Flow Rate Measurements

in

Large Pipes and Open Channels

Contents

This lecture will present to you some basics in fluid dynamics; it should help
you to select the right location and position to place our instruments.
Nevertheless, you will have to try – sometimes you will fail even if it seems
that you have chosen the right place and sometimes measurements may be
possible even if careful considerations recommend to select another place.

A second part will show instruments that may be used for large pipe flows and
open channel flows. It will of course focus on our instruments especially our
OCM Pro.

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Contents

1. Introduction
2. Basics in flow rate measurements
3. Measuring principles
2.1. Flow rate measurement by height and propeller
2.2. Weirs
2.3. Flumes
2.4. Magnetic Inductive Flow Measurement MID
2.5. Radar
2.6. Ultrasonic-Doppler (CW)
2.7. Ultrasonic Pulse-Doppler
2.8. Ultrasonic Transit-Time
2.9. Ultrasonic Cross-Correlation

3. OCM Pro
4. Applications

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Introduction
Introduction

Flow rate measurements in fully filled pipes usually achieve very

high accuracy, especially for smaller pipe diameters < DN200. Due
to a lot of competition, both manufactures and measuring principles,
the price for this instruments is mainly reasonable, too.

The situation changes with large pipes and/or open channels with
irregular velocity profiles, eventually partially filled with backwater,
low flow levels and low flow velocities. You can not expect to
achieve comparable accuracies as for fully filled pipes and the price
for accurate measurements in increasing, too.

Nevertheless, the demands for accurate, reasonable priced instru-

ments has increased in the past and this process is still ongoing.
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Introduction

channel height
v

vn

Q   v( x, y )dA
v2 A
y
v1 x  vA
z

v
channel bottom

To determine the flow rate Q the integral of the velocity v(x,y) over the entire
profile A perpendicular to the channel has to be calculated.
There are different possibilities to determine this profile:
1.) The velocity is measured in a few well known points/areas of the profile. To
calculate Q estimations about the profile and/or the measuring point are required.
2.) The mean velocity is determined by integration; the second formula gives
directly Q.
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Basics

After a proper installation the installed flow rate meter will offer you a reading of measured values.
The user has than the task to decide whether this reading is correct, he may get some advices from
his handbook – but advices are usually very general and do not fit to the individual situation.
Nevertheless, the user has to define his demands, mainly a good reproducibility and linearity may
fulfil his requirements; but sometimes a very good reading of the absolute value is required as well.

Larger deviations of the reading – more than 30 % – are easy to detect in general – they are usually
caused by a poor installation. Often the seller is asked than for help by phone – this help is doubtful
taking into account the problems of the distance and an accurate description of the measuring
position.

If the deviation is less than 10 % it is difficult to decide whether the instrument gives wrong values, a
reference is required and it may be difficult to decide which instrument is wrong. The general
proposal to increase the entrance length may fail – for larger pipes or channels there is often not
enough space to include a longer entrance length.

But:
All flow rate meters are effected by the flow conditions at the measuring position. This may really
cause large errors of reading.

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Basics

Characteristic number: Reynolds number Re:

 
  v D
Re 
  
 
v = mean velocity, D = characteristic length for example pipe diameter.  = cinematic viscosity
Low viscosity = liquids like water, …
High viscosity = liquids like oil, honey, …

Re < 2300 = Laminar flow

= Hagen-Poiseuille flow conditions

Velocity distribution in a pipe ca be calculated:

R2 d p   r  
2

v z (r )   1    
4 d z   R  

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Basics

1.8

1.6

1.4

1.2
The flow profile develops itself from the wall,
1
a fully developed profile requires theoretical
an infinite entrance length. In praxis is is
0.8 sufficient to consider if there is less than 1 %
of deviation at the axis velocity. The entrance
0.6 length is given by:
 
0.4
  la  Re d  Ca
0.2  
The constant was measured to be at about
0 0.04. At Re = 2300 you need 100 D as
-1 -0.5 0 0.5 1 entrance length.

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Basics

For large pipe and open channel flows you have only turbulent flow conditions (Re > 2300).

= different flow conditions = velocities in all directions = local fluctuations of about 10 %

The axial velocity distribution is only a mean distribution, that can not be calculated
theoretical. Experimental distribution – fully developed – is give by:

 
1
    r  n
  v z (r )  vmax 1   
    R 

n is changing from about 7 to 12 with increasing Reynolds number.

= with increasing Reynolds number the profile is becoming more and more flat.

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Basics

Also her the profile is

1,4 developing itself from the
wall. Due to the turbulence
1,2 and fluctuations of the
velocity in all directions
the required entrance
1
length is shorter, usually
20 – 50 D are sufficient;
0,8 independent from the
Reynolds number.
0,6  
A disturbance of the
profile is much faster
0,4 reduced for turbulent flow
conditions than for laminar
0,2 ones.

