Energy and Flow Measurement in

Hydronic Systems
Keys to Achieving the Desired Results

Presented By:
Rob Neumann
Vice President – Sales and Service
ONICON Incorporated, Clearwater, FL
HVAC Flow and Energy Measurement since 1988
 Why Do We Measure Flow?

To control something, you must first

measure it…
Lord Kelvin
Why Do We Need a Flow Meter?
• How Does Buying a Flow Meter
Save Energy?
• Consider the Scale….
– The act of purchasing a scale won’t
reduce your weight, but….
– Would you begin a weight loss program
without first establishing a baseline and
having the ability to measure progress?
 Why Measure Flow in Todays
High-Performance Buildings?
• Advanced Metering in new and existing
buildings offers enormous benefits to
Designers and Users!
– Provides system information required to
commission, validate and operate today’s High-
Performance Buildings
– Provides valuable real world baseline data
information for use in future designs
How do we get the information we
want??
 Step 1: What Do You Want To
Measure?
• Flow Metering Applications Include:
– Chilled Water / Heating Hot Water / Condenser
Water
– Domestic Water / Domestic Hot Water
– Make-Up Water / Blow Down
– Steam / Steam Condensate / Boiler Feed Water
– Natural Gas, downstream of Utility provided gas
meter
 Step 2: What Do You Want To
Do With The Information?
• System Control
– Central Plant Operation and Optimization
– Trending Data, Efficiency Calculations
• Sub-Metering
– Tenant Billing
– Energy Usage / Sustainability Dash Board’s
• Monitoring
– Are We On??
Step 3: How Do We Measure it?
• Flow Meter Selection Criteria
– Minimum Criteria needed to begin the flow meter
selection process.
• Flow Meter Technology Selection
– Which technology works best based on the flow
meter selection criteria?
– How do I compare flow meter technologies?
 Flow Meter Selection Criteria
• Application Requirements
• Accuracy Requirements
• Installation Requirements and Limitations
• Output Requirements, Interconnectivity
Requirements
• Maintenance and Serviceability
• Budget Requirements
 Application Requirements
• Type of Fluid to be Measured
– Liquid / Gas / Steam
• Physical Properties of Fluid to be Measured
– Temperature Range / Pressure / Conductivity /
Acidity / Type of Mixture (Glycol, Brine, et)
• Fluid Quality
– Closed Loop / Open Loop / Blow Down
 Accuracy Requirement

The flow meter technology used for any given

application should be based on the accuracy
required by the application.
 Accuracy Requirements
The following applications are listed from
Highest to Lowest in terms of accuracy typically
required:
Cost Allocation, Billing Applications
System Control Applications
Measurement and Verification
System Monitoring Applications
 Definitions and Relationships
Accuracy – The ability of an instrument to make the
measurement as referenced to a standard
Repeatability – The deviation of multiple
measurements of the same quantity under the
same conditions. Not a measure of absolute
accuracy.
Linearity – The departure of the calibration curve from
a straight line. Not a measure of absolute
accuracy.
Turndown – The range over which an instrument
performs within it’s specified accuracy, typically
presented as a ratio, the maximum of the range
divided by the minimum of the range, Max:Min
 Accuracy Statements
• To be valid, an accuracy statement must
have three criteria:
– % uncertainty of the measurement
– The reference to which the accuracy applies (%
of what, reading or rate, full scale)
– The range over which the accuracy applies, or
turndown
Accuracy Statement Comparison
 Specifying Accuracy and the
Turndown Conundrum
Which is Better?

Spec # 1:
Flow meter shall have an
accuracy of +/- 1% over a
turndown of 30:1 .
Spec # 2:
Flow meter shall have an
accuracy of +/- 2% of reading
over a velocity range of 1 to 10
ft / sec.
 Specifying Accuracy and the
Turndown Conundrum
Spec # 1:
It must be assumed that this
meters’ accuracy is based on
the full scale, which is 30.
Uncertainty = (30 X .01) = 0.3
At the low end, whatever 1 is
equivalent to, the accuracy is
0.3 / 1 = +/- 30% of reading.
Spec # 2:
This is a complete accuracy
statement, even though the
accuracy and turndown (10:1)
appear to be worse, at 1 ft/sec
the accuracy is +/- 2 % of
reading.
 Specifying Accuracy and the
Turn Down Conundrum
Which is Better?

