Flowmeter Accuracy

Accuracy indicates how close a measured value is to the accepted or true value.
Accuracy is the degree of conformance of a measurement to standard or true value"

A measurement system consists normally of a primary element and a secondary element.

Example - in a flow measurement system the orifice is the primary element and the
pressure transmitter is the secondary element. Both the orifice and the pressure
transmitter influence the flow measurement total accuracy.

The accuracy of flow meters can be stated as:

 percent of full span

 percent of rate

Accuracy as Percent of Full Span

Accuracy in percent of full span can be expressed as:

a% = a 100% / s (1)

where

a% = relative accuracy (%)

a = +/- absolute accuracy

s = full scale of the flow meter

Example - Accuracy of Flow Meter in Percent of Full Span

If the absolute accuracy is +/- 10 kg/h - the relative accuracy at full scale 1000 kg/h can
be calculated as:

a% = (+/- 10 kg/h) 100% / (1000 kg/h)

= +/- 1%

The relative accuracy at full scale 100 kg/h can be calculated as:

a% = (+/- 10 kg/h) 100% / (100 kg/h)

= +/- 10%
Accuracy as percent of Rate

Accuracy in percent of rate can be expressed as:

a% = a 100% / q (2)

where

a% = relative accuracy (%)

a = +/- absolute accuracy

q = flow rate

Example - Accuracy of Flow Meter in Percent of Rate

If the relative accuracy is +/- 1% of rate - the absolute accuracy at rate 1000 kg/h can be
calculated as:

a = (+/- 1%) (1000 kg/h)

= +/- 10 kg/h

The absolute accuracy at rate 100 kg/h can be calculated as:

a = (+/- 1%) (100 kg/h)

= +/- 1 kg/h

Hysteresis

Hysteresis is the maximum difference between measurement readings at the same

mechanical set point when the point is set from a value above the set point and reset from
a value below the set point. Hysteresis can increase over time as a result of wear and tear
of the mechanical parts.

Standard Deviation Estimate

Standard Deviation Estimate is the measure of dispersion of a set of data in its

distribution about the mean of the set and can be expressed as

S = [Σ(qa - qi)2 / (n - 1)]1/2 (3)

where

S = standard deviation estimate

qa = mean value of measurements

qi = each individual measurement value from the set

n = number of values in the set of measurements

The mean value can be calculated as

qa = Σqi / n (4)

Example - Estimated Standard Deviation :

The flow through a flow meter is measured to 10 kg/h, 9 kg/h and 8.5 kg/h.

The mean flow can be calculated as

qa = [(10 kg/h) + (9 kg/h) + (8.5 kg/h)] / 3

= 9.2 kg/h

The standard deviation can be estimated as

S = [(((9.2 kg/h) - (10 kg/h))2 + ((9.2 kg/h) - (9 kg/h))2 + ((9.2 kg/h) - (8.5 kg/h))2) / (3 -
1)]1/2

= 0.76 kg/h

Turndown Ratio - Rangeability

Turndown ratio can be expressed as:

TR = qmax / qmin (1)

where

TR = Turndown Ratio

qmax = maximum flow

qmin = minimum flow

Maximum and minimum flow is stated within a specified accuracy and repeatability for
the device.

Example - Turndown Ratio for an Orifice Meter

The turndown ratio - TR - for an orifice meter with maximum flow of 12 kg/s and a
minimum flow of 3 kg/s can be calculated as:

TR = (12 kg/s) / (3 kg/s)

=4

- normally expressed as turndown ratio of 4:1

This is a typical turndown ratio for a orifice plate. In general a orifice plates has
turndown ratio between 3:1 and 5:1.

Flow Measurement :

Flow metering principles - Orifice, Venturi, Flow Nozzles, Pitot Tubes, Target, Variable
Area, Positive Displacement, Turbine, Vortex, Electromagnetic, Ultrasonic Doppler,
Ultrasonic Time-of-travel, Mass Coriolis, Mass Thermal, Weir V-notch, Flume Parshall
and Sluice Gate flow meters and more.

Flowmeter Accuracy vs. Repeatability:

Repeatability is in no way an accuracy guarantee. Therefore, when considering a

measurement device such as a flowmeter, if you see only a repeatability statement and no
accuracy statement, be cautious and consider your application.

Repeatability is the ability of a system or device to reproduce a measurement in

unchanged conditions. Measurements taken by a flowmeter with poor repeatability would
be all over the board. For instance, let’s say you’re asking your flowmeter to measure a
known flow rate of 100 units per minute. A device with poor repeatability might measure
87, 102, and 95 units per minute at any given time. This concept can be compared to hits
on a target. If you fire a rifle at a bullseye multiple times and the bullet holes are spread
out, the rifle is not repeatable.
However, if the holes are tightly grouped, but all miss the bullseye, the rifle is repeatable
but not accurate. In this case, the sights of the rifle can be used to compensate for its
inaccuracy. Similarly, if a flowmeter’ measurements are repeatable― even if they aren’t
accurate― the error could be mapped and compensated for.

