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Differential
ti l Flow
Fl Products
P d t
Past, Present and Future
© ABB Inc.
March 24-26, 2009 | Slide 1
Differential Pressure Flow Measurement
Ancient Technology
Differential
Diff ti l P
Pressure really
ll
did exist in ancient Rome
and the basics of these
principles are still part of
today’s technology
© ABB Group
June 24, 2011 | Slide 2
Differential Pressure Flow Measurement
True Beginnings
Daniel Bernoulli
Introduced the concept of the conservation of
energy for fluid flows
Stated an increase in the velocity of a flowing
fluid increases its kinetic energy while
decreasing its static energy
Horace E Dall
Developed by Horace E. E Dall (ABB -Kent),
Kent) the
Dall Tube is essentially an adaptation of the
Venturi Tube. It’s unique design gives a much
shorter overall length (1.75D instead of 5D), and
an elevated differential pressure (for the same
flow rate and throat ratio) but has a much lower
irrecoverable pressure loss
© ABB Group
June 24, 2011 | Slide 3
Differential Pressure Flow Measurement
True Beginnings
The Pitot tube was invented by French engineer Henri Pitot in
the early 1700s, and was modified to its modern form in the
mid
id 1800s
1800 bby F
Frenchh scientist
i ti t HHenry D
Darcy. It iis widely
id l used
d tto
measure air and gas velocities in industrial applications
While Orifice plates have existed for almost 100 years, Paul
Daniel raised the bar with his patented senior orifice fitting
that allowed for plate exchange without interrupting flow.
Fueled by the research of both industrial and educational
institutions and the 1935 publication of a joint AGA and ASME
reports, the orifice plate remains the number one form of DP
flow measurement across the globe
© ABB Group
June 24, 2011 | Slide 4
Differential Pressure Flow Measurement
The Historyy of ABB
KENT
TAYLOR
BUSH -BEACH
FISHER PORTER
Wedge
g Master
The Superman Syndrome
OriMaster
Venturi
Tried, Trusted and True
Integral Orifice
The Forgotten Ones
© ABB Group
June 24, 2011 | Slide 6
Wedge Master II
Wedge Master II
Unique
q Flow
Unique Flow
Solutions
Solutions
© ABB Inc. - 7 -
March, 2007
© ABB Inc.
March 24-26, 2009 | Slide 7
Differential Pressure Flow Measurement
Wedge Master – What It Is
Dp
p Flow = Conservation of Energy
gy
[P1/ρ1 + V1/2g + Z1] = [P2/ρ2 + V2/2g + Z2]
V1 Z1 Z2 V2
Wedge = Dp Flow
[P1 + V12/2g ] = [P2 + V22/2g]
Higher Pressure, Lower Pressure,
Lower Velocity Higher Velocity
© ABB Group
June 24, 2011 | Slide 8
Differential Pressure Flow Measurement
Wedge Master – How it Works
Wedge restriction characterized by the H/D ratio
ABB offers
ff GENIE II software
ft ffor W
Wedge
d element
l t sizing
i i and
d flow
fl
calculations
Equivalent value for β can be calculated from H/D or found in look-
up tables (Flow Measurement Engineering Handbook)
D H
© ABB Group
June 24, 2011 | Slide 9
Differential Pressure Flow Measurement
Wedge Master – How to Win
Educate end users – Show advantages of reduced up and down
stream
t piping
i i requirements
i t andd hi
higher
h energy savings
i th
thatt contribute
t ib t
to lower initial installation and operational costs.
Installation Concerns
Recommended Upstream and Downstream Pipe Diameters are required to
stabilize the flow profile for proper performance. ABB Wedge Meters can be
installed with reduced pipe conditions that cannot be achieved with other
t h l i
technologies.
Less Piping = Less $ Spent
Downstream
V-Cone
Wedge
Venturi
Upstream Orifice
0 10 20 30
© ABB Group
June 24, 2011 | Slide 10
Differential Pressure Flow Measurement
Wedge Master – How to win
Energy Loss –
The portion of differential pressure drop that is not recovered
downstream of the restriction.
Higher Energy Loss = $$$$$$
100
Orifice Plate
90
80
V-Cone
70
Pressure Loss
Percent of DP 60
50
40
WEDGE
30
20 Venturi
10
© ABB Group
June 24, 2011 | Slide 13
Differential Pressure Flow Measurement
Wedge Master – How to Win
Do not assume all things are equal. ABB design guidelines surpass other
manufacturers with regard to product integrity, origin or materials, levels and
standards of testing and the assurance that each meter is individually factory
calibrated to maximize field performance.
