are based on the flying start and stop gravimetric method. The best relative expanded uncertainty for liquid mass flow rate is 0.05% (k = 2). In the scope of the Joint Research Project Metrowamet and its mission to maintain and develop the French standards for liquid flow, LNE-CETIAT has developed and validated a dynamic primary standard for unsteady liquid flow calibration. This paper will first present the developped system, which is composed of a dynamic flow generator and a dedicated measuring system together with its own software for data acquisition and processing. The validation, realized by intra and inter-laboratory comparisons for static and dynamic flows, is presented in the third chapter. Finally, the validation of the measurement and calibration capabilities, based on internal tests and inter-laboratory comparisons are presented.     

Improved critical flow factors and representative equations for four calibration gases

The critical flow nozzle is widely used to calibrate flowmeters in gas flow measurement. Its use requires the critical flow factor, C*, a parameter dependent upon the thermophysical properties of the gas at the nozzle throat, and the upstream temperature and pressure. This paper presents C* values for four calibration gases (air, argon, nitrogen and methane), calculated from the most recent reference quality equations of state, over a wider range of temperature and pressure than previously available, 200–600 K and up to 20 MPa. In addition, a new empirical equation has been developed to represent the calculated values accurately, thus eliminating the need for complex calculations or interpolations from tables.     

Accurate mass flow and density of bubbly liquids using speed of sound augmented Coriolis technology

Speed of sound augmented Coriolis technology utilizes a process fluid sound speed measurement to improve the accuracy of Coriolis meters operating on bubbly liquids. This paper presents a theoretical development and experimental validation of speed of sound augmented Coriolis meters. The approach utilizes a process fluid sound speed measurement, based on a beam-forming interpretation of a pair of acoustic pressure transducers installed on either side of a Coriolis meter, to quantify, and mitigate, errors in the mass flow, density, and volumetric flow reported by two modern, dual bent-tube Coriolis meters operating on bubbly mixtures of air and water with gas void fractions ranging from 0% to 5%. By improving accuracy of Coriolis meters operating on bubbly liquids, speed of sound augmented Coriolis meters offer the potential to improve the utility of Coriolis meters on many existing applications and expand the application space of Coriolis meters to address additional multiphase measurement challenges.The sources of measurement errors in Coriolis meters operating on bubbly liquids have been well-characterized in the literature. In general, conventional Coriolis meters interpret the mass flow and density of the process fluid using calibrations developed for single-phase process fluids which are essentially incompressible and homogeneous. While these calibrations typically provide sufficient accuracy for single-phase flow applications, their use on bubbly liquids often results in significant errors in both the reported mass flow, density and volumetric flow. Utilizing a process fluid sound speed measurement and an empirically-informed aeroelastic model of bubbly flows in Coriolis meters, the methodology developed herein compensates the output of conventional Coriolis meters for the effects of entrained gas to provide accurate mass flow, density, volumetric flow, and gas void fraction of bubbly liquids.Data presented are limited to air and water mixtures. However, by influencing the effective bubble size through mixture flow velocity, the bubbly liquids tested exhibit decoupling characteristics which spanned theoretical limits from nearly fully-coupled to nearly fully-decoupled flows. Thus, from a non-dimensional parameter perspective, the data presented is representative of a broad range of bubbly liquids likely to be encountered in practice.     

Calibration of hydrogen Coriolis flow meters using nitrogen and air and investigation of the influence of temperature on measurement accuracy

The performance of four Coriolis flow meters designed for use in hydrogen refuelling stations was evaluated with air and nitrogen by three members of the MetroHyVe JRP consortium; NEL, METAS and CESAME EXADEBIT.A wide range of conditions were tested overall, with gas flow rates ranging from (0.05–2) kg/min and pressures ranging from (20–86) bar. The majority of tests were conducted at nominal pressures of either 20 bar or 40 bar, in order to match the density of hydrogen at 350 bar and 20 °C or 700 bar and −40 °C. For the conditions tested, pressure did not have a noticeable influence on meter performance.When the flow meters were operated at ambient temperatures and within the manufacturer's recommended flow rate ranges, errors were generally within ±1%. Errors within ±0.5% were achievable for the medium to high flow rates.The influence of temperature on meter performance was also studied, with testing under both stable and transient conditions and temperatures as low as −40 °C.When the tested flow meters were allowed sufficient time to reach thermal equilibrium with the incoming gas, temperature effects were limited. The magnitude and spread of errors increased, but errors within ±2% were achievable at moderate to high flow rates. Conversely, errors as high as 15% were observed in tests where logging began before temperatures stabilised and there was a large difference in temperature between the flow meter and the incoming gas.One of the flow meters tested with nitrogen was later installed in a hydrogen refuelling station and tested against the METAS Hydrogen Field Test Standard (HFTS). Under these conditions, errors ranged from 0.47% to 0.91%. Testing with nitrogen at the same flow rates yielded errors of −0.61% to −0.82%.     

Effect of ultrasonic irradiations on gas–liquid mass transfer coefficient (kLa); Experiments and modelling

Sonochemical reactors have proven to be very useful for intensification of various reaction systems. However, there is a lack of understanding in mass transfer mechanism under ultrasonication due to dependency of mass transfer on various parameters. The present work aims at investigating the effect of ultrasonic intensity on volumetric gas–liquid mass transfer coefficient, k_La, as a function of gas flow rate and temperature. Response surface methodology (RSM) coupled with central composite design (CCD) was used for design, statistical analysis and evaluation of the interaction between operational parameters. The maximum value of k_La was found to be 0.0128 s⁻¹ in an optimum range of ultrasonic intensity between 320 and 360 W, though gas flow rate was the most influential parameter for k_La. In the next part of the study, a model was developed based on ANFIS to map the input variables to the outputs. Satisfactory agreement was observed between the ANFIS predictions and experimental data.     

Development of a high-precision and wide-range ultrasonic water meter

Ultrasonic water meters offer a number of advantages such as non-intrusiveness, low pressure loss, high accuracy, low power consumption and long service life, which make them a viable option for the next generation of smart water meters. However, the existing ultrasonic water meters have difficulties in balancing the range and accuracy. Therefore, in order to address this issue, this study proposes a novel ultrasonic water meter featured with high-precision and wide-range. First of all, the flow measurement principle of the ultrasonic time difference method is investigated, and a flow measurement model that includes the parameter of radial transit time ($T_D$) is developed. The ultrasonic water meter is designed based on comprehensive consideration of the three aspects of hardware, software and algorithms, and a series of experiments are conducted to verify the performance of the water meter. Eighteen verification test points with the flow range of 0.015–4.509 m³/h are carried out, the results of which suggest that the accuracy level of the ultrasonic water meter reaches 0.5, with the repeatability of 0.09%, and the range ratio of 300:1, indicating the achievement of the design goal of high-precision and wide-range.