0
-1 -0,5 0 0,5 1

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Basics
Fixing of the working range, at the critical Reynolds number of Re > 2300 the flow changes from
laminar to turbulent flow.

v D
Re 
Assumptions: 
v > 0,10 m/s
D > 0,10 m

= 10-6 m²/s (water)

Re = 10.000 > 2300

For waste water turbulent flow

there are only conditions
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Basics

In praxis one considers different disturbances causing problems at the

installation location. The most important are:

1.) bows of 30°, 60°, 90° change of direction

2.) a second bow behind a first one, as S-shape, U-shape or out of

plane

3.) elements in the flow field – valves, sliders, connections, …

4.) jump in the pipe diameter

5.) elements in the flow field causing swirls

The effect of these disturbances is soon reduced in general, but a swirl

is very permanent and may have an influence on the signal even after
50 – 100 D.
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Basics
Some of these disturbances are well known and investigated, for example the
flow behind a 90° bow

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Basics
There are different disturbances that reduce the normal flow field: Valves open and
partly open, sliders, closing elements, temperature elements, connecting elements, …

The disturbance may be swirls effecting the flow field. An asymmetric flow profile will last
for more than 8 times of the height of the disturbing element. The element may also
cause oscillating vortexes, that may influence the flow for more than 20 D.

The flow profile in the reduction is becoming flatter than before. It may therefore be an
ideal place for velocity and flow rate determination.
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Basics
A very strong disturbance is the OIML – disturbance, it is used to determine the
accuracy of flow rate meters:

1.) 2 bows out of plane

2.) half plate between the bows stopping one of the swirls after the first bow

3.) increase of the pipe diameter after the 2 bows

4.) only 2 D of entrance length to the flow rate meter

This disturbance is causing a very strong swirl, the center of this swirl follows a
spiral. Additional there is a strong asymmetry of the velocity profile.

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Basics
The flow profile is determined by:
1. roughness 2. velocity 3. level

V surface V surface V surface

Long. section of an hpart = 1/3 DN hpart = 1/3 DN

ideal pipe „without“
roughness

V surface V surface
V surface

Long. section of a hpart = 1/3 DN hpart = 1/3 DN

pipe with „common”

roughness

Vaverage

flowing: v ~ 0- 0,6m/s streaming: v ~ 0,6-1,8m/s shooting: v >~ 1,8m/s

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Basics
The flow profile is determined by:
1. roughness 2. velocity 3. level
Flow level: hpart<< 1/3 DN hpart< 1/3 DN hpart> 1/3 DN

w h ir l b a n d g o in g m in im u m
w h ir l b a n d ,
Flow profile in a pipe with v o r t ic it y o n ly , d o w n , in c r e a s in g
g o o d flo w p r o f ile
n o f lo w p r o f ile flo w p r o f ile s h a p in g
“common” roughness s h a p in g
s h a p in g
at various levels and
increasing velocity

roughness: small medium large

Flow profile at the same

level hpart  1/3 D s tro n g lo w
a lm o s t n o
flo w p r o f ile s h a p in g ,
f lo w p r o f ile s h a p in g , flo w p r o f ile s h a p in g ,
different pipe roughness s m a ll w h ir l b a n d m e d iu m w h ir l b a n d
b r o a d w h ir l b a n d

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Basics
Required Distances

1 8

2 9

3 10

4 11

5 12

6 13

7 14

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Basics
Required Distances
Installation after: Spot Meas. Path Meas. Multi Path Meas. Installation after: Spot Meas. Path Meas. Multi Path Meas.

L1 L2 L1 L2 L1 L2 L1 L2 L1 L2 L1 L2

[Link] 90° 20 5 7 4 5 3 [Link] Influent 15 4 10 3 5 3

[Link] 45° 10 5 7 3 3 3 [Link] Jump 20 4 10 3 7 3

[Link]/Valve 12* 3* 12* 3* 12* 3* 10. Manhole 10 7 8 5 5 3

[Link] 15 4 10 3 5 3 11. Weir 15* 10* 8

[Link] 15 4 10 3 5 3 Installation bef.:

[Link] 10 3 7 3 5 3 [Link] 10 7 5

[Link]. Influent (T) 15 4 10 3 5 3 [Link] 3 3 3

[Link]. Reduction 20 4 10 3 7 3 [Link] 15 4 8 4 5 3

Alle values must be multiplicated with the pipe diameter or the channel width *) depending on supply pressure/h, values * p in m WS

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Measuring principles
2.1. Flow rate determination by height and propeller
Height
Q / h - Relation

A simple height measurement is not sufficient to determine a flow

rate, but a calibration can be done resulting in a Q / h – curve.
Height

Expensive calibration but easy and cheap technique, usually not

very accurate. Influence of back flow is usually not considered and
may cause high errors.
Flow rate
Propeller

The flow velocity can be measured with hydrometric propellers.

With measurement at different points at different heights of the
cross section the mean velocity can be determined. Measuring the
height of the water and knowing the shape of the channel the flow
rate can be determined.

Problems: Mechanical systems can be blocked, “stationary”

conditions are required to measure at different points.

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Measuring principles
2.2. Weirs
Weirs and over fall sills are mostly found at a
rainfall control basin and bypasses for large
storm quantities.

