Vortex Training

1
Vortex Training

• Market Analysis, Background Information, New
  Electronics - Features, Options, Diagnostics

2
Vortex Training

• Vortex Meter Market
• Size and growth projections
• Major Markets
• Background Information
• Theory and operation
• Product information
• New Features
• Electronics
• Velocity pickup
• Wiring
• Software
• Communications
• HART
• MODBUS
• Fieldbus
• FF
• PROFIBUS PA
• Diagnostics
• Simulation Program

3
Vortex Meters - Marketplace

• Projected Size and Growth

4
Vortex Meters - Marketplace

• Major Markets by Region

5
Vortex Meters - Marketplace

• Projected Sales by Type

6
Vortex Meters - Marketplace

• 2005 Market Share Estimates

7
Major Markets

• District Heating
• Steam Flow
• Chilled Water
• Hot Water
• Industrial Markets
• Steam Flow
• Industrial bulk gas
• Compressed Air
• Natural Gas
• Gas Vapors
• Petroleum derivatives

8
Vortex Meter Background

• In 1911 he made an analysis of the alternating
  double row of vortices behind a stone, bluff
  body, in a fluid stream, now famous as Kármán's
  Vortex Street. This happens when the fluid that
  flows around a body fails to stick to the shape,
  but instead breaks off behind it into a wave. He
  also noted that the distance between the vortices
  was constant and depended solely on the size of
  the rock that formed it.

• Theodore von Karman

9
Examples of Karmans Vortex Street

• Well use a heated plate as the Bluff Body. The
  heat will provide the images using a thermal
  camera to view the generation of the vortices.
• In the first example of Von Karman Vortices, a
  heated plate with a thick initial thermal
  boundary layer is accelerated to 5 m/s in air. 
  The boundary layer is swept downstream and rolls
  up into a pair of shed vortices.  Temperature
  contours are shown in the movie making the flow
  visible

10
Example of Karmans Vortex Street

• Continuation from previous slide

11
Examples of Karmans Vortex Street

• Vortex formation in Nature
• Vortices formed off of Gaudalupe Island

12
Examples of Karmans Vortex Street

• Vortex Formation in Nature
• Flagpole acts as bluff body

13
Additional Findings

• Von Karman also discovered the following
• Shedding frequency ? Fluid velocity!

14
From Nature to Meter Velocity Calculation

• Putting it all together
• Vortices are alternately shed off a bluff body at
  a constant wavelength the wavelength is
  determined by the bluff body width
• Shedding frequency is proportional to velocity
• Then

V velocity
f frequency
D Bluff body width
St Strouhal number (dimensionless number used
to characterize flow)
15
Strouhal Number

• The Strouhal number is the ratio between the
  vortex wavelength and the shedder bar width.
• It is a Reynolds number dependent variable but
  experiments have shown that at Re numbers above
  10,000 it is essentially a constant

16
Linear Range Re Number vs Strouhal Number
17
Simplifying the equations

• St constant
• D shedder body width constant
• Rearranging the equation
• K calibration factor (meter factor)
• Calculated during calibration

18
Physical Measurement

• To become a meter we must measure the frequency
• Two helpful facts
• Vortices are alternately shed
• A vortex is a low pressure zone

19
Physical Measurement

• First vortex is generated
• Low pressure zone creates a DP across sensor
• Sensor is loaded in the direction of the vortex
• Next vortex passes on opposite side of sensor

20
Physical Measurement

• Piezo-electric crystals
• Generate a charge when loaded
• Charge converted to a signal
• Electronics measure frequency of signal
• Electronic calculate velocity from frequency

21
Physical Measurement
22
Physical Measurement
23
What does all this mean?

• Now that we have solved the velocity to frequency
  relationship we can arrive at
• Q volumetric flow rate
• A cross sectional area of pipe (meter body)
• V velocity

24
Temperature and Pressure

• Temperature
• 1000 ohm Platinum RTD
• Pressure
• Solid state Pressure Transducer
• Located behind the velocity pickup
• Proven using multi port sampling valve and
  numerous tests

25
Mass Flow Measurement

• Compensated Volumetric Flowrate (SCFM)
• s Standard conditions (1 atm, 70 F)
• a Actual conditions

26
Pressure Temperature Compensation

• Tables pre-programmed for
• Water, Steam, Air, Ar, NH3 (Gas Liquid), Cl2
  (Gas Liquid), CO, CO2, He, H2, CH4, N2, O2
• Other Gases Liquids
• Use Equations of State
• Real Gas Law
• API 2540
• Goyal Doraiswamy
• AGA 8