Is the pipe wall breached by design? Is there potential damage by design?
ABB
Wedge restriction welded into
pipe ID – no cutting of pipe – no
leak path to exterior of meter
© ABB Group
June 24, 2011 | Slide 14
Differential Pressure Flow Measurement
Wedge Master – How to Win
Does the competing device meet performance needs
Wedge
g Flow meters conforms to principles
p p of true
square root and do not require correction to meter
KD 2 factor based on Reynolds Number
.2H/D
© ABB Group
June 24, 2011 | Slide 15
Differential Pressure Flow Measurement
Wedge Master – How to Win
Does the competition provide a calibrated flow meter?
ABB
All Wedge flow meters are factory flow calibrated to +/-0.5%
accuracy
Worldwide Calibration Facilities to 2 meter + diameter meeting
international standards
NIST, UKAS, PTB, NATA
Preso
Manufacturer offers accuracy and calibration tests of flow meters
through third party calibration provider
NIST
© ABB Group
June 24, 2011 | Slide 16
Differential Pressure Flow Measurement
Wedge Master – How to Win
SHARE SUCCESS STORIES !!
Country End Uer / Project Name Process Project Value Status
SPAIN HOJA MEDIDORES LVGO, HVLO, Vacumm Residues, Raw Crude $211,000 Budgetary
CANADA FLUOR FORT HILLS PETRO CANADA Bitumen and Flotation Froth $410,416 Delayed
US VALERO ST CHARLES COKER UPGRADE Coker Heater Charge $289,000 Expected Q1/09
Wash Oils, Coke Fines, HVGO, Coker Heater
INDIA INDIAN OIL Charge $332 558
$332,558 Expected Q1/09
US CHEVRON Reagents, Refining Products $468,519 Expected Q3/09
US CHEMTEX Process and Syngas $264,949 Under Review
KOREA SAUDI ELECTRICITY Feed Water/ Steam Flow $551,822 Under Review
CHINA FUSHUN PC Crude Oil, Coker Heater Charge $159,623 Under Review
CHINA CHINA DESIGN INSTITUE OF CHEMICALS Quench water $1,015,147 Under Review
INDIA INDONESIA OIL Hydrocarbon gas $58,743 Under Review
CHINA LUOYANG PETROCHEMICAL Hydrocarbons $72,915 Under Review
KOREA PASFOR DSME Hypochlorite $126,000
$ , Under Review
CANADA BANTREL Coker Heater Charge, Slurry Feed $95,000 Won
SPAIN SAUDI KAYAN Phenol, BPA $287,729 Won
CHINA FUJIAN REFINERY Refining $121,000 Won
CANADA ALBIAN SANDS Tars Sands Recovery $196,000 Won
Coker Heater Charge, Quench/Wash Oils,
JAPAN JGC COSMO OIL SAKAI REFINERY Condensates $263,000 Won
FOSTER WHEELER VALERO PORT
US ARTHUR Coker Heater Charge $210,063 Won
US TOTAL Slop Oils, HHC, Coker Heater Charge $806,000 Won
© ABB Group
June 24, 2011 | Slide 17
OriMaster
Click to edit Master subtitle style Compact Orifice
© ABB Group - 18 -
24-Jun-11
© ABB Inc.
March 24-26, 2009 | Slide 18
Differential Pressure Flow Measurement
Why OriMaster?
Market acceptance
p exists,, technology
gy is established
Available revenues believed to be in order of $40M (Primary,
Secondary, MRO and Replacement)
Relatively
y low level of competition
p fosters penetration
p
Emerson leads
E & H and Foxboro at same level as ABB
(ABB Technology has enhancements others do not)
Provide baseline product business to smooth out the
effects of project gains/losses and unstable economy
Promotes ABB Transmitters under guise of a flow
solution
Continues to expand FlowMaster portfolio to reduce walk
away
y sales calls
© ABB Group
June 24, 2011 | Slide 19
Differential Pressure Flow Measurement
Why OriMaster?
