Name: dpn60291_a_1_Ilko
Uploaded: 2022-10-24
Duration: 7 min 29 s
Description: dpn60291_a_1_Ilko. Non-invasive Steam Flow Measurement as an Energy Medium by Clamp-on Ultrasonic Method in Context of Energy Management Concept Implementation, Optimization and Safety.

dpn60291_a_1_Ilko. Non-invasive Steam Flow Measurement as an Energy Medium by Clamp-on Ultrasonic Method in Context of Energy Management Concept Implementation, Optimization and Safety. 

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Non-invasive Steam Flow Measurement as an Energy Medium by Clamp-on Ultrasonic Method in Context of Energy Management Concept Implementation, Optimization and Safety

33rd DAAAM International Symposium| Hosted by Vienna University of Technology, Vienna, Austria, EU

Paper Authors:  Jan Ilko, Miroslav  Rusko  & Jaroslav  Demko

Non-invasive Steam Flow Measurement as an Energy Medium by Clamp-on Ultrasonic Method in Context of Energy Management Concept Implementation, Optimization and Safety. 

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Test  measurements   of   steam   flow   with   ultrasonic   flow   meter   for   the   development   of   energy   balancies   and   the  design  of   optimization   plans . Providing  application   model   for   energy   management   implementation   concepts   and   the   safety   aspects .  Demonstrate   innovative  technology  in  field   of   industrial   measurement .  Preparing   of   collected   data   for   further   research   and   deployment   of  such  technology  in  industrial   practice   to   increase   process   efficiency   and  operational  safety .

33 rd  DAAAM International Symposium – Virtual Edition | Intelligent Manufacturing & Automation: Digitalisation as a new development wave

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Steam  is widely used mainly in industry, but it also finds its place in the energy, pharmaceutical, medical, and other sectors. To monitor consumption, optimize utilization, energy balances and reduce losses, it is necessary to measure its flow reliably and as accurately as possible. Until now, this has been performed by measuring devices that use conventional flow measurement methods, such as e.g., measuring orifice together with differential pressure gauge, etc. All these methods are invasive ones and the integration into the system, repair, or maintenance, require the medium to be redirected to bypass, or in the worst case, shut down of a production section or whole operation. Non-invasive ultrasonic flow meters do not interfere with the process and there is no need to change the operation in any way, which brings huge benefits as financial savings and significantly increases the reliability of the technological process and safety at work.  	In  case of energy management, precise flow and energy monitoring has a significant place in the whole schematics to provide reliable input data for further proceedings. Nowadays, the ISO 50 001 is a common concept to lead to energy efficiency in a proper and reliable way.

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For our test measurement a clamp-on ultrasonic portable flow meter was used.  Clamp-on ultrasonic flow meters have the potential to be applied to existing pipes. Therefore, they have been widely used in industrial plants for measuring liquid and gas flow rates. Their principle is based on the time-of-flight (TOF), which changes with the flow velocity along the propagated ultrasonic pulses. Thus, flow rate is obtained based on the transit time difference of the ultrasonic pulses between upstream and downstream sensors. To measure the flow rate accurately, the transmitted ultrasonic signals must be detected. However, the measurement is difficult in the case of steam flow because ultrasonic attenuation in steam is higher than in liquid. Furthermore, the large difference in the acoustic impedance between the pipe material and steam results in a lower intensity of the transmitted ultrasonic signal for clamp-on ultrasonic flow meters. Thus, measuring liquid flow rates is easier than measuring gas flow rates using the clamp-on system

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For our test we used portable unit  Fluxus  G601ST with ultrasonic sensors GRK1SC3. Before implementing of the ultrasonic sensors, the thermal insulation of the pipe must be dismounted in proper length. The surface of the pipe must be painted with special noise-damping varnish as shown  on the figure.

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Variofix  mounting brackets were used for sensor fixation on the pipe. Both brackets must be mounted in precise opposite position as shown by  the figure.

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By transit time method the sensors need to be heated up on minimum 100 °C to get signal. This can take one hour until the sensors reach the limit. In our case, the sensors were preheated on the surface of another steam pipe on 70 °C to shorten the time of heating up. Before starting of the measurement, the control unit to be configured on proper process parameters. After the parameterisation, the ultrasonic flow meter unit software leads the operator through diagnostic parameters to ensure the reliable measurement. Software supplied by the flow meter producer allows the operator to see the shape of the ultrasonic signals with the diagnostic values, simultaneously. Such screen is shown on the following picture.

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There is an internal data logger integrated in the flow meter unit. In our case, the data logger was set to store the data as average in ten minutes intervals.  Graphical  interpretation of the data  is shown in following graph.

