The Top 10 Fluid Flow Measurement Application Questions

Variable area flow meter (ABB)

Measurement of flow is essential for operation, control, and record keeping for chemical manufacturing, water treatment, oil and gas production, refining, and many other processes. The accurate and reliable measurement of flow is essential to ensuring the proper and efficient operation of any flow control loop. Various technologies such as Coriolis, differential pressure, vortex, magnetic, ultrasonic, turbine and positive displacement meters can be used to measure flow. All of these technologies have advantages and disadvantages. Understanding the differences can be the difference in a successful flow meter implementation or a failure.  Before the proper technology can be selected, there are 10 basic application question that must be answered. They are:

Severe service flow meter
(TECO)

1. Is the measured process media a liquid or a gas?
2. Is the flow measurement occurring in a pipe or in an open channel?
3. What is the the flow rate?
4. How much does the flow vary?
5. If liquid,  is it clean or does it contain suspended solids or air bubbles?
6. What accuracy is required?
7. How much head loss by the flowmeter is permissible? 
8. Is the flow corrosive or erosive?
9. What types of flowmeter technologies can be accommodated in the location?
10. What types of post installation service is available in area?

Positive Displacement Meter (Blancett)

Selecting and configuring a flow measurement device properly, and assuring that installation is done correctly, are necessary tasks to achieving optimal flow meter performance. Reach out to a flow meter specialist with your flow application. By combining your process knowledge with their product application expertise, an effective and long lasting solution will result.

For more information about any flow measurement application, contact Thompson Equipment. The can be reached by calling 800-528-8997 or by visiting https://teco-inc.com.

Flow Measurement for Hydraulic Fracturing and the Production of Shale Gas

Figure 1. Illustration of the fracing (fracking) process.
(Image courtesy of EPA.gov)

A “conventional” gas reservoir is produced from sands and carbonates (such as limestone). In the conventional reservoir, the gas is in interconnected pore spaces, much like a kitchen sponge, that allow easier flow to a well.  In an "unconventional" gas reservoir, such as shale, the reservoir must be mechanically “stimulated” to create additional permeability and free the gas for collection.  Permeability refers to the capacity of a porous, sediment, soil – or rock in this case – to transmit a fluid. Unconventional reservoirs include tight gas (low-porosity sandstones and carbonate reservoirs) and coal bed methane (CBM – gas produced from coal seams).

For shale gas, hydraulic fracturing (known as "fracing" or "fracking") of a reservoir is the preferred stimulation method (figure 1). This typically involves injecting pressurized fluids to stimulate or fracture shale formations and release the natural gas. Sand pumped in with the fluids (often water) helps to keep the fractures open. The type, composition and volume of fluids used depend largely on the geologic structure, formation pressure and the specific geologic formation and target for a well. If water is used as the pressurized fluid, as much as 20 percent can return to the surface via the well (known as flow back). This water can be treated and reused – in fact, reuse of flow back fluids for subsequent hydraulic fracture treatments can significantly reduce the volume of wastewater generated by hydraulic fracturing. 

The hydraulic fracturing process was used in conventional limestone and sandstone reservoirs for decades before the onset of the shale revolution. But it was not until the 1970s that significant attempts to apply the technology to gas shale were made, pioneered by DOE research and demonstration project cost-sharing with industry in such ventures as the Eastern Gas Shales Project (1976-92).

Another major technology often employed in producing natural gas from shale is horizontal drilling. The shallow section of shale wells are drilled vertically (much like a traditional conventional gas well). Just above the target depth – the place where the shale gas formation exists – the well deviates and becomes horizontal. At this location, horizontal wells can be oriented in a direction that maximizes the number of natural fractures intersected in the shale. These fractures can provide additional pathways for the gas that is locked away in the shale, once the hydraulic fracturing operation takes place.

Accurate flow measurement is important in fracking applications and required for reliable data reporting to supervisory agencies. The preferred technology for measuring flow in fracking applications are magnetic flowmeters (magmeters), primarily for their non-obstructive flow path, accuracy and reasonable cost. There are caveats associated with applying magmeters in fracking applications and selection of specialized flow meter components is required. Fracking sand is very erosive and chemicals mixed with the fracking water can be erosive. Any flow meter used in fracking applications must be rugged enough to withstand these harsh conditions. 

Flow meter designed for fracking
applications (as well as for other
abrasive slurries) by TECO.

