Permanent Multipath Clamp-On Transit Time Flow Meter

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1 Permanent Multipath Clamp-On Transit Time Flow Meter By: Dr. J. Skripalle HydroVision GmbH, Germany Introduction For many years now, ultrasonic flow measurements with wetted sensors have been a well established procedure to measure discharge in big pipes in the field of hydro power plants. A lot of research studies show that very precise measuring results can be achieved, under the provision of correct application and consideration of diverse ancillary conditions. Depending on the flow conditions and the definition of the task, systems working in one or several paths are used. Either the sensors are installed inside the pipe wall (internal) or installed from outside (insertion) by drilling holes into the pipe. By doing so, the acoustic path can be aligned in specific planes, which cover the measurement of the velocity profile throughout the cross section of the pipe. Using modern integration procedures (OWICS), the single velocities are weighted and the flow is calculated with reasonably high accuracy. Typically an accuracy of +/-0.83% can be achieved when a straight length of at least 5 pipe diameters is between the measurement section and any bend or change in pipe diameter upstream and 3 pipe diameters downstream of any important irregularity. It could be better if more straight lengths are available. For a new penstock, a wetted sensor system can always be considered because it gives the chance to work on the dewatered pipe. But for operational power plants, especially old and very old power plants, installing a wetted sensor would be highly challenging and most of the time, the idea to measure flow accurately is dropped. Even in the new power plants, many times the designers are reluctant to suggest a wetted sensors system, because of possible maintenance requirements, abrasion of sensors due to high silt conditions etc, and hence, the flow measurement in the penstock is Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 1/10

2 compromised. This paper will discuss the multipath clamp-on technology and explain why it is superior in many applications where drilling and internal mounting of the sensors is not allowed by the operator and where are excessive silt/abrasive materials in the flow that will damage the sensors. Path Arrangement The flow meter consists in minimum of one pair of transducers, with a set of clamp-on assembly (Figure 1) that enable the transducer to be mounted on the outside of the pipe. For larger pipes, the transducers of the clamp-on flow meter are mounted in such a way that the ultrasonic signal goes straight across the pipe. Figure 1: Single path clamp-on transducer with mounting assembly Measurements with a crosswise arrangement of acoustic paths reduce the influence of cross flows. Further improvement in the measuring result can be obtained by arranging an appropriate number of acoustic crossed paths in various planes. These arrangements have special advantages under unfavourable flow conditions or if the lengths of inlet and outlet sections are insufficient thereby preventing the creation of specific flow profiles. Arrangement of the single path or multi-paths is theoretically possible in the entire range of the angle of inclination 0 < < 90 (Figure 2). Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 2/10

3 Figure 2: Crossed-paths arranged in one or multiple planes Transmission Characteristics The huge advantage of clamp-on sensors lies in the fact that no mechanical invasion to the pipe is necessary and therefore the sensor does not come in direct contact with the fluid flow. The sensors are clamped to the outside of the pipe. On the other side reflection, refraction and mode conversion occur at the interface between the coupling socket and the pipe wall and then, in addition, transversal and longitudinal waves are generated in the pipe wall. These waves are converted into longitudinal waves again at the interface between the pipe wall and the water. Since each wave has a different propagation velocity, the ultrasonic sound transmitted in water contains multiple waves and gets complicated. To avoid multiple waves, the transmission angle of the transducer and the coupling material has to be chosen in such a way that the longitudinal part of the wave is entering the pipe wall exactly tangential. This helps to reduce the type of waves present in the pipe wall (Figure 3). Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 3/10

4 Figure 3: Optimized transmission angle However, propagation of sound is much more complex than what is shown here. Also the layer of coupling between the transducers and the pipe is an important factor as it is important that there is a good acoustic contact between the two materials. It is necessary that good contact is maintained between the transducers and the pipe at all times in order to achieve reliable signal strengths. The clamp-on socket should incorporate a fully removable transducer for refreshing the acoustic coupling gel between the transducer and the pipe wall without changing the adjustment of the socket itself. Geometrical Parameter A critical part of the installation of the flow meter is mounting the transducers at the correct distance. This distance is calculated by applying Snell s Law and depends on various input data such as pipe material and pipe dimensions. It is important that the transducers are set at this correct distance and are aligned to the axis of the pipe since the clamp-on method relies on accurate geometrical parameters. Any error in pipe wall Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 4/10

