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[File Name or Event]Emerson Confidential27-Jun-01, Slide 2

IntroductionIntroductionIntroduction

Flow Measurement Essential to Accounting andEnergy Management

Flow Meter Performance Dependent onInstallation Practices!!!

Traditional Methods of Engineering often Sub-

Optimize Technology Best Practice Principles help Optimize

Measurements & Improve Energy Tracking

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Best Practices Dramatically ImproveFlow MeasurementBest Practices Dramatically ImproveBest Practices Dramatically ImproveFlow MeasurementFlow Measurement

Traditional Flow Installation

Utilize diagnostics toenable predictive

maintenance

OK OneLine

TwoLines

Minimize pressure loss

Minimizepiping

requirements

Quantify andoptimize

installedperformance

12.0%0.0% 4.0% 8.0%

Eliminate

impulselines

Measure mass

flow in gas &steam

Select in-lineflowmeter for smallerline sizes & insertionflowmeters for larger

line sizes

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Todays Discussion


Minimizepiping

requirements

Eliminateimpulse

lines

Measure massflow in gas &

steam

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Todays Discussion


Minimizepiping

requirements

Eliminateimpulse

lines


steam

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Direct Mounting Improves Consistencyand therefore accuracyDirect Mounting Improves ConsistencyDirect Mounting Improves Consistencyand therefore accuracyand therefore accuracy

Traditional Installation DP Flowmeter Installation

Eliminates inaccuraciesConsistent installationsReduced complexityLeak points reduced

No leak testing

Instrument Tubing is 10 to 20 feet long,plus several elbows Increased potential leak points and plugging

Transmitter is direct-mounted less than 1foot from the pipe, with straight connections Reduces potential leak points and plugging

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Removing Leak Points Saves Time and MoneyDirect Mounting Reduces Leak PointsRemoving Leak Points Saves Time and MoneyRemoving Leak Points Saves Time and MoneyDirect Mounting Reduces Leak PointsDirect Mounting Reduces Leak Points

All but 2 potential leakpoints factory leak-

checked.

1 leak = $1214/yearin wasted pump energy*

*U.S. Dept. of EnergyOffice of Industrial Technologies

www.oit.doe.gov/bestpractices

Energy to compress fluid escaping through leak iswasted and costs $$

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Removing Leak Points Saves Time and MoneyDirect Mounting Reduces Leak PointsRemoving Leak Points Saves Time and MoneyRemoving Leak Points Saves Time and MoneyDirect Mounting Reduces Leak PointsDirect Mounting Reduces Leak Points

All but 2 potential leakpoints factory leak-

checked.

$1214/year energy per leak PLUS: Value of lost process fluid Personnel safety and risk

Environmental cost, impact Cost of inaccurate measurement Maintenance cost of repairing leaks

*U.S. Dept. of EnergyOffice of Industrial Technologies

www.oit.doe.gov/bestpractices

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Direct Mounting is Easier to EngineerReduced Implementation CostsDirect Mounting is Easier to EngineerDirect Mounting is Easier to EngineerReduced Implementation CostsReduced Implementation Costs

+

+

Design/Specify/Procure/Assemble

30 different parts

Traditional Installation

+

Design/Specify/Procure

Single Integrated Assembly

DP Flowmeter Installation

Typical

installed costsavings = 30%

Line Sizes to > 72 inches

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Todays Discussion


Minimizepiping

requirements

Eliminateimpulse

lines


steam

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Difficult to Find Enough Straight PipeDifficult to Find Enough StraightDifficult to Find Enough StraightPipePipe

Nearby Valves, Elbows, Ts, Fittings Interfere withFlow Meter Installation Requirements

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Flow Meter Specified Straight Run to MeetAccuracy RequirementsFlow Meter Specified Straight Run to MeetFlow Meter Specified Straight Run to Meet

Accuracy RequirementsAccuracy Requirements

AveragingPitot Tube

Conditioning

Orifice

1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435363738394041424344

V-Cone

0.65 Ratio for DP Primary Elements

Magmeter

Nozzles OrificeVortex

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Conditioning Orifice Plate TechnologyOverviewConditioning Orifice Plate TechnologyConditioning Orifice Plate TechnologyOverviewOverview

Traditional Orifice Plate

Up to 75 Diameters

Flow Accuracy:

1.0%

7D44D

2D2D

2D2D

Conditioning Orifice Plate 4 Diameters

Flow Accuracy: 0.7%

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Conditioning Orifice Plate is More AccurateIncreased Design FlexibilityConditioning Orifice Plate is More AccurateConditioning Orifice Plate is More AccurateIncreased Design FlexibilityIncreased Design Flexibility