The calculation of over fall quantity is given by:

The over fall coefficient is dimensionless and

dependent on the sill form, and on over fall
height. b is the weir width (width of over fall), h is
the over fall height. The zero height is at the
beginning of the over fall point.

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Measuring principles
Special Weirs

Flow quantity for low flows, very Flow quantity for medium flows, Flow quantity for higher flows,
sensitive to sedimentation. less sensitive to sedimentation less sensitive to sedimentation
High accuracy Average accuracy Average accuracy

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Measuring principles
2.3. Flumes
Flumes are flow measurement devices specially formed for
channels. The flow is accelerated in the narrowing causing a
reduced height. The geometric shapes varies, some types are
listed in the DIN 19559.

Basic Operation:
The narrowing leads to a damming up of the water in front of
the flume. Usually it is possible to ignore the roughness and
slope of the flume. The measurement of the height of the water
in front of the flume is directly related to the flow measurement
in the flume. The smallest measurable quantity of raw sewage
is about 5 l/s. The ratio Qmax to Qmin is at about 10:1; for special
flumes, may be up to 20:1.

Advantages Disadvantages
accurate measurement • no measurement under backwater
easy to control conditions
applicable for each • low measurement dynamics
medium

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 Measuring principles
2.4. Magnetic Inductive Flow Measurement MID

The magnetic inductive flow measurement is based on

Faraday‘s Law of Induction.

Important is that a high accuracy can be achieved

only for completely filled pipes and velocity profiles
that have a rotational symmetry.

Advantages: Disadvantages:
 No disruptive fittings  Measures only conductive

 
    High accuracy fluids > 5 µS
U v  B W dx dy dz
 Gauging capability  Isolating coatings on the
x, y, z
 Independent of pressure electrodes introduces errors
U  k  B Dv of temperature  Errors due to deposits
 High power requirements
  D U
Q  Heavy weight
4k  B  Expensive with increasing Ø
B = Magnetic Field Strength
D = Inside pipe diameter
U = Induced current
k = Constant
W = Weighting function
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Measuring principles
Magnetic Inductive Flow Measurement MID
Bows are used to have a completely filled pipe –resulting in a very expensive
installation. And:
The flow profile is becoming asymmetric
and swirls arise !!

A reliable accuracy can only be achieved

after a recalibration of the instrument over
the complete, entire flow rate range.

Otherwise the instrument has

to give false values!!
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Measuring principles
MID: partially filled pipes, Channel Mouse
Partially full MID´s operate on the same physical principle as completely
filled MID´s. Devious is that the signal differs with different heights due to
several electrode pairs that are used here. For different flow heights
calibration methods are and need to be used to give a reliable reading.

Disadvantages:
 Measures only conductive fluids >10mS
 No measurement < 10% of filling, increasing errors with low heights
 Isolating coatings on electrodes introduces errors
 High power requirement
 Difficult installation and handling

Also in use in open channel and pipes is a easy mountable magnetic

inductive single sensor, generally named „Channel Mouse“. The level is
measured by a pressure transducer at the bottom of the channel, or an
external level sensor.

Disadvantages:
 Point velocity measurement at centre of sensor
MID Sensor
 Not very accurate
for stationary  Only conductive fluids, isolation of the electrodes causes errors
application  Pressure sensor is unstable, especially at fast or highly turbulent flows.
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Measuring principles
2.5. Radar Flow Measurement (for partially filled pipes and channels)

A new measurement principle is the application of radar waves.

These are preferable in the industry for level measurements. The
radar waves through the antenna are transmitted to the surface of
the medium and reflected.
For flow measurement the Doppler frequency shift is used. At a
certain angle the radar waves are transmitted and reflected. The
flow height is measured by a separate level sensor.
Advantages:
Non-contact measurement
No fittings in the medium
Low mounting costs
Low mobilization
R adar
sensor No particles required

d e fle c t e d Disadvantages
h
s ig n a l Vo  A minimum dielectricity of the medium is required
 The velocity is only measured in a point on the fluid surface
s e d im e n ta tio n  The flow profile needs to be is calculated or empirically determined
 Smooth flow surfaces will not reflected the signal

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Measuring principles
2.6. Ultrasound-Doppler (CW)

 Driving direction
„Emitter“ „Sender“

„Receiver“

Doppler effect:
The movement is changing the frequency of the sound
This effect, first described from Christian Doppler 1842 is used in astronomic, medicine and a lot of
industrial applications. We use this effect for flow rate measurements, fixing emitter and receiver and
having a flow with its scatteres.

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Measuring principles

Velocity of sound c:
(at 20°C)

Water = 1480 m/s

Air = 330 m/s
Steel = 5900 m/s
Methanol = 1100 m/s

The sound send of from the emitter meets the scattering particles moving with the flow velocity v with a
frequency f1 under an angle α. The receiver detects a Doppler shifted frequency of:

f1  c 2  v  f  cos 
f2  This results in a frequency shift of: f  f 2  f1 
c  2  v  cos  c
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Measuring principles
Doppler frequency evaluation

There are 2 piezo crystals in the sensor, one as emitter the other as receiver. The US is
continuously sending into the water (cw = continues wave) with frequency f1, the receiver
detects the Doppler shifted frequency f2..

