A Total Solution for Orifice Plate Calculations
Contents
1. Who Needs Flowel Operating Companies Do More With Less Process facilities face increasing global competition For companies that operate process facilities increased competition means lower margins Simultaneously cus tomers and regulators are imposing new demands e compliance with tougher safety legislation such as the Occupational Safety and Health Act 1910 119 USA e compliance with environmental standards such as the Clean Air Act USA and e increased product quality through Total Quality Man agement and ISO 9000 programs Flowel can help meet these demands Page 2 of 9 e For safety use Flowel to create accurate updated documentation of all flow elements used in hazardous conditions In many places workers have a legislated right to know about information required for safe op erations Such information includes materials of con struction and flow rates Around the world plants use Flowel to keep accurate records e To track fugitive emissions and leaks you need accu rate flow measurement Use Flowel to determine the accuracy i e uncertainty of any flow calculation e Your organization s Total Quality Management or ISO 9000 procedures may require that you verify software against known standards Flowel complies with all major standards used in the world AGA 3 also known as ANSI API 2530 or GPA 8185 ISO 5167 ASME MFC 3M Failure to comply with regulations can result in crippling fine2. We invited several equipment vendors to participate in the Flowel 3 development process Today Flowel is a true profit center for these vendors Join them and give your customers the quality they deserve Regulators Checking the Meter In many places government regulators check flow meas urement calculations involving custody transfer e g natu ral gas sales These individuals inspect meter installations to confirm correct calculation of flows Ideally regulators want a software tool that industry accepts as a standard Flowel is a de facto standard for the measurement com munity e Flowel has a long association with the International Society for Measurement and Control formerly In strument Society of America e A variety of industries use Flowel throughout the world e No other product for the IBM PC has been on the mar ket longer than Flowel A number of government regulators are using Flowel They report that inspected parties readily accept Flowel Regulators find that Flowel is easy to use which reduces errors which in turn builds confidence among inspected parties Make a hard job a little easier use the industry standard Flowel FLOWEL 3 0 Information Fax l How Will Flowel Benefit You Managers If you manage an instrumentation group you know that good software is more than a user manual and some floppy disks The difficult issues are training technical support upgrades and product longevity
3. Kenonic Controls Flowel Version 3 0 for Flow Element Sizing and Documentation Revised July 1998 A Total Solution for Orifice Plate Calculations l Introduction Flowel version 3 0 is an MS Windows application that makes sizing orifice plates nozzles and venturis easier than ever Recently revised new features include updated calculation methods an optional fluid properties package and a redesigned user interface Flowel is part of a total flow element solution that includes training technical support and ISO 9000 validation documentation A 30 day trial is available This document provides a summary of Flowel benefits Why Worry About Orifice Plates Industrial process facilities in the 1990s are experiencing rapid changes in competition safety management and quality assurance To optimize production processors must use accurate flow measurement to track energy feed stocks and products Losses from inaccurate measurement are high Recently an audit of a natural gas facility re vealed losses of 20 million over an eighteen month pe riod due to measurement problems VENT HOLE LOCATION LIQUID PIPE INTERNAL DIAMETER DRAIN HOLE LOCATION VAPOR SERVICE Orifice plates are commonly used to measure flow The process industry commonly uses orifice plates noz zles and venturis to measure flow Relatively inexpensive these devices provide accurate measurement when cor rectly sized and installed
4. For experienced users Flowel has full data import and export capability Perform bulk data entry into a spreadsheet and then import the data into Flowel FLOWEL 3 0 Information Fax Page 5 of 9 Import process data from other software Export data for backup or for use in other programs Purchasing To ensure compliance with your company s equipment standards attach a Flowel generated specification sheet to your purchase orders or quotation requests e Most company standards for flow elements are based on AGA 3 ISO 5167 or ASME MFC 3M Use Flowel off the shelf to support your company standard e With Flowel generate specification sheets that com pletely and unambiguously describe your equipment requirements Minimize follow up discussions with vendors Avoid expensive errors in delivered materi als Flowel generated specification sheets have been used throughout the world since 1985 Plant Maintenance Keep track of your plant s fluids and flow elements with Flowel e Ifyou deal with hazardous materials government regulations e g OSHA 1910 in the USA may re quire you to store and maintain the design documents for orifice plates nozzles and venturis Flowel lets you to electronically store and update your specification sheets e Operators often need a quick way to estimate flow Use Flowel to create graphs of flow rate versus differ ential pressure e When the composition of a process fluid changes
5. Unfortunately sizing and meas urement calculations are complicated Errors are common even though most organizations perform calculations with FLOWEL 3 0 software Bugs poor user interfaces and obsolete equa tions are wide spread Make sure your flow calculations are performed with the best software available The cost of software is negligible compared to the cost of poor flow measurement Look for a product that meets the needs of your entire organization engineering operations network administration and qual ity assurance Protect your investment by selecting a repu table vendor with a proven record Flowel A Brief History Flowel is the result of a long collaboration with our cus tomers Fifteen years ago Kenonic Controls wrote the first version of Flowel for the DEC PDP 11 23 computer In 1981 we rewrote Flowel for the just introduced IBM per sonal computer Much less expensive than a minicom puter the PC offered instrument engineers accessible computing power In 1985 we entered Flowel into a com petition sponsored by the Instrument Society of America Flowel won its class and was included in the ISA catalog In 1985 most instrument engineers still manually per formed flow calculations The equations were familiar computers were not Given this user environment and the limitations of the early PC s Flowel version 1 had a lin ear program flow An instrument engineer started up Flowel and progr