27
Sizing Considerations Liquid Low Flow

• Low Flow Major Consideration
• Liquids
• Reynolds Number limitation - typically liquid
  limiting factor
• Minimum Measurable Velocity, Amplitude
  typically associated with gas and steam

28
Sizing Considerations Gas and Steam Low Flow

• Low Flow Major Consideration
• Gases
• Reynolds Number limitation - typically liquid
  limiting factor
• Minimum Measurable Velocity, Amplitude
  typically associated with gas and steam

29
Sizing Considerations High Flow

• Liquid High Flow Limitation
• Gas and Steam High Flow Limitation
• Resonance of the velocity tab is the limiting
  factor on the high flows note that the ½ and
  ¾ meters have a limit of 180 fps and 230 fps

30
Insertion Reynolds Number Correction

• Insertion Meters are designed to dynamically
  correct for pipe size and Re number
• The larger the pipe the less total flow the
  insertion head sees
• The higher the velocity the more constant the
  flow profile
• The meters electronics takes into account the
  pipe size, the insertion depth and the predicted
  flow profile to compute the average flow reading
  throughout the meters range

31
Vortex Key Points

• Vortex Meters are inherently linear no square
  root extraction etc.
• The shedding phenomena is independent of flowing
  media, i.e. gas, liquid, steam thus the meter can
  be calibrated on water and used on a gas by
  simply programming it for the fluid
• No Moving Parts No drift over time

32
Key Points

• Temperature and Pressure Compensation
• More than just a multi-variable
• Ability to dynamically calculate density and to
  adjust for low Re numbers below 10,000 remember
  the curve
• Ability to measure mass flow with a single
  penetration
• Multiple outputs from a single penetration

33
Inline Meter
34
Insertion Meter
35
Product Portfolio

• Volumetric Meter
• Inexpensive option
• Liquid applications
• Sold on cost and relationship
• Multiparameter Meter
• Multiple outputs
• 3 analog, 3 alarm, 1 pulse and HART
• Options Modbus, EMS ( Energy)
• Sold on technological merit
• Most commonly used on gas and steam
• Energy option
• Input options temperature, pressure, alarm,
  etc.

36
Product Approvals

• Sierra Innova vortex meter approvals
• FM/FMC Class I Div 1, Groups B,C,D
• FM/FMC Class II/III Div 1, Groups E,F,G
• Canadian CRN
• ATEX submitted approval expected July or August
  2007
• PED work in progress expected July or August
  2007

37
Product Portfolio

• Inline
• Flanged - ½ to 8 (DN15-DN200) designs for 10
  and 12 in near future
• Wafer - ½ to 4 (DN15-DN100)
• Materials of construction Carbon Steel,
  Stainless Steel, Hastelloy
• Insertion 2 and up (DN50 and up)
• NPT
• Flanged
• Packing Gland
• Hot Tap with Retractor
• Materials of construction Carbon Steel,
  Stainless Steel, Hastelloy

38
Product Portfolio

• Future Designs
• Reducer for inline meters already sold as a
  special expected fourth quarter 2007
• Different materials of construction
• Plastic inline
• Plastic insertion
• Specials Capability
• High pressure flanged bodies
• Special ANSI pipe schedules
• Face to face dimensions

39
Competitive Comparison

• Yokogawa
• Product offering Inline only
• Flanged ½-12
• Wafer ½-4
• Multivariable with Temperature only
• EH
• Product offering Inline only
• Flanged - ½-12
• Wafer ½-6
• Multivariable with Temperature only

40
Competitive Comparison

• Rosemount
• Product offering Inline only
• Flanged - ½-12
• Wafer ½-4
• Multivariable with Temperature only
• ABB
• Product offering Inline only
• Flanged - ½-12
• Wafer - ½-4
• Multivariable with Temperature only

41
Competitive Comparison

• Pricing N.A. list prices
• Example 2 150LB Flange SS No Display
  Volumetric only
• Yokogawa Price 1850
• Rosemount Price 2050
• EH Price 1750
• Sierra Price 1840

42
Competitive Comparison

• Pricing N.A. list prices
• Example 2 150LB Flange SS Local Display
  Volumetric only
• Yokogawa Price 2132
• Rosemount Price 2300
• EH Price 2030
• Sierra Price 2000

