24/03/2013

Products Solutions Services

Vortex

Prowirl

Slide 1 SW Lim

24/03/2013

Vortex Applications

Vortex - Prowirl

Steam

Liquids

Gases

Slide 2 SW Lim

24/03/2013

Vortex Measuring Principle

Vortex - Prowirl

Slide 3 SW Lim

24/03/2013

All you need for vortex measurement

f = Vortex frequency

V = Volume flow

f ~ V

Bluff Body DSC Sensor

Transmitter

Vortex - Prowirl

Slide 4 SW Lim

24/03/2013

Differential Switched Capacitor Sensor

Vortex - Prowirl

Counter Electrode & Paddle have the same mass = perfectly balanced system = immune against vibrations

Laser welding not in touch with process = no corrosion

Trigger Level

Sign

al A

mpl

itude

The movement of the paddle generates sinusidal voltage change between Electrode 1 and 2

Electrode 2 Electrode 1

Slide 5 SW Lim

24/03/2013

Stable Strouhal Number = Excellent Performance

•The E+H bluff body guarantees a stable Strouhal number over Re 20’000 •The range from Re 4’000 to 20’000 should be avoided when sizing

Vortex - Prowirl

0.75% o.f.s 0.75% o.r.

Slide 6 SW Lim

24/03/2013

Measuring Range of a Vortex Flowmeter

1. Low flow limitation – Reynolds number • Vortex performs best at Re> 20,000 • Increase of viscosity due to low process temperature lower Re number • Small flow velocity lower Re number

2. Low flow limitation – density/velocity • Higher density and velocity creates stronger signal

Vortex - Prowirl

Slide 7 SW Lim

24/03/2013

Effects of build-up and abrasion

Radius because of abrasion

has no effect

Build-up has no effect

If no corrosion and operating at velocity's that could cause erosion (>50m/sec for abrasive gases) then the meter calibration is for life!!! Amplifier or Sensor changes do not influence the performance! *** Life-Time-Calibration ***

Vortex - Prowirl

Slide 8 SW Lim

24/03/2013

Vibration Immunity

Vortex - Prowirl

20 40 60 80 100 120 140 160 180 200 300 400 500

4

3.5

3 2.5

2

1.5

1

0.5

0

Z-Axis Y-Axis

X-Axis

X-Axis Z-Axis Y-Axis

Test proves vibration immunity: exceeds1g in all axes from 20 to 500 Hz

Acc

eler

atio

n (g

)

Frequency (Hz)

Slide 9 SW Lim

24/03/2013

High Resistance to Water Hammer

Puddle of water is shot against the meter if the rupture disc bursts due to high pressure

• Water hammer simulator at University of Karlsruhe

• Tested with water slugs up to 100m/s (>350 km/h)

• No effect on sensor performance or calibration

Vortex - Prowirl

Slide 10 SW Lim

24/03/2013

Vortex Temperature Shock Test

• Heating sensor to +400ºC

• Shock cooling in water +25ºC

• 3X reheating to +400ºC and shock cooling in liquid nitrogen -196ºC

Vortex - Prowirl

Slide 11 SW Lim

24/03/2013

Vortex Temperature Shock Test

Vortex - Prowirl

Slide 12 SW Lim

24/03/2013

Vortex- For liquids, gases and steam

Vortex - Prowirl

Promass 72 Volume Flow Measurement

Promass 73 • Temperature Measurement • Mass Flow Calculation

Prowirl • Measuring accuracy :±0.75% o.r. (liquid) ±1.00% o.r. (gas) • Process temperature: -200 to +400ºC • Process pressure up to 250 bar • Flanged version: DN 15 to 300 (1/2” to 12”) • Wafer version: DN 15 to 150 (1/2” to 6”) • Nominal Diameter Reduction version saves cost and add flexibility • Dualsens: single body meter with two transmitter for redundancy

measurement

Slide 13 SW Lim

24/03/2013

The two sensors for Prowirl 72 and 73

• Prowirl 72 comes with the reliable and proven paddle sensor for volumetric flow measurement

• Prowirl 73 also has additionally

an integrated temperature sensor (PT1000) for mass flow calculations of: • liquids • Saturated steam • gases at constant pressure

The same type of sensor is used for all meter sizes means cost reduction of spare part handling

Vortex - Prowirl

Slide 14 SW Lim

24/03/2013

Common Vortex Installation

About 70% of all vortex installations require a reduction of line size, including:

1. reducer 2. min. 15 DN straight run (inlet) 3. Vortex 4. min. 5 DN straight run (outlet) 5. expander

1. 2. 3. 4. 5.

