Performance Evaluation of Ultrasonic Flow Meters in NIST’s ...

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Performance Evaluation of Ultrasonic Flow Meters in

NIST’s Smokestack Simulator

Liang Zhang

National Institute of Metrology, China

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Performance Evaluation of USM in NIST’s SMSS

Smokestack Simulator of NIM China

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Flue Gas Ultrasonic Flowmeter

,d

,

, ,

cos

cos

1 12cos

ii

i

ii

i u

ii

i i d i u

Lc vtLc vt

Lvt t

θ

θ

θ

+ =

− =

⇒ = −

Path Velocity Multi Path USMDiametric Path

Mid-Radius Path

2

12

N

v i ii

q R W v=

= ∑

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USM Evaluation Using CFD Simulation

Calculate the flow field in the SMSS using CFD

Estimate the performance of different USMs

Give recommendation for the path layout of spool

piece

Provide users with a reference when selecting USM.

Use for extrapolate the SMSS test result to real

stack.

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CFD Simulation Method

Test SectionReference

MeterLocation

ReferenceSection

Inlet Cone

Dref

Dtest

x y

z

ϕ

0°

90°

180°

270°cross section

z

y

Meshing: Ansys Meshing, patch independent tetrahedral, 14.7 million

cells, 20 layer prism mesh at the boundary , Y+ around 1

CFD Simulation: Fluent, 3D, steady state

Fluid: Incompressible air, constant density, constant viscosity

Turbulence model: Realizable k-ε, Enhance Wall Treatment

Boundary conditions: Pressure inlet, Exhaust Fan

Solution Method: SIMPLEC

Second order

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CFD Flow Field in SMSS

38.0 m/s36.1 m/s34.2 m/s32.3 m/s30.4 m/s28.5 m/s26.6 m/s24.7 m/s22.8 m/s

17.1 m/s

20.9 m/s19.0 m/s

15.2 m/s13.3 m/s11.4 m/s

7.60 m/s9.50 m/s

5.70 m/s3.80 m/s1.90 m/s0.00 m/s

ReferenceSection

Inlet Cone

Test Section

D ref

D testx

Figs.5A & C Figs.5B & D

Fig.4ReferenceFlow MeterLocation

5 D test

10 D test

13.2 Dref

ϕ

180°

270°

90°

0°

ϕ

180°

270°

90°

0°

Plane 1

Plane 2 Plane 3

ϕ

180°

270°

90°

0°

ϕ

180°

270°

90°

0°

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Mid-Radius USM Error Analysis Method

( )

USM act

1

1 1

1 1 1 1

1

tan

tan

lim lim tan

lim

n

i ai ci c reali

n n

i ai c real i ci ci i

n m m n

i ai c j aj c j aj c real i ci cm mi j j i

n

i ai c j aj cmi j

E Q Q

w v v S Q

w v S Q w v S

w v S w v S w v S Q w v S

w v S w v S

θ

θ

θ

=

= =

→∞ →∞= = = =

→∞=

= −

= − −

= − − = − + − −

= −

∑

∑ ∑

∑ ∑ ∑ ∑

∑1 1 1

lim cot tanm m n

i cj c i ci cm j i

w v S w v Sθ θ→∞= = =

− −

∑ ∑ ∑

Ai’

Ai

Vc

Vaθ

θ

Y

X

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Mid-Radius USM Error Analysis Method

Ai’

Ai

Vaθ

Axial Velocity Integral Error

11 1

limn m

i ai c j aj cmi jE w v S w v S

→∞= =

= −∑ ∑

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Mid-Radius USM Error Analysis Method

Transverse Flow Projection Error

31

tann

i ci ci

E w v Sθ=

= −∑

Ai’

Ai

Vc

Vaθ

θ

VcP

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Mid-Radius USM Error Analysis Method

Axial Velocity Changing Error

Ai’

Ai

Vc

Vaθθ

VP

/ sinPc

QVS θ

=

21

lim cotm

i cj cm jE w v Sθ

→∞=

= − ∑

Q Sc

Y

X

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Mid-Radius USM Error Analysis Method

Cross Path/Plane Compensation

1, 1,

1 1lim cot tan

2 2 2

B A B Am ncj cjA B ci ci

AB j c i cm j i

v vE E v vE w S w Sθ θ→∞

= =

−+ −= + +∑ ∑

Ai

Vc A

Ai’

Vc B

Bi

Bi’

1,ABE 2,ABE 3,ABE

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Velocity Impact on Measurement In the velocity range of 10m/s to 25m/s, velocity dose not have

obvious impact on USMs measurement errors

Cross Path Diametric USM 4*2 Path Mid-Radius USM (Gauss-Jacobi)

