FLEXIMOverview and Technology Distinguishers
Agenda
• Water and Wastewater Applications
• Flexim Advantages
• Transducer Selection
• Calibration and Temperature Compensation
• Mounting Solutions
• Types of Meters
• Applications
Introduction
Recent developments in the technology from Flexim• More simplistic installation and Easier set up
• Ability to operate where others will not
• No need to zero the meter by shutting off the flow when you
install NIST traceable wet calibration
• Drift free measurement - Temperature compensated transducers
• Stable Zero - Smart signal processing
• Shear and Lamb wave transducers - ability to measure liquid or
gas
• Maintenance free transducers in the field – “grease free”
Coupling pad
The Flexim meter accurately performs where others
do not.
Introduction
• In the past, many utility providers have used
ultrasonic meters with varying results.
• First Doppler, then Transit- Time. The Doppler
technique requires partials in the water that can
reflect the signal.
• Transit-Time measures across the flow stream from
one transducer to the other.
Flexim Advantages
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Flexim utilizes a fully digitized
signal of 50 to 200 points
depending on transducer frequency
range, ensuring a high quality
signal.
Other manufacturers use a single digital
mark in the average of the signal. The
digital mark movers based on changing
temperature and process conditions,
creating meter drift and often falling
outside of the meters detection limits,
which leads to loss of signal.
Flexim utilizes smart digital processing where the signal is digitized many
times over the entire sinusoidal wave, leaving no margin for error.
Flexim
Others
Better Signal Processing
• High noise suppression
- For high accuracy
- For short inlet and outlet
straight lengths
- For high moisture or solid
contents
- For small diameters (<DN25)
• Stabile zero
flow
(no zeroing
necessary)
• No drift
• No offset
• Up to 1000 signals per
second
• Fast signal processing
using
a digital signal processor
(DSP)
Cross Check Signal Processing
Cross Correlation
• Up to 1000 signals per second
are generated
• Fast signal evaluation with
DSP (digital signal processor)
• Time difference calculated by
cross correlation
excellent noise
suppression
whole signal is employed
• Resolution and Zero Stability:
• 1/4000 of a Signal period
0.75mm/s for a 16“ /
DN400 Natural Gas Line
Competitors Signal Processing
• Only 1 single point on the
signal is processed
• Manual adjustment of
crossover point
FLEXIM Unique Noise
Suppression
Signal Processing
1060 1080 1100 1120 1140 11601.
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• Digital signal processing of
full signal enables highly
efficient random noise
suppression
• Benefit: robust
measurement even under
difficult conditions
Transducer Design
• Stainless
steel housing
and cable
• SENS-Prom
Transducer
data
Calibration
data
• Matched
transducers
• Calibration
certificate
Transducer Technologies
• FLEXIM covers full application range
due to two different complementary
transducer technologies
• Maximum flexibility depending on
application specification.
• Shear wave transducer:
• All pipe wall materials
• All pipe wall thicknesses
• Lamb wave transducers:
• Multi Product Pipelines
• Changing Liquids – changing sound speed
(e.g. concentration)
• Viscous liquids
• FLEXIM offers two different
complementary transducer technologies
• Maximum flexibility depending on
application specification.
• Shear wave transducer:
• All pipe wall materials
• All pipe wall thicknesses
• Lamb wave transducers:
• Multi Product Pipelines
• Changing Liquids (e.g.
concentration)
• Viscous liquids
Transducer Technologies
Unique Transducers• Matched Transducers
– Piezo elements selected according
their parameters
– Stainless steel housing and cable
– SENS-Prom
– Transducer data
– Calibration data
– Enables primarily the drift free
measurement
– Eliminates zeroing
– Provides reliable measurement
values even under difficult
conditions
– ASME MFC-5M-1985 standard
– Switch to Noise Trek when
necessary
NIST Traceable Flow Calibration7407 and F601
Every meter is delivered with a multi- point wet
flow calibration and traceable calibration
certificate.
As a result of the high degree of attention to
accuracy, the installed accuracy of the Flexim
meter is typically better than 1% (“out of the Box”
Accuracy) with the capability of achieving
calibrateable accuracy of 0.25%.