2" line size with a 0.4 Beta

2D straight run withInduced swirl

-1.0%

-0.5%

0.0%

0.5%

1.0%

2.0%

3.0%

4.0%

5.0%

6.0%

7.0%

8.0%

0 20000 40000 60000 80000 100000 120000 140000 160000

Bore Reynolds Number

Dev.

from

StraightRunTest

Flow Test Data Book Available on Request

Standard Orifice 405C Conditioning Compact Orifice

C diti i O ifi W k i Diffi ltC diti i O ifi W k i Diffi ltC diti i O ifi W k i Diffi lt

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Conditioning Orifice Works in DifficultInstallationsConditioning Orifice Works in DifficultConditioning Orifice Works in DifficultInstallationsInstallations

Boiler Plant Modernization Measurement of steam supply to

various campus facilities

Needed to measure in short-runs

Installed 2 pipe diametersfrom two out-of plane elbows Also installed 3095MV

w/conventional orifice (60D) as areference meter

3095MFC tracked within 1.0% ofthe reference meter

Application Information

Product: 3095MFC Mass Flowmeter

Line Size: 4 sch 40 Installation: 2 out of plane elbows

Fluid Type: Saturated Steam

Flow Rate: 1000 to 8000 lb/hr

Press / Temp: 125 psig / 350 F

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Conditioning Orifice has 2 Flexible PlatformReduced Installation and Modular DesignConditioning Orifice has 2 Flexible PlatformConditioning Orifice has 2 Flexible PlatformsReduced Installation and Modular DesignReduced Installation and Modular Design

2 to 8 lines

Cd Uncertainty: 0.5% for 0.4and 0.75% for 0.65

3-valve, direct-mount head Fits between standard flanges

Packaged as Volumetric or MassIntegrated Flowmeter

Compact Design

2 to 24 lines (to 72 as Specials)

Cd Uncertainty: 0.5% for 0.4and 0.75% for 0.65

Fits between orifice flanges Retrofits existing installations

Packaged as EngineeredAssembly Integrated flowmeters

Orifice Plate Design

R d V tRed cer Vorte

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Reducer VortexReducer VortexMeasures lower than any other Vortex meterMeasures lower than any other Vortex meter

(ft/s)0.5 1.0

Traditional Vortex = 0.7 ft/s to 25 ft/s

Reducer Vortex = 0.3 ft/s to 12 ft/s

Rosemount Reducer Vortex Measures the Low Flows missed by Traditional Vortex Meters

0.0

Missed Flow

Traditional Vortex = 0.7 ft/s to 25 ft/s

Reducer Vortex = 0.3 ft/s to 12 ft/s

50 10 252015(ft/s)

R d VR d V t

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Reducer VortexReducer VortexReduces Project Risk and Engineering CostsReduces Project Risk and Engineering Costs

Face-To-Face dimension matches line-size Vortex

Calibrated in Flow Lab = No impact on accuracy

No reduction/expansion or new straight pipe = lower cost

Easier to fix if flow changes from sizing conditions = lower risk

B t P ti D ti ll IB t P ti D ti ll I

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Todays Discussion


Minimizepiping

requirements

Eliminateimpulse

lines


steam

B t P tiB t P ti

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Best PracticeBest PracticeMinimize Pressure LossMinimize Pressure Loss

Pressure at Destination < Pressure at Source

Destination

FT4

BoilerPL1

PL2

PL3

PL4

PL5

PL6

PL7Energy In

Machine #1

Machine #2

Machine #3

Machine #4

FT6

FT5

FT7

FT2

FT1

FT3

Source

Lowering Pressure Loss

1. Reduces pumping/compressing Costs

2. Increases Capacity

3. Minimizes Compressor, Pump or Boiler Size

Orifice/Nozzle/

Vcone

Vortex AveragingPitot Tube

Magmeter

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AnnubarTechnology OverviewAnnubarAnnubar Technology OverviewTechnology Overview

Patentedintegralthermowell

Stagnationports in quietzone reduces

noise

Direct Mount Platform 0.75% Accuracy

Insusceptible to wear,

warp, and plugging

Easy installation

Can be hot-tapped

Low Permanentpressure loss

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PPL(psi) = ENERGY = OPERATING COST

> 3:1 Ratio

TechnologyDP at Max

Flow (inH2O)

PPL

(inH2O)

Energy

(hp)

Orifice - Beta =0.7 100 54.4 4.012

Annubar - Sensor 25 43 16.8 1.239

Vortex - 4 Inch N/A 27.2 2.006

Line size = 4 Inch Pressure = 50 psig Min/Norm/Max = 250/1500/ 2500 SCFMExample: Air