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Flow Profile Correction Factor

( )( )( )

( )

13 68

1

3 62

0.237 3 63

1 0.2488 Re 3 10 Re 10

1.119 0.011 log Re 3 10 Re 5 10

1 0.01 6.25 431 Re 3 10 Re 10

K

K

K

−

−

= + ⋅ × ≤ ≤

= − ⋅ × ≤ ≤ ×

= + + ⋅ × ≤ ≤

Flow profile correction factors (FPCF)

PA45º, AB Cross-Path IA=0ºPA45º, A Single Path IA=0º

L. C. Lynnworth, 1989

J. C. Jung et al., 2000

Korean Nuclear Society, 2001

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Error Analysis of Diametric USMsEt E1

E2

Installation Angle 0º

Installation Angle 90º

E3

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Integration Methods for Mid-Radius USMs

Path Angle 45º, 15m/s, IA=0º Path Angle 45º, 15m/s, IA=90º

Gauss-Jacobi and Optimized Weighted Integration for Circular Section

(OWICS) are the most accurate integration method for USMs in

circular pipes.

For 2*2 path USM, the measurement error of OWICS USMs decrease

quicker than Gauss-Jacobi USMs.

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Error Analysis of Mid-Radius USMs–PN 2&4

Et

E3E2

E1

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Error Analysis of Mid-Radius USMs–PN 4&8Et

E3E2

E1

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Error Analysis of Mid-Radius USMs–PN 3&6

IA=0º Et IA=90º Et

Staggered path USMs transverse flow error compensation effects

depend on the flow field in the pipe and path layout.

OWICS, Path Angle 45º, 15m/s

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Impact of USM Path Angle

1 1 1 1

1 1 1

lim lim cot tan

lim 2sin 2

n m m n

i ai c j aj c i cj c i ci cm mi j j i

n m ni cj c

i ai c j aj cmi j i

E w v S w v S w v S w v S

w v Sw v S w v S

θ θ

θ

→∞ →∞= = = =

→∞= = =

= − − −

≈ − −

∑ ∑ ∑ ∑

∑ ∑ ∑

E1 of different path angle USM depend

on the flow field in the pipe

2-4 path single plane USM may have the

minimum absolute E2+E3 in 45º path

angle

For cross-plane USM, the E2+E3 can be

partially or completely canceled out, it

depends on the distribution of

transverse velocity in the pipe.

Ai

Vc A Vc B

Bi’

θ

Ai’Bi

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Conclusion

Flowrate have little effect on the measurement errors of diametric

path and mid-radius path USMs

USMs measurement errors reduced with the increase of upstream

straight pipe length

Using cross-plane or cross-path USM configuration, measurement

errors introduced by transverse flow can be totally or partially

compensate

Optimization of the USM installation angle will reduce the

transverse flow velocity component in the path, especially for a

single plane USM

Diametric USMs integration errors are significantly greater than the

mid-radius USMs

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Conclusion

For diametric USMs, using dual cross-path do not obviously

enhance the USM performance compared to cross-path USM.

Overall, the measurement errors of OWICS USMs are lower than

Gauss-Jacobi USMs, especially when the path number is low

Mid-radius path USMs measurement errors decrease with the path

number increase

For a single-plane USM, usually in 45º path angle, measurement

error introduced by the transverse flow may reach the smallest

value.

Recommendation for spool piece: cross plane mid-radius USM

using OWICS integration method

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Performance Evaluation of USM in NIST’s SMSS

Smokestack Simulator of NIM China

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Smoke Stack Simulator of NIM

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Smoke Stack Simulator of NIM

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Components Smoke Stack Simulator

Reference Section

Test SectionAxial Fan

Expansion & Contraction

Tubulence & Swirl Generator

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Primary Standard

Dual LDA Primary Standard

DN800 (31.5Inch)

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LDA Velocity Area Method3D LDA

1D LDA

Boundary LayerLDA

1D LDA

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Pitot Tube Calibration Section

Pitot Tube Calibration Section

TubulenceGenerator

Yaw Angle

Pitch Angle

Pitot Tube

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USM Working Standard

Working Standard:DN800 8-Path Flowsic600

Ultrasonic Flowmeter

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Test Section

Test SectionDN1000 Circular Pipe

1*0.7m Rectangular Pipe

DN700 Circular Pipe

8-Path Flowsic100Ultrasonic Flowmeter

Pitot Tube

Yaw Yaw

Swirl & TurbulanceGenerator

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Completion Time: November 2015

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Thank you for your attention

[email protected]