No other ultrasonic meter company delivers this
Transducer Selection
K
M
2” 4” 8” 12” 24” 48”
Pipe Size
Transducer Selection
Connection System
• Junction Box / TS
– Easy to install
– Stainless steel
– Galvanic isolation
• Portable LEMO connector
– Rough industrial design
– Stored transducer data
– No mix up up/down stream
PermaLok
• Stainless Steel
• Tough Protection
• Avoids Interruptions
• Complete sealed from the
atmosphere
• Like spool without a spool
PermaLok
PermaStrap
PermaRail
Variofix
Flexim Meters
5107/5207
7407
Flexim Meters
Fluxus H20
coming Q3,
2013
F601
Portable Flow Meter F601
• Automatic detection of the
transducer type and
transmission of the
transducer calibration data
• Data logger with a capacity
of > 100,000 measured
values
• Supporting 6 transducers
(tuned filters)
• Carry Case – very smartly
designed
• 14 – 20hr battery
• Flow and Energy
• Transit-time and Doppler
FLUXUS F601 for Liquids
• Portable flowmeter
• 2 channel
• Integrated wall
thickness
measurement
• 4 Output/Input/Temp
• Transducer detection
• Data logger
• FluxData software
• RS – 232 Output
FLUXUS G601 for Gases
• Portable flowmeter
• 2 channel
• Lamb and Shear
Wave
• Integrated wall
thickness
measurement
• Transducer detection
• Data logger
• FluxData software
FLUXUS F601
• Portable flowmeter
• 2 channel
• I/O’s
• RTD’s, Electrical Inputs
• Integrated wall
thickness
measurement
• Transducer detection
• Data logger
• FluxData software
FLUXUS 7407 for Liquids
• 1 or 2 channel
• Data logger
• Transducer detection
• I/O’s 4 input, 4 output
(mA, binary …)
• Extremely fast pulse
output up to 1 ms
• FluxData software
Ultrasonic Measurement of Liquid, Gas,
Concentration analysis, Energy, & Extreme
Temperatures - 7407
The 7404 offers one or two flow
measurement channels.
It can be equipped with various outputs
and up to 4 process inputs. The input
quantities (e.g. temperature or pressure)
can be used by the flowmeter together
with the measured flow for the calculation
of further quantities: e.g. energy, mass
flow, etc.
FLUXUS 5107/5207 For Water
• Low Cost
Water,
Wastewater
Meter
• Integrated
Transducer
with 35ft
cable (no
armored
cables).
• Wet flow
calibration is
optional
• No Data
Logger
Ultrasonic Measurement of Water
Flow – 5107 & 5207
• Non-invasive flow measurement with high
measuring
accuracy for stationary use
• Precise bi-directional, highly dynamic flow
measurement
• Water-tight transducers (IP67) are
characterized by
their high robustness
• Simple retrofitting of measurements in existing
networks
and systems without interrupting the supply or
the need for pipe work
• User-friendly menu navigation - the firmware is
specifically
adapted to the needs of the water industry
• For nominal diameters of ½ “ to 98”
• Installation and commissioning can be carried
out
during operation
• Digital signal processor (DSP) and signal
processing
ensure stable and reliable results even under
difficult
measurement conditions
• High measuring accuracy, even at low flow
velocities
• Cost-efficient for large rated diameters
• Optional NIST tracable Calibration is done with
the flow computer and transducers
Coupling Pad
means years of
maintenance
free operation
Transit Time and Doppler
Mode
FLEXIM Flow meters are capable of both technologies:
• Transit time as standard for liquids with < 10% of gas /
solids
• NoiseTrek = combines Doppler method with signal
travelling time
– for liquids with > 10% of gas / solids
• Programmable automatic switchover between both
principles (HybridTrek mode)
Dual Channel Measuring
- Options
Purpose of dual channel measurements
• 2 measurements at the time
• comparison of 2 lines: e.g. Y = A – B
• sum up : Y = A + B
• averaging: Y = (A+B)/2
• redundance: Y = (A+B)/n = averaging when both channels
work, one channel when the other is disturbed
– valid measurement even under difficult
conditions (bubbles, particles)
– compensation of unsymmetrical flow profile
at short straight runs (< recommended
lengths)
> 10D
> 5D
Diagnostics
Purpose of Diagnostics:
• Full meter support in the field
• All diagnostic values are
– real-time displayed
– accessible via process interface
Optimizing Installation
• Idealized operation at
installation
• Minimize deviation to
ideal operation
Meaning of Diagnostics
Normal/optimal operation
during operation
• Long term monitoring by
observing changes
• Reliability, quality of
measurement
• Planning of maintenance
Availability of Diagnostics
Full meter support in the field:
• All diagnostic values are
– Displayed
– Can be driven via process interface
Data logger:
• Stores signal related and application diagnostic values for offline
analysis
• FluxData: read out and analysis
SnapView:
• Stores ultrasonic signal and diagnostics for offline analysis
– On manual request
– Automatically triggered
Wastewater Treatment
Plant Flow
InfluentCompliance flow meter to
match the final effluent
Collection SystemPumping stations need flow
measurement
Secondary ClarificationSludge removal, activated
sludge and wasted sludge is s
flow measurement opportunity
Chemical addition
For Disinfection Flow measurement of
Sodium Hypochlorite
Primary ClarificationFlow Measurement on Sludge
Activated and waste
AerationFlow measurement to the
aeration basin
Final EffluentCompliance monitoring of
what is leaving the plant, must
match the influent
Flow metering:
Collection, Clarification
Chemical Addition , Sludge
reactivation, Sludge removal
and Effluent
Nutrient RemovalFlow measurement of
Chemical addition
Chemical addition
To remove residuals Flow measurement Sulfur Dioxide
Grit RemovalSand and grit Removal
Wastewater Treatment
Metering Points
FF
F
F
F
F
F
F
F
City of Christchurch
Water Plant Flow
Water source
ground water
reservoir, or surface
Abstraction with
screens / course
filters
AerationPretreatment with Chlorine is
possible here
Chemical Treatment For Coagulation,
Flocculation and Fluoride
Chemical addition
For Disinfection Sodium Hypochlorite
Clarification
AdsorptionGranular activated carbon
FiltrationSand filter is most common
StorageWater tower or above ground
storage tank
DistributionWater pumped to the
customer
Flow metering at
every stage
Water Plant Flow
City of Saskatoon
F
FF
FF
F
FF
F
F
FF
F FF
F
F
Applications
The 5th largest utility in the nation has
issues with meters coating with magnetite.