Vortex - Prowirl

Slide 15 SW Lim

24/03/2013

All of this is replaced now – by one flow meter! with the same specifications…

Vortex - Prowirl

Prowirl F sensor DN100/4” standard

Prowirl F sensor DN100/4” R Style reduced by one line size to DN80/3”

Prowirl F sensor DN100/4” S Style super reduced by two line sizes to DN50/2”

DN100

DN100 to DN80

DN100 to DN50

Slide 16 SW Lim

24/03/2013

Prowirl F, FR, FS “Dualsens”

• The Dualsens model has one single meter body with only one bluff body but two individual sensors and transmitters

• The model is used in applications where

redundancy of a measuring point is required • When a plant/process can’t be shut

down in case of a failure (e.g. boiler mains)

• When a critical process variable needs crosschecking with a second value

Vortex - Prowirl

Slide 17 SW Lim

24/03/2013

Steam Measurement with Prowirl

• Because of the technological advantages of Prowirl most of its applications can be found in steam metering

• About half of all Prowirl are installed in steam applications • Temperature shocks and water hammer at startup require an extremely

robust flow meter such as Prowirl • The Prowirl measures the volumetric flowrate of steam accurate and

independently of process conditions • The Prowirl 73 can additionally compute the massflow of saturated steam

Vortex - Prowirl

Slide 18 SW Lim

24/03/2013

Vortex - Prowirl

What type of steam is measured? 1. Saturated steam >85% of Vortex steam applications

• In most industries used for heating and to be added to processes • Density is defined by either pressure OR temperature • Process conditions usually 4…15 bar /145…200°C • Saturated steam sometimes becomes slightly overheated. This leads to

small errors if not considered

2. Superheated steam Normally measured with a Dp solution • Used for high energy flow i.e. power generation • To define density pressure AND temperature is needed • Process conditions often >300°C and pressure >80 bar

3. Wet steam • Not commonly used in process industries • Difficult or impossible to measure because of likely 2nd phase flow • Prowirl is able to measure steam qualities better 95% (vol.)

Slide 19 SW Lim

24/03/2013

Vortex Solutions for Steam Mass Flow

Prowirl 72 Constant Process

Conditions

Prowirl 73 Sat. Steam Measurement

with Integrated T-Measurement

Price

Func

tiona

lity

Prowirl 72 + RMS + p-Sensor + T-Sensor

Superheated Steam

Prowirl 73 with HART Input

Superheated Steam

Vortex - Prowirl

Slide 20 SW Lim

24/03/2013

Limitations in Vortex Steam Applications

1. Nominal Bore • In power generation and very large main line after the boiler sizes >NB

300 are installed • Diameters larger NB150 versions in general are quite expensive compared

with other technologies

2. Hi Pressure • High pressure versions of Prowirl cover up to PN250 but are limited to

max. NB150 • High pressure versions are generally more expensive then dP solutions for

this applications

3. Hi Temperature • Whilst saturated steam applications are well below 400°C superheated

steam is occasionally even higher in temperature

Vortex - Prowirl

Slide 21 SW Lim

24/03/2013

Installation requirement

Vortex - Prowirl

Slide 22 SW Lim

24/03/2013

Vortex - Prowirl

Flow conditioner to reduce inlet run

Slide 23 SW Lim

24/03/2013

Vortex - Prowirl

What should be improved?

Slide 24 SW Lim

24/03/2013

Prowirl 73F – Saturated Steam in Chemical Plant

Vortex - Prowirl

• Borden Chemicals

• Brisbane, Australia

• Saturated steam

• Prowirl 73F

• Remote electronics for easy access

Slide 25 SW Lim

24/03/2013

Prowirl 72F – High pressure steam

Vortex - Prowirl

• Saturated steam, wet

• Pressure 110 bar/1635 PSI

• Temperature 320 °C/610 °F

• Flow Range 680 kg/h /1500 lb/h

• Prowirl 72F:72F40-S92AA1NAB0AW

• NB 1 ½” and 2” Cl.1500 TSP flanges

Chevron Bakersfield, California

Slide 26 SW Lim

24/03/2013

Superheated Steam

Vortex - Prowirl

• Internal Billing Application in chemical industry

• Superheated steam measurement

• V, T and P wired to flow computer

• Mass calculation of superheated steam

Slide 27 SW Lim

24/03/2013

Prowirl 72F – Demineralized Water

Vortex - Prowirl

Measurement technology: • PROline Prowirl 7x

Process: • Monitoring the flow rate of demi-

water for controlling the desalination plant.

• Medium: Demineralized water • Operation: max. 2 bar, max. 25°C

Features: • Compact device with flanges for easy

instrumentation without extra equipment.

• Wide turndown of up to 40:1 for safety flow rates while fluctuate process.

• Proven capacitive sensor and the „Vortex“ system itself for long term accuracy.

Slide 28 SW Lim

24/03/2013

Prowirl 72F Dualsens – Liquid Bitumen

Vortex - Prowirl

• Chemical plant

• Liquid bitumen

• 300°C

• Dualsens model

Slide 29 SW Lim

24/03/2013

Prowirl 72F – Liquid Nitrogen

Vortex - Prowirl

• Ossigeno, Switzerland

• Road tanker unloading

• Several temperature shocks of >200 °K / week

• Liquid N2

• -190 °C, 10 bar

Slide 30 SW Lim

24/03/2013

Prowirl 72F - Liquid Nitrogen

Vortex - Prowirl

Slide 31 SW Lim

24/03/2013

Advantages and Limitation

Vortex - Prowirl

Advantages • High pressure range • Suitable for gas, steam and

liquids • High temperature range • Independent of gas properties

Limitations • Sizes max. DN 300 • Min. flow limitation

Slide 32 SW Lim

24/03/2013

Products Solutions Services

Any Questions?

Slide 33 SW Lim

24/03/2013

Products Solutions Services

Thank you very much for your attention

Slide 34 SW Lim