Re-directs $$$$’s
$$$$ s spent
internally by our customers to
sales
l channel
h l pockets
k t
$$$$
© ABB Group
June 24, 2011 | Slide 20
Differential Pressure Flow Measurement
OriMaster - a better way…….
way
© ABB Group
June 24, 2011 | Slide 21
Differential Pressure Flow Measurement
Construction
Integral transmitter
316L 3
3-valve
valve manifold
Fully welded construction
© ABB Group
June 24, 2011 | Slide 22
Differential Pressure Flow Measurement
Orifice flow metering made simple
Cl
Clean liliquids,
id gases and d satt steam
t iin pipe
i sizes
i
from 1" up to 8" NB
Supplied
pp with integral,
g , directly-mounted
y ABB
DP transmitter
© ABB Group
June 24, 2011 | Slide 23
Differential Pressure Flow Measurement
OriMaster V – Volumetric Flow
Rugged compact construction
– 364D All stainless body (316) and housing (304)
– Optional 316 housing
– Hastelloy
H t ll process di
diaphragms
h
Best in class total performance
– long term DP stability of 0.15% for 10 years
– base DP accuracy of 0.06%
– integral flow totalizer
Inherent leakage prevention
– one piece stainless steel design process
chambers
– gasket free sensor coupling with
conventional 54mm connections
© ABB Group
June 24, 2011 | Slide 24
Differential Pressure Flow Measurement
Orimaster M – Mass Flow
OR
ABB EXCLUSIVE - Optional Integral PT100
temp. element, fully wired
- true,
t one-piece
i mass flflowmeter
t
- no need for added cost of separate thermowell/
temperature elements
© ABB Group
June 24, 2011 | Slide 25
Differential Pressure Flow Measurement
Accurate Installation
Meets the requirements of global standards with
regard to proper installation and effects on accuracy
ANSI/API 2530
The orifice must be concentric with the inside of the meter
tube/ orifice fitting within 3 percent of the inside diameter of the
meter tube/fitting
AGA Report No. 3 (1985)– Orifice Metering of Natural Gas
q
requires that when centering g the orifice p
plates,, the orifice must
be concentric with the inside of the meter tube to within 3% of
the inside diameter. This is more critical in small pipes and for
orifice plates with large beta ratios
ISO5167
The orifice must be concentric with the inside of the meter OriMaster's alignment tool –
tube/ orifice fitting to within the following percentages of the Supplied with every meter to
inside diameter of the meter tube/fitting g ((depending
p g on beta ensure that the device is
ratio): correctly centred
© ABB Group
June 24, 2011 | Slide 26
Differential Pressure Flow Measurement
Product Positioning
g
Shifts the expense and time of installing standard
orifice plate technology to a controlled
environment with real cost reductions.
reductions
© ABB Group
June 24, 2011 | Slide 27
Differential Pressure Flow Measurement
Product Positioning – Improved Reliability - Reduced Liability
Conventional Installations OriMaster
Leakage
L k att joints/couplings
j i t / li causes fugitive
f iti OriMaster reduces potential leak points which
emissions and also degrades the pressure reduces liabilities under Fugitive Emissions
signals and hence poorer accuracy regulations. Pressure tested at the factory
ensures the integrity of the impulse path right up
to and including the transmitter
Tx-Manifold
j i t
joint
Valves (3
locations)
Gasket surfaces (2
sides)
© ABB Group
June 24, 2011 | Slide 28
Differential Pressure Flow Measurement
Product Positioning – Realizing Cost Benefits
© ABB Group
June 24, 2011 | Slide 29
Differential Pressure Flow Measurement
OriMaster Application
Energy
- Combustion control
- Feedwater control
- Industrial heat and steam generators
All are pparticularly
y dependent
p on exact mass flow measurements of combustion air, fuel,
steam and feedwater.
Chemical Industry
y
Process gas flow
- Refineries
- Petrochemical plant
- Chemical plant
plant.
Food and Beverage
- Water & steam measurement in boiler houses
- Alcohol steam flow
flo in alcohol man
manufacture.
fact re
© ABB Group
June 24, 2011 | Slide 31
Differential Pressure Flow Measurement
OriMaster Sales Collateral
www.abbwin.com
© ABB Group
June 24, 2011 | Slide 32
Differential Pressure Flow Measurement
Orimaster Sizing and Configuration Tool
© ABB Group
June 24, 2011 | Slide 33 www.abb.com/flow
Differential Pressure Flow Measurement
OriMaster Sales Collateral - Press Release
© ABB Group
June 24, 2011 | Slide 34
Differential Pressure Flow Measurement
OriMaster Sales Collateral - Success
Hats off to Craig and the Applied Analytic team , ABB appreciates the efforts of
all.