43
Competitive Advantage

• Sierra Innova vortex product line
• Widest range of meter configurations
• Inline Meter
• Insertion Meter
• Low cost alternative to large inline meter
• Little competition from major manufacturers
• Multiparameter Technology
• High Accuracy Repeatability
• Multiple Outputs
• Wide fluid ranges, gas, liquids, steam
• Little to no competition sell on technological
  merit
• Volumetric Technology
• Ability to address low end commercial market
• Competitive cost structure

44
Competitive Advantage

• Sierra Innova vortex product line
• Mechanical Features
• Low Mass cantilevered velocity tab
• Minimizes pipe stress effects
• Low mass-small area design increase noise
  immunity
• Design allows the sensor to be potted eliminating
  triboelectric affects
• Signal Processing
• New predictive filter techniques
• Able to accurately predict amplitude and
  frequency from entered information to set filter
• Better flow signal resolution
• Driven cable allows for a greater signal ampitude
  and minimizes the triboelectric affect

45
New Product Features - Electronics

• Velocity Pickup
• 4 A/D converters with constant gain vs Variable
  Gain and 1 A/D converter
• Reduces the possibility of amplifying noise
• Better signal resolution
• Loop Powered Mass
• 24X Loop Power and HART
• Same as 22X with the addition of TP

46
New Product Features - Electronics

• Wiring Layout
• Backlight for 22X and 24X Loop Powered meters

47
New Product Features - Electronics

• Wiring Layout
• High Power DC
• Option 1 and Option 2 can be used for external
  inputs, i.e. pressure, temperature etc.

48
New Product Features - Electronics

• Wiring Layout
• 24X AC powered units now have a DC out terminal
• Optional input terminals for external pressure,
  temperature or discrete alarm input
• DC layout similar without the DC out option

49
New Product Features - Software

• Communications
• HART Standard on volumetric, loop powered mass
  and mass meter
• MODBUS optional output can be ordered on any
  configuration except that it makes the meter a
  high power unit no longer loop powered
• Fieldbus
• Profibus PA working with a consulting firm
  expect it to be complete end of fourth quarter
• Foundation Fieldbus future after Profibus PA

50
New Product Features - Software

• Units Menu
• Added ability to display and output pressure
  units in Absolute or Gauge
• Need to enter the atmospheric pressure at meter
  location or default atmospheric, i.e. 14.7 psia
  at sea level

51
New Product Features - Software

• Calibration Column
• Low Flow Cutoff
• A/D counts larger number than the previous
  meters
• Right Arrow for approximate volumetric units
• Right Arrow again for approximated mass units

52
New Product Features - Software

• Hidden Diagnostics Column 1
• A1, A2, A3, A4 four A/D converters and relative
  signal strength, amplitude
• Ck dynamic calculated value relates signal
  strength, velocity and density to set the
  adaptive filter fi. Can also use this value to
  check the meters Ck setting in the calibration
  menu
• Lvl threshold level. At no flow Lvl must be
  below the LFCO or you will have indicated flow in
  a no flow situation
• Adj. Filter adjustable filter. If this reads a
  negative number the Ck setting is not set
  correctly

53
New Product Features - Software

• Hidden Diagnostics Column 2
• Alarm 1-3 Test allows you to choose a high (on)
  or low level (off) to test the circuit and relay
• Reynolds Correction enable it for insertion
  meters, disable for inline meters
• Gain Control Manual Control default is one
  in tough applications you can raise it to try and
  get better low end reading

54
Special Configurations - EMS

• Energy Meter Menu
• Sent from Factory as Sent flow only 0 return
  with a 1000 ohm resistor in the wiring connector
  for RTD 2
• If to be used other than a sent flow only wire
  in the customer supplied 1000 ohm RTD

55
Special Configurations - EMS

• Energy Meter Menu
• Wiring Diagram

56
Meter Simulation Programs

• Volumetric Meter Simulator
• Same exact software that is loaded in the meter
• Used to duplicate customers set up to see how the
  meter will react
• Built in frequency generation to monitor meter
  diagnostics and outputs
• Mass Meter Simulator
• Same as above except for the mass meters
• Up/Down Interface
• Used to upload and download information to the
  meters
• Possible to have customer download meter, save it
  and send the file to you so that you can upload
  it and see for yourself how the meters is
  behaving
• Hart Interface
• Used just like a HART handheld
• Download at www.vortekinst.com

57
Meter Simulator Programs

• Typical K-factors for Inline meter body sizes
• ½ 13,500
• ¾ 5,400
• 1 2000
• 1.5 560
• 2 260
• 3 79
• 4 34
• 6 9
• 8 4.4

• Typical K-factors for Insertion meters
• 221/241 9.6