The measured frequency is digitalized in pulses. Measuring the period time has the
advantage to measure low frequencies = low velocities, too. The data are stored and
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stochastically evaluated.
Measuring principles

Number of
samples The frequency range is parted
maximum
in different frequency groups.
100 samples are put in these
groups.

The maximum is used to

Frequency
group
calculate the mean frequency
0 0

Frequency collecting
and the mean velocity.

Reflection of US beam The measuring depth may

Reflection with Flow Velocity from Waves achieve 5 m, depending on the
particle concentration.

Flow

Low water level

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Measuring principles
Doppler (CW) signal evaluation

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Measuring principles

OCM EM

OCM E OCM ER

 OCM – Applications
 Influent and Effluent Flow Monitoring
Pipe sensor
 Storm and CSO Monitoring DER
 Industrial Effluent Monitoring and Control
 WWTP Process Control
 Pre-treatment Compliance Wedge sensor
 NPDES Permitting DEK
 Power Plant Cooling- and Feed Water
Measurement and Control
 Mining By-Wash Monitoring
 Pump Station Monitoring and Control
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Measuring principles

The CW Doppler is not

determining the intrusion depth

? and hence evaluates any

particle within the flow profile!

Advantages: Disadvantages:
Due to the flow profile and Easy mounting  Gas bubbles or solids
numerous reflecting particles a Immersion sensors and required
frequency spectrum for different  No spatial resolution possible
„clamp on“ sensors suitable
velocities is measured. Using
Intrusion depth several feet  Not very accurate
this velocity, a mean velocity v in
the ultra sonic beam can be No disruptive constructions  Calibration required for better
determined. The flow height is accuracy
measured by a separate level
sensor.

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Measuring principles
2.7. Ultrasonic Pulse-Doppler transmitted. Based on a defined beam angle and the
sound velocity, the sensor transmits the signal and
receives it after a certain time. This allows the
determination of a position where the velocity is
measured from the “normal Doppler” frequency shift.
Reflections of particles in other areas do not affect
the velocity measurement.
Knowing parts of the velocity profile assumptions of
the entire velocity profile can be done allowing the
calculation of the flow rate. Also in use is the search
for the maximum velocity, a well known factor may
than be used to determine the flow rate.

Advantages:
Easy mounting
Immersion sensors and „clamp on“ sensors
suitable
No disruptive constructions
Spatial resolution of velocity profile
Disadvantages:
The Ultrasonic Pulse Doppler Principle is a new  Gas bubbles or solids required
development that supersedes all the older Doppler  US calibration required for better accuracy
principles. Short ultrasonic frequency bundles are  Spatial resolution of velocity profile limited
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Measuring principles
Puls Flow Evaluation (single point
measurement)
1. vmax preferred measurement method, the scan

window is at the centre of the pipe (C = r)

2. vaverage the scan window is at the point of mean
flow velocity (rm = 0,77 x r)

Signal intrusion depth, flow velocity results in a

certain scan frequency. Here the pulse repeat rate
(Repeat Frequency) transmitting a new measurement
impulse is important.
Velocity Max. Signal Intrusion Max. Pipe Ø [DN] Max. Pipe Ø [DN] at Repeat
Depth at vmax Evaluation vaverage Evaluation Frequency
at 750kHz Transmitting
Frequency
0 - 1 m/s (0 - 3 ft/s) 340 mm (13.4 in) 680 mm (26.8 in) 2.800 mm (110.2 in) 1463 Hz
0 - 2 m/s (0 – 6.5 ft/s) 170 mm (6.7 in) 340 mm (13.4 in) 1.500 mm (59.1 in) 2927 Hz
0 - 4 m/s (0 - 13 ft/S) 85 mm (3.3 in) 170 mm (6.7 in) 750 mm (29.5 in) 5954 Hz
Adjustment is made automatically, manual adjustment is possible.
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Measuring principles

Transmitter
Installation Example Sensors with Threads

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Measuring principles
2.8. Correlation Picture 1
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 Copyright by NIVUS 39
Measuring principles
Picture 2
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 Copyright by NIVUS 40
Measuring principles
Correlation
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 Copyright by NIVUS 41
Measuring principles
Correlation flow rate measurement

Picture 1 Picture 2
Sensor 1 Sensor 2
Electronic
f1(t) f2(t)
signal

Correlation gives the

Transport velocity

 Copyright by NIVUS 42
Measuring principles
Correlation flow rate measurement
Picture 1 Picture 2
Sensor 1 Sensor 2
Signal Signal
14 14

12 12

Signal height
Signal height

10 10

8 8

6 6

4 4

2 2

0 0
0 5 10 15 20 25 30 35 40 45 50 0 5 10 15 20 25 30 35 40 45 50

Time Time

Correlation gives the Comparison of

Transport velocity signals checking
the time delay
 Copyright by NIVUS 43
 Measuring principles
Correlation
Signal Signal
14 14