An excellent solution that provides all the the virtues of magnetic flowmeters and overcomes performance and longevity issues referred to as "severe service flowmeters" or "slurry flow meters" designed with components matched specifically to withstand the mechanical and chemical abuse they will see. Their modifications include: 

• A ceramic sleeved liner made of magnesia partially stabilized zirconia. This ceramic can handle the abrasion and chemical attack with very little degradation.
• Highly polished, ultra-smooth Tungsten electrodes. The Tungsten provides outstanding wear resistance while the high-polish reduces electrical noise introduced in the electrode circuitry.
• Special coatings, or paints, to provide exterior protection.

For more information on fracking (or fracing) magnetic flow meters, contact Thompson Equipment Company (TECO) by calling 800-528-8997 or visit https://teco-inc.com.

Source: How is Shale Gas Produced? https://www.energy.gov/fe/shale-gas-101

Electromagnetic Flow Metering

Cutaways of electromagnetic flow meters - one
removed from service (right) and one
remanufactured (left).

Electromagnetic flow metering is widely used for conductive liquids, such as water acids and alkalis. It's also effective in many other process applications using clean, dirty, and process liquids and slurries. While electromagnetic flow metering is primarily used in full pipes, they can also be applied to partially full pipes and channels often found in effluent applications.

Electromagnetic flow metering is based on the principles of Michael Faraday's 1832 discovery. When a conductive liquid, such as water, is moved through a magnetic field a voltage is induced in the liquid at right angles to the magnetic field. The size of the voltage is directly proportional to the volume flow rate. This induced voltage is detected by sensors known as electrodes. These electrodes transfer the voltage signal to the processing electronics where it can be converted into a usable industrial standard signal.

It's important that the flow meter tube is non-magnetic, and austenitic stainless steel is the most commonly used material. It's also essential that the flow meter tube has a lining that electrically insulates it from the liquid inside, and provides a non-reactive barrier with any corrosive liquids being measured. Distinguishing between flow induced voltage changes, electrochemical noise, and plant induced noise, is a barrier to accurate electromagnetic flow metering. This can be particularly difficult in dirty and industrial applications. The choice of electromagnetic flowmeters with advanced noise suppression can mitigate unwanted noise and provide extremely high orders of accuracy as a result.

To ensure that your electromagnetic flow meters will be optimized for safety, longevity, and performance, the advice of a qualified flow instrumentation expert should be sought out. That expert will be able to help you with the best selection of the appropriate flow device for your specific application, be it electromagnetic flow meters or another flow technology.

Magnetic Flow Meters for Abrasive Service

Magnetic flow meters (magmeters) apply Faraday’s Law of Electromagnetic Induction to measure flow. They are specifically designed for conductive fluids like water, acids, caustic liquids, and slurries.

Magnetic flowmeters differ in materials, size, corrosion resistance, pressure and temperature performance. Properly applying magnetic flow meters for abrasive and/or erosive slurry measurement is one of the most challenging applications for plant engineers and maintenance managers to address. The proper combination of design components is critical.

If you have a challenging flow measurement application that involves abrasive or erosive media, contact TECO for assistance. A short conversation with one of our application engineers will save you a great deal of time and money.

Thompson Equipment Company
http://www.teco-inc.com
800-528-8997

Magnetic Flow Meters with Specialized Construction Still the Best Bet for Dredging Applications

Electromagnetic flow meters commonly measure slurry mixture flow on cutter suction dredgers and trailing suction hopper dredgers. These type of flow meters use exposed electrodes and non-conductive flow tubes. Ordinary magnetic flow meter flow tubes  are not designed to withstand the abrasive conditions prevalent in dredging. Standard magnetic flow meter electrodes  are prone to wear, breakage, and polarization requiring frequent re-adjustment. Standard electrode seals may also deteriorate and cause leaks and false readings.

As an alternative, non-invasive (non-wetted) flow meters, such as clamp-on or Doppler ultrasonic flow meters, have long been proposed because of their  ease of installation and maintenance savings. However, testing of clamp-on or Doppler ultrasonic flow meters has never panned out in dredging applications. While there has been limited success on smaller sized diameters, there are few, if any, large diameter dredging pipe application success stories.

Dredging engineers always seek the simplest and most accurate method of measuring slurry flow. Considering this, there is convincing evidence that the use of customized electromagnetic flow meters, specifically designed to stand up to the rigors of dredging, look to be the best overall option.

Dredging flow meter.
(TECO)

Dredging-specific flow meters provide wear solutions that can extend the life of equipment and keep systems at maximum operational levels. Some users report life span up to 10 years.