Customer and Case
• The City of Jacksonville Florida has
extremely hard water and magnetite
coats the inside of magnetic flow meters
causing a short and meter reads low and
lower over time.
• JEA is the 5th largest utility in the Nation.
Application - Customer
Motivation
Potable water wells are monitored for depth, conductivity for salt water
intrusion and flow.
The World Class Magnetic flow meter company thought they had a
solution with their electrode cleaning circuit.
The magnetic flow meters came calibrated from the factory and worked
perfectly measuring water production wells for the first six months.
The flow meters began to drift downward after six months until they
read 50% of the actual flow after a period of one year.
When the 12 inch meters were removed from service, and the
electrodes cleaned with Vinegar, the meters once again read
accurately.
JEA has hundreds of meters and can not remove them and clean them
every six months.
Application - Measurement
Point
• A meter test was performed
between all ultrasonic
meters agains their meter
test standard.
• A newly calibrated
electromagnetic
flowmeter
• A newly calibrated
turbine flowmeter
• A graduated tank over
time.
• The utility tested the meter
over various flow rates
• The accuracy of the Flexim
meter was ± 0.9%
Application - Technical
Details Potable water
Re-Use water
Raw Sewage
8” – 36” Ductile Iron pipe with cement liner
60° to 80° F operating temperature.
26° to 100° F ambient temperature.
5 to 70 PSIG pressure.
Solution - Installation
Flexim single channel 5107 and 7404
meters
M transducers strapped directly to the
ductile iron pipe.
Permalok is used to protect the
transducers from the elements
4-20mA output for volumetric flow
Solution - Results
Based on previous testing,
customer recently placed
order for (36) complete
dedicated meters, and 2
portable meters.
Customer Benefits
Improved system reliability.
Installation is easy.
No special equipment and no down time.
The utility no longer has to remove the magnetic
flowmeters and clean them.
The utility managers can trust the readings.
Calibration of the meters satisfies the governing
authority.
The cost does not increase with the size of the meter.
Why Flexim?• Calibration – FLEXIM provides NIST traceable calibration certificate acc. ISO9001
• Temperature Compensation - RTD in transducer to compensate for temperature changes enables FLEXIM to meet ASME MFC 5M sect.3 requirements for temperature compensation, while all others do not.
• Application Guarantee - FLEXIM provides an application guarantee on all equipment sold. If it doesn’t work, we take it back.
• Sensitivity - The ZERO sensitivity of FLEXIM’s instruments will provide unprecedented sensitivity to the extremely low flowrates.
• Very large turndown - Dynamic range (0.01ft/sec to >80 ft/sec) and Diagnostic Rich outputs (Empty Pipe detection, and Aeration)
• Low flowing conditions - Because of this digital processing, Flexim provides accurate flow metering down to .03 ft/sec. Other meters cannot accurately measure flow in that low range. This is why their accuracy statements list such higher velocities.
• Dynamic Transducer Compensation - The Flexim meter has no zero calibration and no zero drift. All competitive units have some zero drift (both at constant and changing temperatures) in the meter which is dealt with by using a deadband cutoff. This deadband hides zero drift but the drift still produces an error in the reading that can be extremely large especially under off peak or low/no flow conditions that will exist at your well site. Flexim has engineered the drift out of the transducers including even the need to calibrate zero.
• Maintenance - Flexim has developed permanent coupling pads, eliminating the need for recoupling the transducers to the pipe. Set it and forget it. There is no need to maintain the transducers once they are attached to the pipe. With other meters, re-coupling the transducers may be required as often as every 3 to 6 months. It can be quite time consuming keeping up with 30 meters over the entire facility.
In Conclusion
I hope you enjoyed the presentation and learned something
about FLEXIM products
I encourage you to think right now about some application
issues you can solve with our non intrusive clamp- on meters
Feel free to call us anytime with questions
Thank You!
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