12 12
Signal height

Signal height

10 10

8 8

6 6

4 4

2 2

0 0
0 5 10
0 15
5 20
10 25
15 30
20 35
25 40
30 45
35 50
40 45 50

Time Time
Time delay
 Copyright by NIVUS 44
Measuring principles
Correlation flow rate measurement 2

Picture 1 Picture 2
Sensor 1 Sensor 2
Electronic
f1(t) f2(t)
signal

Correlation gives the Comparison of

Transport velocity signals checking
the time delay
 Copyright by NIVUS 45
Measuring principles

This measuring principle is used with different

sensors, i.e. optical, acoustical, electronically and
other physical sensors.
The individual set up defines the selection of
suitable sensors and determines the achievable
accuracy for flow rate measurements.

The next section describes the use of this principle

for an acoustic sensor.

 Copyright by NIVUS 46
Measuring principles

Ultra sonic – cross correlation

Sensor:
Ultra sonic sender and
Ultra sonic receiver

 Copyright by NIVUS 47
Measuring principles

 Copyright by NIVUS 48
Measuring principles

The next generation of flow rate meters,

respectively velocity profile meters is our new ultra
sonic cross correlation based COM Pro. Similar to
pulse Doppler is the spatial determination of the
Picture 1
velocity profile, but with a much higher resolution
due to a completely different signal evaluation that

Velocity-Sensor

Bild 1

Memory Korrelator
Bild 2

Picture 2

is based on correlation technique. A ultrasonic pulse

Velocity-Sensor is transmitted and the echo is received twice, with a
small time delay. Correlating this echo's the mean
velocity of the window (yellow, green, red,…) can be
„Ultrasonic Camera“
determined. The profile determination can be done
Correlation of two similar picture samples
than over 16 different scan layers.
 Copyright by NIVUS 49
Measuring principles

This set up allows the measurement of the velocity in up to 16 “windows“

and therefore the determination of the entire velocity profile.

We use this to measure the flow rate in fully filled pipes. For example the
mean velocity along the path can be calculated and corrected to the mean
velocity by use of the typical formulas well known for example from the
ultra sonic clamp on systems.

But there is a big advantage:

Additional to the mean path velocity a profile measurement is included,
that may be used to estimate the quality of the measuring place. With
some more effort a correction of poor readings can be done as well.

 Copyright by NIVUS 54
Measuring principles
Flow simulation in the City of Vienna according to the SIMK
method by Dr. Koelling

 Copyright by NIVUS 55
Measuring principles
This velocity profile can be used to perform flow rate measurements in open
channels or partly filled pipes, too. The additional
height determination can be realized with the
integrated ultra sonic sensor or an external sensor.

The integrated additional water level sensor has the advantage of an easy
mounting; foam or similar things do not influence the level measurement.
The connection of an external level sensor however is possible and under
certain circumstances, recommended. The gates are adapted in size and
positioned variable. At low levels the number of gates is decreasing.
 Copyright by NIVUS 56
Measuring principles
Uncertainties
Some errors influence the overall error in the usual way:
f1 = time error = velocity measurement = 0,10 % of rate
f2 = angle of installation (5°) = 0,75 %
f3 = flow profile = 0-10 % typical 1 %
f4 = measured path length in the flow profile = 0-20 % typical 1 %
f5 = number of gates = 1/ N for 4 Gates 0,5 %
f6 = black zones 6 = 0-50 % typical 1 %

Total mean uncertainty (typical)

 i
f
11
2

= 1,96 %

Advantages Coatings causes no error – it will stop

High accuracy – measurement is time based, No disturbing construction
not frequency based Low Energy Consumption
Integrated level measurement
Suitable for large channels Disadvantages
Low mounting costs even at larger diameters  Requires particles, minerals or gas
Measures oil, no minimum conductivity bubbles in the medium
 Copyright by NIVUS 57
Comparison between Doppler and Correlation
Looking at the basics of Doppler and Cross-Correlation You will find:

Doppler:
f basic  c
Doppler shifted frequency: f shifted 
c  2  v  cos 
2  v  f basic  cos 
Detected frequency: f  f shifted  f basic 
c

 Copyright by NIVUS 58
Measuring principles

Doppler – Systems: Correlation – Systems:

Typical minimal spatial resolution: Spatial resolution is 5-10 times higher

> 0.3 – 0.4 m 0,01 – 0,02 m

Velocity = 0, Frequency = 0 Velocity = 0, frequency = 0

cant be measured Can be measured
Minimal velocity (typical): Minimal velocity:

v > 0.05 – 0.1 m/s v = 0 m/s

Depending from the basic No frequency (temperature)

frequency: dependency towards velocity
Aging effects, temperature effects, determination
(annual calibrations may be required)

 Copyright by NIVUS 59
OCM Pro
OCM Pro
OCM Pro makes
flow visible!