© ABB Group
June 24, 2011 | Slide 35
Venturi Meters
Wedge Master II
Market Focused Unique Flow
Solutions
Products
© ABB Inc. - 36 -
March, 2007
© ABB Inc.
March 24-26, 2009 | Slide 36
Differential Pressure Flow Measurement
Venturi and Dall Flow Tubes
ABB s history of supplying Venturi and Dall flow tubes dates back
ABB’s
100 years through legacy companies of Kent, Bush Beach, Fisher
and Porter and Taylor
In the US, ABB’s strategy is to target projects within the downstream
sector of the Oil and Gas industry that are driven by Major End
Users and EPC’s.
Within this defined market segment, venturi products are most suited
to GTL and LNG applications, based on energy cost savings and
reduced CO2 emissions as a result of lower ppressure loss when
compared to other Dp or mechanically driven flow meters
ABB has the experience and technical staffing to conform to
international standards and meet customers precise requirements
with regard to meter design, material selection and QA levels.
© ABB Group
June 24, 2011 | Slide 37
Differential Pressure Flow Measurement
Wh Focus
Why F on GTL and
d LNG
Source : Douglas-Westwood
© ABB Group
June 24, 2011 | Slide 38
Differential Pressure Flow Measurement
Venturi - Energy Cost Comparison
Meter Size 20 in NB
Power Required kW 25.13 110.51 119.52
Annual Power
Beta 0.5
required 220154 968104 1046986
kWh
DP 100 in H2O
Efficiency 1
Annual Energy Cost $11,008 $48405 $52349
Density 0.3952 lbm/ft3
Operating
Hours per 8760 hr Cost Ratio
(Venturi = 1.0)
1.00 4.40 4.76
year
$/kWh 0.05
© ABB Group
June 24, 2011 | Slide 39
Differential Pressure Flow Measurement
Venturi - Reduced Environmental Cost
© ABB Group
June 24, 2011 | Slide 40
Integral Orifice
Wedge Master II
Flowmeters
Unique Flow
Solutions
© ABB Inc. - 41 -
March, 2007
© ABB Inc.
March 24-26, 2009 | Slide 41
Differential Pressure Flow Measurement
Integral Orifice Features
Taylor legacy product that continues to serve
chemical and specialty
p yggas markets
Suitable for clean fluids – Liquid, Gas or Vapor
Fills the gap in Dp technology for small size meters
while improving performance in low flow
applications. Low cost alternative to mechanical
flow meters.
Direct mounting of standard or multivariable
transmitter
Optional
O ti l meter
t runs provide
id up and
dddown stream
t
piping requirements
Field replaceable
p orifice p
plate kits with q
quick
change out features
© ABB Group
June 24, 2011 | Slide 42
Differential Pressure Flow Measurement
Integral Orifice Features
Pipe Sizes
½, 1.0, 1-1/2”
Standard orifice bores from 0.020 to 1.127”
Materials of Construction –
316 body w/ 316 SST plate
316 b
body
d w// H
Hastt C plate
l t
Threaded End Connections
Flanged End Connections – Class 150,
150 300,
300 600
Optional Factory Water Calibration
© ABB Group
June 24, 2011 | Slide 43
Differential Pressure Flow Measurement
Target Applications
Oil and Gas Power Chem - Petro Chemical General
Upstream Downstream
Target Wet Gas Extraction GTL LNG Refining Processing Utilites OEM Institutional
Applications
Coke Charges
Oil Sands Hazardous
Flow Quench Oils FCC
Recovery Boiler Materials
Monitoring & Cracking Fuel Oil Feed Fuel Oil Feed
Well Head Blowdown Non-Newtonian
(Non CT) Bottoms Coal
Injection Fluids
Liquifaction
Steam Supply
Steam Supply Steam Supply
Process Steam Additives, Feed Water
Feed Water Feed Water
Feed water Specialty Gas Energy Billing
Process Gas Process Gas
Flow Monitoringg
Recycle Gas
C3/Propane
MP/IP Steam Superheated
Mixed Refrig. Air-
Regen Gas Steam (PTC6)
Steam Fuel Gas
SynGas
Additives Additives,
Specialty Gas Specialty Gas
Utilites Specialty Gas
© ABB Group
June 24, 2011 | Slide 44
Differential Pressure Flow Measurement
Competition
© ABB Group
June 24, 2011 | Slide 45
© ABB Group
June 24, 2011 | Slide 46