Spec # 1:
Flow meter shall have an
accuracy of +/- 1% over a
turndown of 30:1.
Spec # 2:
Flow meter shall have an
accuracy of +/- 2% of reading
over a velocity range of 1 to 10
ft / sec.

Spec # 2 is BETTER! In most HVAC applications, design

flow velocity is between 1 to 8 ft/sec, meaning a 30: 1
turndown is probably not relevant.
 Accuracy and Calibration
• Three different methods of calibration are
typically used in regards to flow meters:
– A dimensional check is performed, confirming certain
physical or mechanical dimensions of the sensing element
are met, calibration factors are then based on empirical
tables established in a “batch process”
– A dry calibration, where mechanical or electrical signals are
used to “simulate” flow
– A wet calibration, meaning the flow meter was placed in and
calibrated for the actual conditions in which it will operate.
Calibration Method Matters
The calibration method
ultimately determines
the level of accuracy a
flow meter can achieve.
Wet calibrations are the
most accurate.
 Accuracy and Installation

After calibration, the largest contributor to the

accuracy achieved by any flow meter is based
on meeting the installation requirements and
operating ranges of the selected meter.
 Installation Requirements
Things to Consider
• New Construction
• Existing Construction / Renovation
– System Isolation
– Permanent vs. Temporary Installation
• Piping System
– Carbon Steel / Ductile Iron / Stainless Steel /
Fiberglass / HDPE
 Installation Requirements

• Velocity profile is distorted by pipe obstructions

and direction changes.
• Friction from the pipe wall “conditions” the velocity
profile, eventually flattening the profile. The length
of pipe, straight run, required to achieve this is
based on the obstruction, velocity and viscosity of
the fluid.
 Straight Pipe Run Requirements

Most flow meters require minimum lengths of straight

pipe before and after the meter location to maintain
accuracy.

Example of straight pipe run

recommendation:
 Accuracy and Installation

Trade-offs can be made in terms of straight run

vs. accuracy required when faced with real
world (mechanical room) installation issues.
 Straight Run Matters!
A Flow Meter Manufacturers Dream, literally miles and
miles of straight run!
 Straight Run Matters!
With a little planning, straight run requirements can
typically be met within Central Plant systems.
 Straight Pipe Run – The Real World

Real World Flow Meter

Installations rarely have the
straight run required by the
manufacturer to achieve the
published accuracy.
Example of straight pipe run
actually encountered in flow
meter used for billing
application, two (2) diameters
downstream of an isolation
valve, one (1) diameter
upstream of an outflowing tee.
Straight Run Requirements
The “Real” Industry Standard
Straight Pipe Run Requirements
Actual upstream/downstream dimensions depend on
the type of pipe obstruction & meter type.
Consider both “supply” and “return” lines when
locating available pipe run.
Locating Meters - Trade Offs

Avoid locating
meters
downstream of
inflowing tees.

Avoid locating meters

downstream of
modulating valves.
 Output Requirements
• Typical Outputs
– Instantaneous flow rate requires analog signal, 4-
20mA, 0-10 or 0-5 VDC typical
– Totalization of flow requires pulse output, dry
contact is typical
– Serial communications, multi-variable outputs
• Interconnectivity Requirements
– Building automation system, new or existing
communication protocol
 Output Selection
Outputs Typically Used for System Control
• Analog Signals
– Signals include 4-20mA, 0-10 VDC and 0-5 VDC.
– Used as feedback for control system operations, provides
instantaneous rate information.
• Frequency Signals
– Typically provided by flow sensing element directly, raw data.
 Output Selection
Outputs Typically Used for Establishing
Usage / Monitoring / Cost Allocation
• Scaled Pulse Output
– Pulse equivalent to a specific amount (1 pulse = 10 Gallons),
cannot be integrated to calculate flow rate.
• Serial Communication Output
– Excellent format for transmitting large amounts of meter data for
control system operations which are NOT time dependent.
– Typical communication protocols in the HVAC world include: BACnet®
MS/TP & IP; Modbus RTU & TCP; LONWORKS®
 Flow Meter Technology
Quote of the day:

“There is not a flow meter manufactured, no

matter how good, that when installed in-
correctly or miss-applied, cannot fail
spectacularly and cost the consulting engineer
time, money, reputation or all three”.
 Common Flow Meter Types
in HVAC Applications
• BTU Meters – Complete System Approach
• Turbine – Best Cost vs. Performance
• Full Bore Mag - Highest Accuracy
• Insertion Mag - Ideal Solution
• Ultrasonic Transit Time- Clamp-On
– Non-intrusive
• Full Bore Vortex Shedding-Robust Performance
– For steam and high temperature hot water
• Thermal Dispersion-Mass Flow Meter
– For Gas Applications
Dedicated BTU Metering System
• Dedicated hydronic energy (BTU)
measurement system.
• Easily interfaced with common building
automation protocols.
• Best choice for accurate hydronic
energy measurement, provided:
• Temperature sensors are matched
over range
• Flow Meter is wet calibrated
• Provides serial communication
Insertion Turbine Meters
• Easy to install, immersion style sensor, direct
reading.
• High turndown, linear response over a wide
range of flow.
• Hot Tappable, no system shut down required.
• Wet calibrated versions have high accuracy to
cost ratio, good value in clean, closed loop
systems.
• Good accuracy over wide turndown, provided
straight run requirements are met.
Insertion Electromagnetic Meters
• Easy to install, immersion style sensor.
• Hot Tappable, no system shut down.
• Electromagnetic technology, no moving parts.
• High accuracy over wide turndown, provided
straight run requirements are met.
• Requires conductive fluid to operate.
• Good value in open loop, conductive fluid
systems.
Full Bore Electromagnetic Meters
• Highest accuracy & reliability, best short
straight pipe run performance.
• Requires conductive fluid to operate.
• Installation, service, or calibration requires
shutdown and drain.
• Suitable for use in most open loop and
closed loop HVAC systems.
• Best choice for high dollar custody transfer.
Full Bore Vortex Shedding Meter
• Robust sensing technology, no moving parts,
capable of measuring liquids, gases or steam.
• Ideally suited for steam applications.
• Limited turndown due to sensing technology,
proper sizing of meter is paramount.
• Installation, service, or calibration requires
shutdown and drain.
• Multi-variable technology provides good value in
saturated steam applications.
Clamp On Ultrasonic Meter
• High accuracy & turndown.
• Can measure bi-directional flow.
• Fairly high cost for small pipes, better
value on larger pipes.
• Non-invasive design can be installed
with no shutdown & no tapping the line.
• Type of transducers and sensing
method best suited for application can
be dependent on type of pipe and fluid
properties.
Thermal Dispersion Meter
• High accuracy & turndown.
• Immersion sensor, Hottapable versions
available.
• Suitable for Gas and Compressed Air
Applications.
• Compensated mass flow measurement
technology
• Electronic based sensing system,
provides outputs compatible with the BAS
directly.
 Grading Technologies
• Specifying the correct flow meter technology
for any application should be based on
meeting the project goals.
• Grading the applications at the beginning of
the project, in terms of accuracy requirements,
installation requirements and budget
constraints, will minimize the VE scramble at
design completion.
 Grading Technologies Metering Technology

Turbine Electromagnetic Clamp On Ultrasonic Vortex Shedding Thermal Dispersion Venturi / Differential Pressure Positive Displacement

Closed Loop Chilled Water A A B NR NA D D

Closed Loop Hot Water Heating < 2000F A A B NR NA D D

Closed Loop Condenser Water A A B NR NA D D

Closed Loop GeoThermal Water A A B NR NA D D

Closed Loop Solar Hot Water A B B NR NA D B

Closed Loop High Temperature Heating Water > 2000F B C A B NA D D

Closed Loop Pumped Steam Condensate B B B C NA D A

Closed Loop Boiler Feed Water C C B B NA D D

Open Loop Condenser Water D A B NR NA D D

Applicat
ions Open Loop Geothermal Water D A B NR NA D D

Open Loop Well, Pond, Pool, Water D B B D NA D D

Open Loop Cooling Tower Blow Down Water D A B D NA D D

Sea Water B A B D NA D C

Domestic Water, Potable Systems C A B NR NA D A

Domestic Hot Water C A B NR NA D A

Domestic Make Up Water A A B NR NA D A

C NA NA A NA C NA

B NA NR C A C B
In Conclusion, Why Meter Flows in
High-Performance Buildings?

• Advanced Metering in new and existing

buildings offers enormous benefits to
Designers and Users!
– By providing the system information required to
commission, validate and operate today’s High-
Performance Buildings
– By providing valuable real world baseline data
information for use in future designs
Thank You!

Questions??