Leyers

Vaverage Vmax

 Copyright by NIVUS 64
OCM Pro
Operating Instructions

 Copyright by NIVUS 65
OCM Pro
Sensors
The sensors are available as
combination sensor (v + h) or just as velocity (v) sensors

Wedge sensor
(v + h)
PEEK-Sensor with
PTEF Cable

 Copyright by NIVUS 66
OCM Pro
Sensor mounting

Several Sensors
 Copyright by NIVUS 67
OCM Pro Italy Trento

 Copyright by NIVUS 69
OCM Pro Airport Vienna

Datum ARA-Zul. Berechnung Abweichung Abweichung Max.

m³ Soll ARA-Zul. m³ % Abweichung
11.08.2006 51.740 #BEZUG! #BEZUG! #BEZUG! 4,0 %
12.08.2006 44.360 43.259 1.101 2,5 % 4,0 %
13.08.2006 45.120 44.532 588 1,3 % 5,0 %
14.08.2006 65.030 63.134 1.896 2,9 % 4,0 %
15.08.2006 35.040 35.573 -533 -1,5 % 4,0 %
16.08.2006 39.680 38.680 1.000 2,5 % 4,0 %
17.08.2006 36.770 37.059 -289 -0,8 % 4,0 %
 Copyright by NIVUS 70
 Vienna

 Copyright by NIVUS 71
OCM Pro
Sensors
The sensors are available as
combination sensor (v + h) or
just as velocity (v) sensors

Flange version with ball walve

Insertion sensor Pipe sensor

Sensor with external Extension with ball-and-socket joint
 Copyright by NIVUS 72
OCM Pro
Sensors
One 1400mm Magnetic Inductive Flow meter has to be replaced in a sludge pipe.
At an existing drainage (emptying) pipe end the OCM was installed within hour.
The Magnetic Inductive Flow meter wasn't dismantled. Cost saving approx. 30.000 €.

Pipe sensor with ball valve

Flow Measurement for

Slide Control

 Copyright by NIVUS 73
OCM Pro
Sensor mounting

 Copyright by NIVUS 74
PCM Pro

The correlation technique is also available as portable unit

 Copyright by NIVUS 75
PCM Pro

Operation modes
• cyclical: 1 – 60 min cycle
• event: level or digital input
• Internal storage –14 days storage capacity
(means high data security)
• trend display (displaying the past 14 days:
Q, v and h)
• rechargeable battery:
min. 21.000 measuring cycles

 Copyright by NIVUS 76
PCM Pro
Redundant level measurement
• Integrated water-ultrasonic probe (mounting on the channel
bottom)
• Integrated pressure probe
(backwater and levels
up to 3.5 m)
• External air - ultrasonic probe
(for low levels)

 high flexibility and variability

 Copyright by NIVUS 77
Flow Portable * Cross Correlation
PCM Pro portableFlow Data Logger
• portable for all channel profiles
• high accurate real flow profile
measurement
• drift free and no calibration
required
• using the proven cross correlation
method
• with redundant level measurement
Air ultrasonic sensor
for flow level
measurement

Water ultrasonic
sensor for flow
level measure-
ment

Pressure sensor for flow

level measurement
 Copyright by NIVUS 78
Flow Portable * Cross Correlation
PCM Pro Flow Data Logger in Ex-Version
Flow Velocity Measurement Principle:
Ultrasonic Cross Correlation with digital Pattern Detection

Flow Level Measurement Principle

Water Ultrasonic 0-2000mm ± 2mm
Air Ultrasonic 0-1500mm ± 2mm
piezoresistive Press. Probe 0-3500mm ± 0.35% FS
Ext. Level Measurement Input 4-20mA

General Specifications
Temperature Meas. -20 to + 60°C
Lifetime min. 21.000 Measurement Cycles
At hourly Storage 1 Year
Calc. Batt. Capacity 25Ah
Data Storage Capacity up to 128 MB Flash Card

Data transmission Flash Card, RS 485, wireless

Radio and Modem available later
Storage intervals 1,2,3,4,5,6,10,12,15,20,30,60 Minutes
Dimensions 272x249x137mm (WxHxD)
Weight approx. 6.5kg
Ex Approval ATEX Zone 1
Protection IP67
 Copyright by NIVUS 79
Flow Portable * Cross Correlation
PCM 4 Flow Data Logger
18
10

1 Connection plug, IP68 10 Level sensor, air-ultrasonic

2 Air filter / Dryer 11 connection combi sensor
3 Sensor cable 12 Output 0-10V DC
4 Sensor enclosure 13 Output switching contact
5 Mounting plate 14 Input 0/4-20mA
16 6 Cable gland 15 Input switching contact
7 Flow velocity crystal 16 Battery charger socket
10 8 Level sensor, hydrostatic 17 Flash card
9 Level sensor, water- 18 Pipe mounting system
ultrasonic
11

12 13

14 15
17

 Copyright by NIVUS 80
Flow Portable * Minimum Volumes
Two possibilities to capture minimum volumes:

Dam-up element

NPP
NIVUS Pipe Profiler

 Copyright by NIVUS 81
Flow Portable * Minimum Volumes
NPP for Recording of Minimum Volumes