The dredging modifications include custom engineered ceramic brick or polyurethane liners, 3/4" stainless steel inlet and outlet protectors, independently sealed electrode wells, and field accessible Hastelloy B electrodes.

Thompson Equipment (TECO), a manufacturer of severe service magnetic flow meters located in New Orleans, will "remanufacture" any make or model of electromagnetic flow meter for dredging service. They have decades of experience servicing and remanufacturing instrumentation, and are leaders in building severe service flow meters.

Electromagnetic flow meters have always been appealing for dredging applications in terms of accuracy, resolution, and response time. Their performance problems, caused by the direct and continuous flow of abrasive slurries, are mitigated through specialized construction.  By applying electromagnetic flow meters specifically designed for the application, dredging engineers now achieve excellent reliability, long life and significant reduction in maintenance and operational costs.

Selecting the Proper Flow Meter: Other Considerations

You Get What You Pay For

Engineers and maintenance personnel who purchase flow meters should remember that accurate instruments cost more based on their features and capabilities. It is always better to search for the type of flow meter best suited to a specific application before sacrificing features in favor of lower cost.

Flow meter specifiers should also take the time to examine long-term ownership costs. It may turn out that flow meters with low purchase prices may be very expensive to maintain. On the other hand, a flow meter with a high purchase price may require little or no service, and therefore lower cost of ownership over time. Lower purchase prices do not always represent the best long term, installed value.

Know Your Process

Users need to closely evaluate their overall process conditions, which include flow rates, pressure and temperature, and operating ranges. Be cautious of lower priced alternatives whose operating parameters don't fully support the requirements of the application.

All flow meters are affected to some extent by the process media and the way they are installed. As a result, their real-time performance will often be different from the controlled reference conditions under which they calibrated. There are some general rules that can be applied to flow meters to assist in reducing uncertainty:

• For the lowest uncertainty of measurement, positive displacement meters are generally the best option. 
• Electromagnetic meters provide for the widest flow range and turbine meters are usually the best choice for the highest short-term repeatability.
• Despite their high initial cost, Coriolis meters are ideal for measuring particularly viscous substances and anywhere that the measurement of mass rather than volume is required.

General Selection Concepts:

• In general, flow meters with few or no moving parts require less time and attention than more complex flow meters. 
• Meters constructed with multiple moving parts may malfunction because of dirt, grit or grime present in the process fluid.
• Flow meters with impulse lines can also plug or corrode.
• Flow meters with flow dividers and pipe bends sometimes suffer from abrasive media wear and blockages.
• Swings in ambient temperature may affect the internal dimensions of the flow meter and could require temperature compensation.

Calibration/Recalibration

The need for recalibration of flow meters is generally a function of how well the instrument is paired to its particular application. Should the application be critical, the flow meter accuracy should be checked at frequent, regular intervals. In some instances, mostly non-critical applications, recalibration may not be necessary for a period of years, becuase the application operating parameters never change.

Keep in mind though, that no matter what flow meter technology is chosen, overall system accuracy can never exceed the accuracy of the equipment used to perform the flow meter calibration. With that said, the most precise flow calibration systems on the market employ a positive displacement design. This type of calibrator, directly traceable to the National Institute of Standards and Technology (NIST) via water draw validation, provides total accuracy of at least 0.05 percent.

For more information on flow meter selection, installation, calibration, service, and replacement contact Thompson Equipment Company (TECO). Call them at 800-528-8997 or visit their web site at https://teco-inc.com.

Failed Flowmeter - Replace with New or Remanufactured?

Many companies don't realize that when you have a failed mag meter or mass meter, it's often more cost-effective and efficient to have them restored to mint condition, than it is to replace them with new units.

But if you send meters to the original manufacturer they can disappear into their system for weeks or months. And you have no idea how long it will really take, or if it will fail again later from undetected problems. The fact is you can't afford the loss of productivity or downtime. But what if there were a place you could send broken flow meters that could save you money and time by restoring them to pristine condition. A cost-effective specialist who could guarantee rapid turn around time and premium customer service. A team of experienced professionals with the capabilities to keep equipment in service, even if it's no longer supported by others.

For a proven partner like this, there's only TECO. Established in 1947, TECO has become the global leader in restoration and customization of magnetic flow meters, Coriolis meters, and other process control instruments.

TECO understands that time is money, which is why they provide the fastest turnaround time in the
industry. They don't simply repair a broken part and return it, they do a full restoration and back the whole meter with a full warranty. Their quality control includes NIST traceable flow calibration, which is often required by regulatory agencies, and ISO 9000 standards. They also provide independent calibration to serve your preventive maintenance and metrology needs.