A flowmeter with good repeatability might measure 97, 99 and 101 units per minute.
Because the difference between each measurement is smaller, the measurements are more
repeatable. Over time, an operator may find that setting a flow rate of 97 units per minute
actually results in the desired output of 100 units per minute. Consequently, in some cases
and depending on the application, repeatability is more critical than accuracy because any
repeatable error can be compensated for.

As long as the flowmeter’s output is chaotic, it will not correspond closely enough with
the characteristic curve. In other words, once a flowmeter’s measurements are
determined to be repeatable, only then can it be considered accurate.

There are several applications that would be able to function with a flowmeter that is only
repeatable, if that is all that is necessary. For example, if a tank level raises, its level
controller will increase its effluent flow in order to maintain the level setting. In this case,
it seems unnecessary to accurately measure the flow rate, but as long as the flowmeter is
repeatable, equal flow setting changes will result in equal flow changes. And, since
repeatable flowmeters are typically less expensive than accurate flowmeters, this would
be an opportunity to cut costs.

However, often overlooked is the opportunity — or even necessity — of performing

calculations to ensure the economics of a process or the effectiveness of process
improvements. For example, if the effluent flowmeter mentioned above is a distillation
column’s overhead take-off, its measurements may be used to calculate the column reflux
flow rate. The original system design may not have accounted for this, but operating
experience may determine that this control strategy would provide better control of the
column. Many applications like this exist, and many of these opportunities are discovered
only after the plant is operating. Sometimes, repeatable flowmeters should be replaced
with accurate flowmeters in order to obtain operating data and accommodate
improvements.

Accurate flowmeters are advantageous because they repeatedly and reliably provide
measurements that closely reflect the true flow rate. Repeatable meters may not provide
accurate measurements, but they still have their place in many applications. Which is
most appropriate will depend in part on the application and your budget.
Piping Requirements For Flow Meter Installation

A distorted fluid velocity profile is one of the most common reasons for inaccurate flow
meter readings. Swirls or other distortions in the flow are caused by the tees, elbows and
valves that make piping systems functional. But, to keep your flow meter functional as
well, there are some piping requirements regarding the fluid’s flow profile, which is
almost entirely dependent on a system’s piping orientation.

Optimally, fluid with a “laminar” flow profile is moving smoothly through the pipe. The
velocity of laminar flow is highest in the center of the flow and slower as it reaches the
pipe walls. In most cases, natural laminar flow only exists in straight-run piping. When
90 degree angles, half-open valves, misaligned flanges, or even pipe wall pitting exist
within a piping system, the fluid flowing through it is disrupted, which can cause
inaccurate flow meter readings. The less straight run there is before and after the flow
meter, the exponentially higher the meter’s error rate percentage becomes. Because of
this, flow meter manufacturers will suggest a certain length of straight-run that must exist
upstream and downstream of their meters. These requirements will vary by technology
and manufacturer.

Below are some very general suggestions for straight-run piping based on the type of
flow measurement technology installed.

Piping Insertion

Pipes smaller than 6 inches in diameter will need, at the very least, 20x the piping
diameter in straight run upstream of the meter and 10x the piping diameter in straight run
downstream. Pipes 6 inches or more in diameter require 15x the piping diameter in
upstream straight run and 7.5x the piping diameter in downstream straight run.

Turbine
The amount of straight run needed can depend on how many disturbances exist upstream,
especially when using a turbine style flow meter. Straight run should be at least 20x the
piping diameter when an elbow, tee, filter or other disruption exists upstream of the
meter. But, a partially open valve upstream of the meter will require 25X the piping
diameter, and multiple disruptions, such as a spiral or consecutive elbows, can require
50x the piping diameter. In general, downstream straight run requirements for turbine
flow meters are around 5-10x the piping diameter.

Magmeter

Magmeters can be installed in horizontal lines, however this orientation is not ideal. In
this case, there must be at least 5x the piping diameter in straight run upstream of the
meter and 3x the piping diameter downstream. Any less than 3x the piping diameter, and
tests show that flow disruptions can add as much as 1.5% to the meter’s error rate. Best
practice in magmeter installation calls for the device to be located on a section of vertical
piping with flow moving upward.

Vortex

When installing a vortex flow meter, it doesn’t matter how the piping is arranged. What’s
more critical is that the fluid fills the pipe completely and that the flow profile is
completely free of any swirls or distortions. This usually requires a couple of control
valves, used to reduce the pipe size and keep the meter full, and a generous amount of
upstream straight run piping. Between the upstream control valve and the meter there
must be 30x the piping diameter in straight run. And, between the meter and the
downstream valve there should be straight run equaling at least 5x the piping diameter.

Ultrasonic

Ultrasonic meters with multiple beams will be affected less by flow profile disturbances
than meters with just one beam. Like many others, this type of flowmeter should be
installed upstream of elbows, valves, or reducers. Make sure to allow for the longest
possible straight run piping between the meter and the obstacle. The length of straight run
can be as short as 5x the piping diameter as long as an additional error of 1% is
acceptable.