NPP – Installation in a manhole

NPP – NIVUS Pipe Profiler

Flow measurement in a
permanently full filled
pipe (NPP) with PCM Pro

 Copyright by NIVUS 82
OCM Pro LR
OCM Pro LR

M16 x 1,5

35,5
226
120 50,0

L e v e l o p t io n a l

 Copyright by NIVUS 88
OCM Pro LR

OCM Pro LR

1420,7
3,7 m3,7 m
3,7 m

 Copyright by NIVUS 89
OCM Pro LR

OCM Pro LR

Measurements up to several meters; verified 5 m in „clean

water“

Inlet of Beckton; London:

Float system with water us height sensor for sludge
detection and external air us sensor

Sensors in Ex-Zone 2, Ex 1/0 not possible !!

 Copyright by NIVUS 90
OCM Pro LR

 Copyright by NIVUS 91
OCM Pro LR

 Copyright by NIVUS 92
OCM Pro LR
* KA Dradenau, Feuerbach

 Copyright by NIVUS 93
Transit time
Transit time

Measurement of the mean velocity along the path.

To be used in clean (?) water, in pipes, open channels and almost all surface
flows. To achieve higher accuracies up to 8 paths may be used.

 Copyright by NIVUS 95
Transit time

L
t 
c  v  cos 

L
t 
c  v  cos 
 Copyright by NIVUS 96
Transit time

L L
With t   and t   You get:
c  v  cos  c  v  cos 

L L

1 1 t  t c  v  cos  c  v  cos  2  ( v  cos  )
   
t t t  t L L L

c  v  cos  c  v  cos 


t  t  L 
v  
t  t  2 cos  
 Copyright by NIVUS 97
Transit time

How do you measure the

transit time
???

 Copyright by NIVUS 98
Transit time

Leading Edge methode

Sensor 1 Sensor 2

U U

T T

Voltage pulse Received pulse

 Copyright by NIVUS 99
Transit time

Determination by Leading Edge

 Copyright by NIVUS 100
Transit time

Correlation methode
U

„Comparison“ of the Correlation

received signal

 Copyright by NIVUS 101

Transit time

We measure the transit time by correlation method;

therefore we may also use it to determine the velocity
profile in front of each sensor by our well known cross
correlation technique.

Limitations:

passive sensors, i.e. damping by long cables, thick walls

(ClampOn technique)
high velocities and larger distances

 Copyright by NIVUS 102

Transit time

Aims:
1. Investigating and documenting the flow conditions at
the start up of maintenance of the device.
Including to use the data for a calibration of the
device.

2. Using both technologies:

Transit time will still work with longer cables – it will
fail with high pollution. Here the correlation profiler
will still work; but with reduced entrance length.

 Copyright by NIVUS 103

Transit time

Transit time
L

L
t 
+ c(T )  v  cos 


t  t L
V c 
- t  t 2

The sum of the transit times will result in a relation of distance of

the sensors and sound velocity as a function of the temperature.
 Copyright by NIVUS 104
NivuSonic
NivuSonic

screw-in sensor plug-in sensor

for pipe installation for pipe installation
from outside from inside

 Copyright by NIVUS 106

NivuSonic

Flow velocity measurement in full filled pipes

Measurement principle Transit time and cross correlation for profiling

Measurement range from -20 m/s to +20 m/s
Error limits 1 path (1E1P): 3 - 5 % o.r. + 0,025 m/s • cross-section
(depending on hydraulic 2 path (1E2P; 2E2P) 2 - 4 % o.r. + 0,020 m/s • cross-section
conditions) 4 path (1E4P; 2E4P) 1 - 2 % o.r. + 0,010 m/s • cross-section
8 path (2E8P) 0.5 - 1 % o.r. + 0,005 m/s • cross-section
Nominal width from 0,2 m to 12 m inside diameter (DN 200 to DN 12000)
Number of sensor pairs 1 to 8 measurement paths; pipes: 1E1P to 2E8P, according to IEC41
Measuring frequency 1 MHz
Protection rating IP 68
Operating temperature -20° C to +50° C ( -4°F to 122°F)
Storage temperature -30° C to +70° C ( -22°F to 158°F)

 Copyright by NIVUS 107

NivuSonic
Flow velocity measurement in full filled pipes

Operating pressure max. 80 bar

Cable length 10/15/20/30/50/100 m,
extendable up to max. 200 m cable length via adapter box
Cable type Twinax, 100 Ohm
Cable outside diameter 8.5 mm
Cable to the interface RS 485
Sensor types for use screw-in sensors for pipe installation from outside
in pipes (wall thickness plug-in sensors for pipe installation from inside
10 to 60 mm)
Medium contacting stainless steel 1.4301, CFK (Carbon), Viton
materials •
Temperature measurement Measurement range 0° C to +60° C
via sound velocity error ±1 K
 Copyright by NIVUS 108
NivuSonic

 Copyright by NIVUS 109

NivuSonic

NivuSonic

Durchmesser

 Copyright by NIVUS 110

Internet Access

OCM Pro und

NivuSonic sind
per Internet
konfigurierbar
und abrufbar.