While their low cost, high quality work has made them the industry leader, it's their commitment to premium customer service that keeps their clients loyal. Extensive capabilities, combined with a focus on service, also means they can manufacture custom flow meter solutions to meet the demands of severe applications.

• Low cost, rapid restoration of mag meters, mass meters and other instruments. 
• Pristine, like-new equipment, backed with a full warranty. 
• Customized solutions and expert customer service you can trust. 

It's all part of the package with TECO.

If you have failed mag meters, Coriolis meters, or other instruments, call TECO today. After receiving your equipment they'll turn around a quote in 48 hours or less - no return authorization required. To develop a customized solution for your needs, contact TECO.

Phone (504) 833-6381
Visit https://teco-inc.com

Flow Meter Designed for Corrosive Slurries, Acids, Bases & Solvents

TECO Severe Applications Meter (SAM)

A patent pending magnetic flowmeter with abrasion resistant ceramic trim that exceeds the capabilities of Alumina or Yttria Zirconia. Capable of withstanding a variety of corrosive slurries, acids, bases, and solvents.

800-528-8997

Severe Service Flow Meters by TECO

Get Your Process Flow Meters Remanufactured Instead of Buying New

Cutaway before and after of remanufactured flow meter.

Head scratcher. Why buy brand new flow meters when there are companies in the USA that have the trained technicians and facilities ready to remanufacture your old flow meters to a condition better than new?

Remanufactured flow meters meet or exceed all OEM specifications and performance standards. Here's how it works. Experienced technicians break down your flow meter to it's core components - flowtube, electronics, enclosure, flanges, and electrical. All parts are evaluated for wear and tear. All components are cleaned, primed, and painted. New electronics, flow sensors, liners, and electrical connections are installed. Once assembly is complete, the "remanufactured" flow meter goes through an exhaustive quality control process and is calibrated to NIST traceable standards using an advanced, state-of-the-art calibration facility.

Remanufactured flow meter.

All this is done very efficiently, quickly and cost-effectively.  You just ship your old instrument in to the attention of the "Repair Department". No RMA is required. The company evaluates your old flow meter and then generates a quote with delivery time for the remanufactured meter (normally within 48 hours).

Here is a summary of the benefits for choosing remanufacturing:

• All brands of flow meters are candidates.
• NIST traceable certificate is provided.
• Obsolete flow meters are no problem.
• No evaluation fees charged.
• Accessories are included.
• New warranty is given.
• Failure analysis is provided.
• Flow meters can be repurposed for severe service (enhanced during remanufacturing).
• Remanufacturing is GREEN and environmentally friendly.

For more information, visit this flow meter remanufacturing link or call 800-528-8997.

The Coriolis Effect: Understanding How Coriolis Flowmeters Work

The Coriolis effect, a derivative of Newtonian motion mechanics, describes the force resulting from the acceleration of a mass moving to (or from) the center of rotation. As this video demonstrates, the flowing water in a loop of flexible hose that is “swung” back and forth in front of the body with both hands. Because the water is flowing toward and away from the hands, opposite forces are generated and cause the hose to twist. Coriolis flowmeters apply this principle to measure fluid flow. To learn more about the Coriolis effect and how Coriolis flowmeters work, read this earlier post (http://blog.teco-inc.com/2017/01/understanding-coriolis-flow-measurement.html).

Contact TECO for any process flow requirement, including flow meter remanufacturing, custom flow solutions, full service repair, and calibration. http://www.teco-inc.com | 800-528-8997.

ifm Flow Switches and Meters

In almost all fields of process and plant engineering liquids or gases are used. For coolant and lubricant supply of plant and machinery, ventilation of installations and buildings and the processing of products. In case of no flow of these media considerable damage and downtime may result. Therefore it is important to monitor these media. In modern installations electronic flow monitors are used for this purpose. They work without wear and tear and without mechanical components. This guarantees reliable monitoring even in case of difficult media over a long period.

ifm, a leading manufacturer of industrial sensors and controls, offers a complete line of flow switches and meters.

Direct or remote mount:

• The SI flow switch mounts directly in process
• The SR and SN control monitors and sensing probes offer a modular and remote alternative

Mount in-line:

• The SM magmeter monitors conductive media up to 26 gpm
• The SU ultrasonic flow meter monitors water, oil and glycol
• The SQ flow meter measure small dosing quantities
• The SD flow meter monitors air and gas leaks
• The SL air flow switch monitors ventilation systems

Check out the video below for more information on ifm flow sensors. Thanks for watching.