0

500

1000

1500

2000

Orifice Vortex Annubar

$

Average Flow

Max Flow Reduce Energy by:50% with Vortex ($980)

67% with Annubar ($1360)

B t P ti D ti ll IBest Practices Dramaticall Impro eBest Practices Dramatically Improve

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Todays Discussion


Minimizepiping

requirements

Eliminateimpulse

lines


steam

Best PracticeBest Practice

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P = 38 2 psi


Measure Mass Flow in Gas and SteamMeasure Mass Flow in Gas and Steam

RegulatorP = 40 psi 20 ft

(6 m)

4 Saturated Steam LineFlowrate = 7500 lb/hr

RegulatorDroop

PipeFriction*

Barometric

Variation

ManufacturersSpecification

20 ft pipe2 elbows

Typical

variation

0.55 psi 1.0%

0.92 psi 1.7%

0.5 psi 0.9%

Total 1.97 psi 3.6%

Max Variation

* Per Crane Handbook

Pressure Varies over Flow Rate -Pressure Varies over Flow RatePressure Varies over Flow Rate --

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Pressure Varies over Flow Rate -not constant and NOT repeatable!Pressure Varies over Flow RatePressure Varies over Flow Rate not constant and NOT repeatable!not constant and NOT repeatable!

Pressure Variation vs. Flow Rate

0

1

2

3

4

0 25 50 75 100

% Flow

%P

ressu

reVariation

Barometric

Friction

Regulator/Header

Total

Barometric

TOTA

L

Friction

Regulator

3.6%

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Error in Density Equals Error in Mass FlowError in Density Equals Error in Mass FlowError in Density Equals Error in Mass Flow

0 1 2 3 4

Uncompensated

Velocity

Uncompensated

DP

Multivariable

3.6%

1.8%

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Flow Error Costs MoneyFlow Error Costs MoneyFlow Error Costs Money

0 1 2 3 4

Uncompensated

Velocity

Uncompensated

DP

Multivariable

3.6%

1.8%

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MultiVariableMultiVariable Technology makesTechnology makescompensation easy and affordablecompensation easy and affordable

MassProBarMassProBar

AnnubarAnnubarfor largerfor larger

line sizesline sizes

DP Press Transmitter

GP Press Transmitter

Temperature Transmitter

Temperature Sensor

Thermowell

Temperature Wiring

Manifold

Hook-Up Hardware

Flow Computer

Indicator

Totalizer

Logging

MultivariableMultivariable

TransmittersTransmitters

MassProPlateMassProPlate

orifice meter fororifice meter for

smaller line sizessmaller line sizes

M ltiV i bl TM T h l M kMultiVariableMultiVariableTMTM Technology MakesTechnology Makes

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MultiVariableTMTechnology MakesCompensation Easy and AffordableMultiVariableMultiVariableTMTM Technology MakesTechnology Makes

Compensation Easy and AffordableCompensation Easy and Affordable

Multivariable Vortex Delivers Value in SaturatedSteam Flows

TemperatureTransmitter

Temp SensorThermowell

Indicator

TotalizerTemperature Wiring

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Flow Computer Complements MV VortexFlow Computer Complements MV VortexFlow Computer Complements MV Vortex

Rosemount FlowComputer also available

P&T compensated mass

flow in superheated steamand gases

Energy calculations (Btu/hr)

Data logging and peak

demand calculations

Remote communications(RS-485 / Modbus)

Temp compensated massflow for liquids

Pulse =

Flow

PressureTransmitter

4-20 =

Temp


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Measure Mass Flow in Gas and SteamMeasure Mass Flow in Gas and Steam

*Conditions:

Natural Gas

Flange-tap Orifice Plate

D = 3 inch Sch 40

d = 1.897 inchesT = 60 F

100 inH2O

2.9% repeatability error2 psi pressure change

P = 20 psig 1000 SCFM

P = 22 psig 1029 SCFM

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SummarySummarySummary

Effective Energy Management Depends onAccurate & Repeatable Flow Measurement

Ensure Good Installed Accuracy

Flow Meter Installation Matters a Lot!!!

Simplify Piping Practices

Reduce or Eliminate Impulse Lines Compensate for Pressure & Temperature Changes in

Gas & Steam

Flow Meter Itself is an Energy Consumer

Consider Pressure (Energy) Losses in MeterSelection

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Energy ManagementEnergy ManagementMeasurement Best PracticesMeasurement Best Practices

Joel LemkeAmericas Marketing Manager, DP Flow

IDEA 98thAnnual ConferenceScottsdale, Arizona

June 2007

2B3_Lemke

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