Volumetric flow rate [m³/h] 44472.213541666701 44472.220486111102 44472.227430555598 44472.234375 44472.241319444402 44472.248263888898 44472.255208333299 44472.262152777803 44472.269097222197 44472.276041666701 44472.282986111102 44472.289930555598 44472.296875 44472.303819444402 44472.310763888898 44472.317708333299 44472.324652777803 44472.331597222197 44472.338541666701 44472.345486111102 44472.352430555598 44472.359375 44472.366319444402 44472.373263888898 44472.380208333299 44472.387152777803 44472.394097222197 44472.401041666701 44472.407986111102 44472.414930555598 44472.421875 44472.428819444402 44472.435763888898 44472.442708333299 44472.449652777803 44472.456597222197 44472.463541666701 44472.470486111102 44472.477430555598 44472.484375 44472.491319444402 44472.498263888898 44472.505208333299 250.96710920333899 252.695256471634 258.83982181549101 256.91965520381899 263.44825923442801 261.91210448741901 259.22386050224299 263.06422054767597 251.92717909812899 253.65535318851499 270.74491381645203 251.92717909812899 243.28638911247299 243.86244714260101 231.381297111511 223.31655174493801 206.034958362579 206.611016392708 204.306811094284 204.69083636999099 203.346714377403 190.673545002937 179.72853630781199 187.985301017761 175.50415098667099 167.247399687767 163.98309767246201 166.671341657639 165.711258351803 149.19772893190401 155.726332962513 139.40483629703499 153.23010832071299 144.973343610764 142.86114424467101 124.235428869724 134.41237360239001 142.28509962558701 132.10815489292099 130.379994213581 126.92368626594499 121.547184884548 128.26780825853299

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Using the software supplied by the flow meter producer, there is possibility to generate a report with the uncertainty of the measurement. The uncertainties are shown in the Table  below.  Graphical evaluation of the measurement uncertainty is shown in the  figure at the next slide.

Standard uncertainty component Source of uncertainty  Value of standard uncertainty  Sensitivity factor Flow velocity 0.10 m/s  0.37 m/s  1.36 m/s  5.00 m/s  Transit time difference 9.682e -8  s  3.582e -7  s  1.317e -6  s  4.841e -6  s  u(x i )    u(x i ) u r (x i )=u(x i )/x i c r,i =c i *x i /ύ Contribution   |c r,i u r (x i )| u(K Re ) Flow profile   0.28 % 1 0.28 % 0.28 % 0.28 % 0.28 % u(A) Cross sect. area   0.08 % 1 0.08 % 0.08 % 0.08 % 0.08 % u(K α ) Acoustical cal. factor   0.96 % 1 0.96 % 0.96 % 0.96 % 0.96 % u(Δt) Transit time difference 6e -10   1 0.62 % 0.17 % 0.05 % 0.01 % u(t o ) Delay time   0.37 % 0.03 0.01 % 0.01 % 0.01 % 0.01 % u(t tr ) Transit time    0.01 % -1 0.01 % 0.01 % 0.01 % 0.01 % Standard uncertainty   u r (ύ)=u(ύ)/ύ                                                                                                                            1.18% 1.02% 1.00% 1.00% Expanded uncertainty 2.36% 2.03% 2.00% 2.00%

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02
0.3
0.4
0.6
FW velxity [misl
1.0
1.6
4.0

Graphical  evaluation of the measurement  uncertainty:

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The  measurement was done without any problems or data interruption. The signals SCNR and SNR are in stable and proper level, normally the SCNR should be kept higher than 25 dB to get the real and correct data. SNR is the signal provided by the electronics to be kept around 10  dB.  One of the most important diagnostic parameters is the sound speed of the media shown in the Table 1. This value must correlate to the sound speed value awaited at the real media temperature. When it is correlating then the measurement is precise and provides correct measurement results. The data are compared to an existing older in situ flow meter and they are correlating what makes place for modernisation of the process control using ultrasonic technology. 	Such  system provides very high precision of calibration and of course very high precision in the process. This system called transit time is nowadays suitable only for the steam parameters between 130 and 200 °C but there is a new principle invented by Flexim to be able to measure high temperature steam using non-invasive ultrasonic principle, so called CFM.

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The goal of this measurement was to perform the steam flow measurement with innovative clamp-on ultrasonic measurement technology for balances and the design of optimization plans. Second target was to use collected data for further research and deployment of such technology in industrial practice to increase process efficiency and operational safety. One of the big advantages of clamp-on technology is the possibility to change the measuring point without any process interruption. This type of flow meter has the possibility to also measure gases and liquids as well. These units are calibrated by the producer using a special kind of calibration, invented by the producer itself, where the fluid is in stable state and the sensors mounted on a moving system with very precise movement control are moving on the surface of the calibration fluid.  Results of this study were presented to specialists from energy management as a progressive measurement method of measurement to be implemented in energy strategy plans. Ultrasonic monitoring systems by specific configuration allow to monitor the energy consumption and have a potential for implementation in energy consumption reduction concepts in industry and facility management as well. Comparing to standard heat energy monitors is higher  in the  price  but  precision and technical and mechanical properties do this kind of measurement devices high valued and comfortable mounting and operation.

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