 Copyright by NIVUS 111

NivuChannel
1. Applikation
Transit time measuring device

 Copyright by NIVUS 113

1. Applikation

Natural water:
Rivers, ..

Artificial water:
channels, inlet, outlet

 Copyright by NIVUS 114

2. Theory

Q   v( x, y )dA
A

 vA

To determine the flow rate Q the integral of the velocity v(x,y) over the entire
profile A perpendicular to the channel has to be calculated.
The mean velocity is determined by a “numerical” integration, measuring the
velocities in one to several paths. To calculate Q estimations and/or calibrations
along the profile are required.
 Copyright by NIVUS 115
2. Theory

• possible configurations

Main flow direction Main flow direction

1 Path 2 crossed paths

 Copyright by NIVUS 116

2. Theory

Single path configuration

 Copyright by NIVUS 117

2. Theory

Crossed paths
Required if the main flow direction is not parallel to the river banks

 Copyright by NIVUS 118

2. Theory

Several paths in the cross section

Required if the cross section of the water is changing due to significantly changing
water levels. Results in a higher accuracy.

4 3
2 1

Each path can be configured as single or crossed path.

 Copyright by NIVUS 119

2. Theory
Flow rate determination
DIN 6416 (meanwhile European law as well)

L1 2  1 1 
Q  k  A  vg  k  A 
  
2 cos 1 2  t1 2 t 2 1 

All QS will be summed up, the highest and lowest section has to weighted
correctly.
 Copyright by NIVUS 120
3. Calibration

Transit time only determines the mean velocity

between the 2 sensors –
that is not the mean velocita across the whole
cross section.

Therefore always a calibration is required.

 Copyright by NIVUS 121

3. Calibration

Q = A  vg  k 1  k 2

Correction factors:
k1 theoretical velocity corrector

k2 application corrector

 Copyright by NIVUS 122

3. Calibration

Determination of k1: Determination of k2:

• Empirical • Measurements in place

• Logarithmic • numerical flow modelling
(for example SIMK®)
• Hydro numeric
• Hydraulic assumptions

 Copyright by NIVUS 123

3. Calibration
Calibration with a turbine

n
tio
i rec
d
w
n flo
i
Ma
Perpendicular to the
flow direction

Due to DIN EN ISO 6416 a calibration is essential !!

 Copyright by NIVUS 124

4. Uncertainties
Air bubbles

no measurement possible

 Copyright by NIVUS 125

4. Uncertainties
Temperature

Significant vertical density difference

due to sun shine

no measurement possible

 Copyright by NIVUS 126

4. Uncertainties
Salt content

Significant vertical density difference

due to salt content

no measurement possible

 Copyright by NIVUS 127

4. Uncertainties
Vegetation

no measurement possible

 Copyright by NIVUS 128

4. Uncertainties

Entrance length: (5-)10 x width

Outlet length: (1-) 2 x width
Alternative: crossed paths
Back flow: usually no problem
(may be more paths required)

Water level: sensors need to be covered

(+ wave height, [+ offset recommended])

Uniform velocity profile is required for highest accuracies

No influence of wind

 Copyright by NIVUS 129

5. Installation

Access may be with machines

Energy 200V, alternative 24 V (or solar energy 12 V [under investigation])

Cabeling in protection hoses, may be along bridges;

if on the ground chains are recommended
Access should be near by to do reference measurements
(turbines, ADCP)

 Copyright by NIVUS 130

6. Measurements

Sensor v
Level h

Calculated
flow rate Q

Results

 Copyright by NIVUS 131

7. Measuring system

Channel

Communication

Office

 Copyright by NIVUS 133

7. Measuring system
Sensor

Piezo-ceramic
Distance dependant from sending frequency and sending power

 Copyright by NIVUS 134

7. Measuring system
Sensor

Tube sensor

Half ball sensor

 Copyright by NIVUS 135

7. Measuring system
Mounting of the sensors

 Copyright by NIVUS 136

7. Measuring system
Cabeling

 Copyright by NIVUS 137

7. Measuring system
cabeling

Protection hose Cabeling under a

bridge

Cabeling with chains

under at the ground

 Copyright by NIVUS 138

7. Measuring system
transmitter

 Copyright by NIVUS 139

7. Measuring system
Level meter

NIVUS offers several different techniques

 Copyright by NIVUS 140
7. Measuring system
Firmware

As usual for OCM Pro, ... Very easy to handle the unit.
Menue driven, storing of data, graphical output

 Copyright by NIVUS 141

7. Measuring system

Diagnostic tool for adjustment of the sensors

 Copyright by NIVUS 142

8. Applications
Prototype Witten/ Ruhrverband

 Copyright by NIVUS 143

8. Applications
Wassenairbrug/Netherland in cooperation with mit ODS

 Copyright by NIVUS 144

8. Applications
Pegel Berching (Main- Donau- Kanal)

 Copyright by NIVUS 145