Important Flowmeter Performance Metrics

Animation of differential flow

Common to most flowmeters are rated levels of performance; some of the more universal
performance metrics include accuracy, precision/repeatability, turndown ratio, resolution, ease of installation, straight pipe run requirements, on-going operations and maintenance, and costs.

Accuracy
Accuracy is the difference between a measured value and the actual value. No flowmeter is 100% accurate and most manufacturers provide a range of accuracies in their product line - tighter accuracy requirements are typically more expensive and may also be more restrictive to specific applications.

Precision/Repeatability
The precision or repeatability of a measurement entails the ability to reproduce the same value (e.g., flow rate) with multiple measurements of the same parameter, under the same conditions.

Turndown Ratio

Rotameter
(ABB)

The turndown ratio refers to the flow rates over which a meter will maintain a certain accuracy and repeatability. For example, a steam flow meter that can measure accurately from 1,000 pounds per hour (pph) to 25,000 pph has a turndown ratio of 25:1. The larger the turndown ratio, the greater the range over which the meter can measure the parameter within the accuracy stated.

Resolution
The resolution is the smallest increment of flow that can be incrementally registered by the meter. For example, a water meter designed for a small diameter pipe may be able to provide a resolution of 100 pulses per gallon (or more) as a signal output, but a meter designed for a larger pipe or higher maximum flow may only be able to provide 1 pulse per 100 gallons. Further, a very large flow meter may only be able to provide 1 pulse per 1000 gallons. The metering system may have limitations with regard to peak signal frequency or minimum time between pulses to properly register the data signal.

Ease of Installation
Select make-and-model decisions considering size and weight constraints, specific electrical and communications needs, and the overall environment the flowmeter will operate in.

Magnetic flowmeter
(TECO)

Straight-pipe Run Requirements
Applicable to some types of fluid (gas, liquid and steam) flowmeters, straight-pipe run requirements relate to the length of unobstructed straight pipe required leading up to and immediately following the flow meter’s location. Obstructions in the fluid flow (such as elbows, tees, filters, valves, and sensor fittings) cause changes in the flow pattern (flow regime and velocity profile). Straight-pipe runs allow the flow pattern to normalize/stabilize making measurements by velocity-type and differential-pressure-type flow meters less prone to measurement error. Straight-pipe run requirements are usually expressed in terms of the number of pipe diameters.

The straight pipe requirement is in addition to the length of the flowmeter itself. The straight-pipe run requirements can be reduced with the addition of flow straightening or flow conditioning devices installed upstream.

Ongoing Operations and Maintenance

Vortex flowmeter
(ABB)

The lowest cost flow metering technology may not be the best choice if it has high associated maintenance costs (e.g., frequent service, calibration and recalibration, sensor replacement). As with most capital purchases, a life-cycle cost approach (including all capital and recurring costs) is recommended for decision making.

Installation Versus Capital Cost
In some situations, the cost to install a flowmeter can be greater than the capital cost; this can be true where system shutdowns are necessary for flowmeter installations, or where significant redesign efforts are needed to accommodate a flowmeter’s physical size, weight, or required connection. In these cases, decision makers should consider alternative technologies that may have a higher capital cost but a much lower installed cost. A good example of this is the use of non-intrusive flow metering technologies (e.g., ultrasonic flowmeters) that typically have a high capital cost but often a significantly reduced installed cost. It is recommended that meters be installed with isolation valves or switches making it easier to remove, replace, or service the meter in the future.

Reprinted and abstracted from US Department of Energy paper titled "Metering Best Practices: A Guide to Achieving Utility Resource Efficiency, "

Severe Service Magmeters for Fracing Operations

Proven in the heat of a West Texas summer, and the cold of an Alberta winter, this TECO magmeter is designed from the ground up to withstand corrosive slurries, acids, bases and solvents.

Severe Application Meter (TECO)

Magnetic flow meters (magmeters) installed on blender trucks are of particular concern. The application involves accurately measuring the flow of an extremely erosive slurry comprised of sand and “frac water” (a mixture of water and harsh chemicals). Replacing failed magmeters can take up to 4 hours, and requires the shutting down of the entire frac spread.

Calling upon sixty-plus years experience in magmeter application, failure analysis, repair, and design, TECO developed several innovative magmeter features intended to improve longevity in fracing operations.

FRAC Trucks

First, TECO developed a ceramic sleeved liner made of “magnesia partially stabilized zirconia”, a very tough ceramic used in severe-service applications that provides corrosion resistance and durability.

Second, TECO developed electrodes built from a solid tungsten carbide billet, which afford unparalleled wear resistance. Given the sand density in the frac fluid, noise reduction is critically important; so, the tungsten carbide is polished leaving a hard, smooth finish that significantly reduces noise in the electrode circuit.

Erosive sand tears up
other magmeters. 

Finally, TECO designed the magmeter as a drop-in replacement. It operates with a variety of secondaries and matches the “lay length” of the meter being replaced. There is no need for a new transmitter and no need for repiping, allowing for simple retrofit in existing installations.

Internal view of SAM after 500,000,000
pounds of sand flowed though the core.
Upon inspection, the customer found the
flow tube to be looking “brand new”.

