Flow Calibration
ABB Facilities Overview 3 Calibration Methods Compared
3 Calibration Methods Compared
Gravimetric Volumetric Comparison
Maximum run time Limited by size of tank/scale Limited by size of tank Unlimited
Minimum run time Fixed by size of tank/scale Fixed by size of tank Unlimited
Depends on scale uncertainty, Depends on volumetric tank
Depends only on the
density uncertainty, buoyancy calibration uncertainty,
Uncertainty reference meter
uncertainty and temperature temperature uncertainty and
uncertainty
uncertainty. timing uncertainty.
Run time at maximum flowrates is Run time at maximum flowrates is
governed by the time taken to fill governed by the time taken to fill
the tank. the tank.
Run time at minimum flowrates is Run time at minimum flowrates is
governed by the amount of water governed by the amount of water
Limits on run time Unlimited
required to be put into the tank to required to be put into the tank to
ensure that the weight can be ensure that the volume can be
measured with an acceptable measured with an acceptable
uncertainty (normally around 25% uncertainty (normally 100% of its
of its capacity). capacity).
Can make run times very long, Can make run times very long,
Effects of run times at low
introducing uncertainties (for introducing uncertainties (for No effect
flowrates
example, evaporation). example, evaporation).
Tank capacity can make run times Tank capacity can make run times
Effects of run times at high
very short – they must be ≥30 very short – they must be ≥30 No effect
flowrates
seconds. seconds.
Table 3.1 Flow Calibration Method Comparison
There is no best method; all reputable laboratories use the
method best suited to achieving the most accurate result and
this depends on circumstances. The gravimetric calibration
method is often perceived to be the best but, as most
flowmeters are volumetric, mass measurement must be
converted into volume allowing errors to be introduced.
At Stonehouse, ABB manufacture and calibrate a range of
flowmeters with bores ranging in size from 15 to 2200 mm (0.6
to 86.6 in). The diversity of such a large range of sizes means
that different calibration methods must be used.
ABB use the gravimetric, volumetric (ball prover) and
comparison methods. Having this range of methods available
means that the most applicable methodology can be chosen to
suit the best interests of ABB's customers.
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Flow Calibration
ABB Facilities Overview 4 Laboratory Accreditation
4 Laboratory Accreditation
In the United Kingdom, the laboratory accreditation body is the
'United Kingdom Calibration Service' (UKAS). UKAS is the sole
national accreditation body recognized by government to
assess, against internationally agreed standards, organizations
that provide certification, testing, inspection and calibration
services.
Accreditation by UKAS demonstrates the competence,
impartiality and performance capability of these evaluators.
Customers can be confident that a UKAS-accredited laboratory
will carry out the calibration correctly, in accordance with laid
down and UKAS approved procedures that will provide results
within the uncertainty budgets published in the accreditation
documentation.
ABB's UK laboratory at Stonehouse is accredited by UKAS1 as
laboratory 0255.
ABB's Australian Laboratory in Sydney is accredited by the
'National Association of Testing Authorities' (NATA2). NATA uses
ABB's flow laboratory as the Australian Standard.
ABB's USA Laboratory at Warminster is accredited by the
'National Institute of Standards and Technology' (NIST3).
ABB's German Laboratory is accredited by the
'Physikalisch-Technische Bundesanstalt' (PTB4).
ABB's Chinese Laboratory is accredited by the 'Shanghai
Institute of Measurement and Testing Technology' (SIMT5).
ABB's Indian Laboratory will be accredited by the 'National
Accreditation Board for Testing and Calibration Laboratories
(NABL6).
All the above laboratories are linked by means of the
'International Laboratory Accreditation Cooperation' (ILAC7),
ensuring that, irrespective of where in the world a meter is
calibrated, provided that it is calibrated at a nationally accredited
laboratory, the calibration will be within the published uncertainty
for that laboratory.
1. For more information contact [Link]
2. [Link]
3. [Link]
4. [Link]
5. [Link]
6. [Link]
7. [Link]
TD/FC Issue 1 5
Flow Calibration
ABB Facilities Overview 5 UKAS-Accredited 0255 Calibration Laboratory Schedule of Accreditation
5 UKAS-Accredited 0255 Calibration Laboratory Schedule of Accreditation
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Flow Calibration
ABB Facilities Overview 6 Large Flow Laboratory
6 Large Flow Laboratory
Control Room Pump Manifold and Valves
Inlet Manifold and Valves
Transfer Standard Meters
Prover Inlet Manifold and Valves
4-way Diverter
Valve
Prover Launch
Chamber
Prover Control Valve
Outlet Manifold
Fig. 6.1 The World's Largest Continuous Flow Laboratory
Flowrate capacity 7 to 2800 l/s (1.85 to 740 US gal/s)
Accredited to UKAS and International Flow Standards
The keystone of ABB's Global Flow Calibration Ability
The large flow laboratory contains 3 work centers, designated lines 1, 2 and 3. Each has a choice of up to 4 transfer reference
standards, depending on velocity. These reference standards require calibration and functional checking every 2 months. The
calibration procedures for the product range testing are contained in work instruction F.F.I.3.08.01.
TD/FC Issue 1 7
Flow Calibration
ABB Facilities Overview 6 Large Flow Laboratory
6.1 Capacity 6.2 Summary of Operation
The Large Flow Laboratory is UKAS-accredited (Laboratory no.
6.2.1 In-line Proving
0255), to a maximum flow of 2800 l/s (740 US gal/s). The The primary measurement device used is a 762 mm (30 in)
laboratory is served by two large 909 l/s (240 US gal/s) and two meter prover loop, calibrated to BS EN ISO 7278-2 1996. This
small 454 l/s (120 US gal/s) pumps for parallel operation, prover loop is used to calibrate the 4 Transfer Standard streams
providing a maximum throughput of 2700 l/s (713 US gal/s) at 2 consisting of 150, 350, 400 and 450 mm (5.9, 13.8, 15.75 and
bar (29 psi) pressure. The combined power consumption at 17.7 in) MagMaster flowmetering systems.
2000 l/s (528 US gal/s) is 1032 kW.
The prover loop is a volumetric calibration device comprising a
The water is circulated continuously from a main sump holding pipe section of a known volume of 32,227.250 litres (8,513.54
approximately 1,000,000 litres (264,000 US gallons). The sump US gallons) containing a polyurethane proving sphere. The
is equipped with de-aeration chambers to remove entrained air sphere is approximately 3% larger than the pipe section,
from the water. providing a good interference fit to eliminate leakage past the
sphere.
The sphere is introduced or 'launched' into the flow of water
from the meter in calibration and propelled through the prover
pipe by the differential pressure across the sphere. Detector
switches mounted on the prover pipe walls, a fixed distance
apart, enable the sphere travel time to be measured. The
volume of water passed between the switches is known. The
process is repeated at different flow rates, in both forward and
reverse directions, across the range of each individual stream,
thus setting the primary measurement that the transfer meters
are adjusted to, if required. The uncertainty of measurement for
the transfer standard meters must be less than 0.1 % of actual
measurement. The calibration repeatability of the prover is
achieved by performing 2 or more consecutive runs within
<0.02 % of the average base volume. A third run (or more if
necessary) is carried out at varying flowrates to verify the
absence of a consistent leak.
Fig. 6.2 ABB Prover Loop Calibration Report with a Repeatability of 0.012 %
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