5 thickness, pipe diameter and distance between the transducers will result in a compounded error in discharge. For example, an error of 0.1 in path angle will lead to 0.9% in discharge, and an error of 0.5 in path angle will lead to 5% in discharge. For this, sound velocity of the pipe material, the wall thickness and the diameter of the pipe should always be measured at the site. Available drawings with planned pipe diameter and wall thickness should be rejected. In order to find the right position of the sensors, or to measure the already installed transducers correctly, a new method which is based on the principle of spatial triangulation of pictures can be applied. The portable 3D measuring device consists of a high resolution digital camera as acquisition device. The object to be measured is marked at all geometry relevant points with targets first. In a second step the object is captured from different viewing directions to get a complete coverage of any kind of object. These images are processed with a powerful software on a standard notebook to calculate the 3D coordinates of all relevant geometry points. No pre-calibration is necessary due to an integrated simultaneous calibration procedure. This commercial system is highly flexible at limited space and allows the analysis of the real position at the site with an accuracy of +/- 0,015 mm/m. Flow Calculation Method In clamp-on methodology, the physical mounting limitation does not allow the external sensor to be fitted in a multi-plane configuration, hence the ultrasonic paths are not in different planes, but are radially passing through the central axis of the pipe. Figure 4 illustrates the axial planes of the clamp-on system and the parallel planes of the wetted sensors system, installed after a 90 elbow. Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 5/10

6 Figure 4: Ultrasonic paths for clamp-on (left) and wetted sensors (right) Only for a path arrangement with a single plane the integration methods according to Gauss-Jacobi or OWICS can be applied. When using multiple planes, new methods have to be developed for clamp-on sensors to calculate the discharge, especially under unfavourable flow conditions. HydroVision implemented a modern numerical model in their flow meter to calculate online the 3D velocity distribution. Input parameters are the measured velocities in the different paths, the fact that in pipe axis the velocity in all paths is equal and that the velocities at the pipe wall are zero. In addition, a normalized velocity distribution is part of the model, based on the actual outline of the pipe, calculated in advance for various flow conditions and entered into the system. Application Note In 2008, four multi-path clamp-on flow meters were installed at a pump-storage plant in Austria. It has a 1.2 km long tunnel from the reservoir up the hill down to three Pelton type turbines. The difference in altitude is 710 m, the pipe diameter of the tunnel is 3.8 m Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 6/10

7 and it is at a longitudinal slope of One flow meter is installed at the end of the tunnel for leak detection (together with an existing flow meter with 4 path internal mount wetted sensors up the hill). The outer diameter of the pipe is 3.95 m, a steel coated pipe of wall thickness of 72 mm. Three other flow meters are installed in front of each turbine for process monitoring. Here the outer diameter of the pipe is 1.99 m with a wall thickness of 46 mm. All sites are instrumented with four acoustic paths (Figure 5). The challenges included the request to install into an existing system without physically altering the pipe. The meters used have to be capable of operating during the 3 phases used Turbine mode, Pump mode and Hydraulic Short Circuit mode, provide continuous monitoring, and require very low maintenance. Figure 5: Pump storage plant with flow meter location Figures 6 and 7 illustrate the transducer arrangement and the clamp-on assembly with a guided block for transducer installation to assure correct positioning of the path angle. This block also ensures proper reinstallation of the transducer in the correct position if the transducers are removed for maintenance purposes. Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 7/10

8 Figure 6: Clamp-on arrangement, 4 paths crossed Figure 7: Clamp-on assembly with guided block for transducer installation In December 2008, tests were performed to check the accuracy of the flow meters. Separate runs under different flow conditions have been carried out by measuring the discharge with the flow meters and by calculating the discharged volume in the lower reservoir of the pump storage plant. A test performed between 16:00 to 18:30 o clock is shown, using 171,740 cubic meters of water. Figures 8 and 9 shows the measured time series and summarize the result in form of the integrated discharged volume. Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 8/10

9 Figure 8: Time series and integrated volumetric flow rate Figure 9: Integrated volumetric flow rate Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 9/10

10 The leak detection clamp-on flow meter measured 172,500 cubic meters with an accuracy of % while the turbine clamp-on flow meter measured 171,500 cubic meters with an accuracy of %. The flow meter with wetted sensors installed at the beginning of the tunnel measured 169,670 cubic meters with an accuracy of %. This result should not indicate that a clamp-on flow meter is better than a system with wetted sensors as measuring inaccuracies have to be considered in the volume of the reservoir, too. But the results give confidence that with a well installed clamp-on flow meter, with adapted acoustic transmission and modern flow calculation methods, accurate measurements can be achieved. Summary and conclusions This work is being carried out to understand the effect of various parameters on the accuracy of a clamp-on ultrasonic flow meter. This paper has focused on the issue of transmission characteristics, the geometrical parameters and the flow calculation methods. Additionally, an application note of an already installed clamp-on flow meter was given, inclusive drop test to compare the overall accuracy. The results to date are encouraging and give confidence. Ultrasonic clamp-on flow meters can be used to meet plant monitoring and documentation requirements by providing highly accurate and continuous flow rate measurement. The flow meter can be configured for multiple acoustic paths, making them highly accurate over a wide range of changing flow conditions. The hot work is totally eliminated, thus it offers the ease of installation, and since the sensors are non-wetted, the abrasion and effects due to high siltation are avoided. Moreover, the plant can use one system to check various penstock discharges from time to time. Water Power XVI, July 27-30, 2009, Spokane, Washington USA Page 10/10

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