In 2017 TECO introduced the SAM (Severe Application Meter) magmeter as a flow meter designed specifically for hydraulic fracturing operations. By specifying SAM, operators save money through increased uptime; decreased health, safety and environmental risk; and reduced costs related to magmeter purchase and repair.

Download the PDF version of this article here.

Contact TECO by visiting https://teco-inc.com of call 800-528-8997 for more information.

Oval Gear Flow Meters: Accurate, Robust, and Long Life

Although there are many types of flow meters used to measure fluid flow rates, positive displacement (PD) designs, including Oval Gear flow meters, are unique as they are the only meters on the market that directly measure actual volume. All other metering techniques infer the volume by making a type of measurement and equating it to the flow rate.

One of the key criteria in selecting the right flow meter is the degree of accuracy dictated by the application. To meet high-precision requirements in various industrial environments, Oval Gear flow meters fit the bill. These meters feature a wide flow range, low pressure drop and extended viscosity range. Oval Gear flow meters offer easy installation and high accuracy, plus measure high temperature, viscous and caustic liquids with simple calibration.

Oval gear flow meters are simple and robust. They operate by interlocking two oval gears, offset by 90 degrees, inside the meter housing which are then rotated by the flowing media. They are very rugged and designed to operate in very harsh environments. Accuracy is maintained irrespective of temperature, viscosity change, or flow pulsation. It's not unusual to see these meters perform in the field for upwards of 40 years.

Flow path and operation of Oval Gear Flow Meter

Oval Gear flow meters are an excellent choice for any number of industrial applications including:

• Chemicals
• Petrochemicals
• Water and Wastewater
• Oils and Diesel Fuel
• Pulp and Paper
• Paints and Coatings
• Printing

Download Oval Gear flow meter brochure here.

For more information on Oval Gear flow meters visit https://teco-inc.com or call 800-528-8997.

Compact and Ultrafast Response Temperature Transmitters: The IFM TA2

Traditional temperature sensors are constructed from multiple components, assembled and calibrated together. The assembly and calibration of the components is time consuming and requires a high level of skill. These temperature instrument assemblies, due to their open design, are susceptible to moisture, corrosion and other environmental conditions which are a major cause for instrument stress.  Furthermore, periodic maintenance for verification of calibration is needed, adding costs that directly affect profitability.

IFM's innovative TA2 temperature instrument solves this problem. Constructed of 316 stainless steel, this fully laser welded,  one piece hermetically sealed instrument is rated IP69K. There are no points of ingress to cause drift or damage the sensor and they are fully calibrated during manufacture and ready to use right out of the box. The sensor is pre-scaled in various popular ranges and fully scaleable to custom ranges using the IO-Link communication and programming tool.

With a compact 3-1/4" diameter and 1-1/2" long housing, the TA2 installs into the tightest locations. A bright led located in the M12 connector gives visible indication that the sensor is operational. Wiring is conventional 2-wire loop power for easy installation.

The IFM TA2 transmitter line is available both with standard threaded process connections for standard applications, and the popular sanitary process connection, for applications in the food and beverage industries.

Finally, the TA2 temperature transmitters dramatically reduce response time. The standard fast response unit can react to 50% of the temperature change in less than 1.0 second, and just 3.0 seconds to 90%, while the ultrafast versions react in just 0.5 seconds and 1.0 seconds, respectively.

For more information on the IFM TA2, call TECO at 800-528-8997 or visit https://teco-inc.com.

What Customers Say About TECO

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

Top 5 Reasons TECO Consistency Transmitters Stand Above the Competition

1. TECO Consistency Transmitters are shipped with built-in flow-rate compensation. This is important because blade style consistency sensors are sensitive to shifts in production flow-rate. This means that their output has a component which is strictly a function of flow-rate. If this isn’t compensated for, changes in flow-rate will look like changes in consistency. TECO Consistency Transmitters include a flow-rate input so that this flow-rate function which automatically gets applied to the consistency signal. This feature is unique to TECO.
2. The key feature of our C3000 and C5000 probe style sensors is that they aren't sensitive to flow-rate changes to begin with. The C3000 and C5000 are insensitive to shifts in production flow-rate below 3.0 fps. This means that as long as the flow-rate stays below 3.0 fps, shifts in flow-rate will not produce any negligible affect on the probe output signal. For flow-rates above 3.0 fps when using C3/5000 series sensors, it is recommended that active compensation be used.
3. The C5000 sensor is retractable, allowing it to be removed from an active process. This feature is particularly useful when installed in hostile measurement environments, such as blow lines and bleach plant operations. The retractable feature allows for quick change-out when it comes time for replacement, allowing the restoration of a critical measurement in minutes, instead of waiting weeks or months for a scheduled shutdown. This is a strong competitive advantage for C5000 users.
4. All TECO sensors are hot-swappable, saving the time and effort of a recalibration procedure when a sensor is replaced. All that is required is use the built-in normalization procedure and "zero" the replacement sensor. Your new sensor is ready to use.
5. TECO consistency transmitters can be upgraded to act as a consistency controller, or function as multi-input controller, so that other process parameters can be adjusted for in the consistency control loop.

More Reasons:

• TECO consistency transmitters can also be set up as a dilution controller.
• 100% Made in the USA. 
• TECO consistency transmitters are very competitively priced.

More information at https://teco-inc.com

800-528-8997