6. We offer a total solution that addresses all of these issues e For ninety days after a Flowel purchase we will pro vide support and upgrades After ninety days you may purchase a maintenance agreement that provides for continued support and select upgrades Alternatively you may elect to purchase support when necessary and upgrades upon availability Ask us about the details e The Flowel user manual provides a tutorial on pro gram usage Most users familiar with orifice plate cal culations or with other programs will find the tutorial sufficient For users that are not familiar with flow measurement concepts we can provide training either at our location or on site We have also custom devel oped courses for delivery by computer Contact us for more details l P Our engineers perform work around the world e We can provide engineering services related to any as pect of flow measurement or control systems Our en gineers have performed work throughout North and South America Projects have involved PLCs flow computers SCADA and DCS applications Of special note is our Flow Measurement group This group can help you with plant balance and custody transfer ap plications Please call us for a detailed description of our qualifications Page 4 of 9 e We constantly upgrade Flowel with the latest stan dards from AGA ISO ASME and others We also upgrade Flowel to support the latest
7. Today we are challenged to accurately employ these new standards Few of us have time to study or even find the latest flow calculation methods we must rely on our software tools Flowel version 3 provides the latest flow calculation meth ods from the American Gas Association American Soci ety of Mechanical Engineers the British Standards Insti tute and the International Standards Organization It pro vides a database of over six hundred fluids and methods for calculating density viscosity isentropic exponent and vapor pressure Flowel 3 provides access to all major functions with only a few screens Before designing Flowel 3 we reviewed FLOWEL 3 0 Information Fax hundreds of customer comments and technical support calls Built for MS Windows the Flowel 3 user interface provides for both new and experienced users New users can access on line help and follow a guided sequence of screens Experienced users can proceed directly to a de sired screen and set extensive program defaults for ele ment type base conditions etc Flowel 3 went through six months of beta testing to ensure that Flowel truly offered exciting increases in productiv ity Testers included operating companies equipment ven dors and engineering contractors The production version of Flowel 3 has been on the market since November 1994 Extensive sales to customers throughout the world indicate Flowel s wide acceptance by a broad user community
8. computer operat ing systems and networks We protect your investment in Flowel e Flowel 3 includes a utility to import your existing Flowel 2 database another example of how we pro tect your investment Network Administrators Software has become a major corporate asset To optimize software usage while minimizing administration costs many organizations use networks e You can install Flowel on any network server running DOS MS Windows or Novell Netware See System Requirements for more details We ship Flowel with all necessary instructions and files required for net work installation e Our technical support engineers help you achieve a successful network installation In our test facility we have servers running Netware DOS and Windows e Flowel is an MS Windows application As a result it is compatible with virtually all popular computers monitors and printers Quality Assurance To verify Flowel s accuracy your QA group must verify hundreds of equations To minimize your expenses we provide a number of documents e The Flowel documentation includes a complete de scription of each equation including detailed foot notes that reference original publications This allows an auditor to compare Flowel equations against origi nal source material e We describe each equation using a common set of symbols Flowel documentation is a valuable refer ence for anyone that deals with a variety of flow siz
9. of Burlington USA Kenonic licenses PowerBuilder from Powersoft for both product development and distribution Flowel employs the Watcom SQL relational database engine Kenonic licenses the engine from Watcom Interna tional Corporation of Waterloo Canada Kenonic Controls authors Flowel database files System Requirements As a minimum Flowel 3 0 requires MS Windows 3 1 a 486 computer with 8 megabytes RAM a hard drive with 10 megabytes free a single floppy drive a mouse and a VGA monitor We recommend a PENTIUM computer with 16 megabytes of RAM a CD ROM drive and a Su per VGA monitor Flowel supports MS Windows 3 11 Win 95 NT 3 5 and NT 4 0 Network Server Support Flowel supports installation on network servers running one of the following operating systems DOS 6 0 or higher MS Windows for Workgroups 3 1 MS Windows 3 11 Win 95 NT 3 5 and NT 4 0 Novell Netware version 3 1 or 4 1 not 4 0 We may provide support for other network operating sys tems Please call for information Fluid Property Calculator We provide Flowel with an optional Fluid Property Cal culator that provides methods for determining viscosity isentropic exponent vapor pressure and bubblepoint as well as additional methods to calculate density e Density Methods Soave Redlich Kwong Peng Robinson Lee Kessler and various NBS methods e Viscosity Methods IAPS 1975 Viscosity Eqn water steam only and Lu
10. SGPD ShL hr USGPH SIMPBPD USGPM SIMPBPH USGPS SIMPGPD DEG C SIMPGPH DEG F SIMPGPM DEG K SIMPGPS DEGR atm Bar Hastelloy B Hastelloy C 347 SS Hastelloy B Hastelloy C Pipe Tables Unlimited User Definable Built in 1 8 inch to 32 inch Atmospheric Pressure US Std Atm 1976 by NOAA NASA USAF in H20 kg cm2 kPa mm H20 MPa psia in m micron mm yd cP gm cm sec gmf secicm2 kg m hr Ib ft Ar lb ftsec lb in sec lbf sec in2 mPa sec N sec m2 P Pa sec Btu ft3 Btu in3 kcal m3 kJ dm3 kJ m3 MJ m3 in in F mm mm C Information Fax
11. ailed AGA 8 1992 SG HV CO2 AGA 8 1992 SG CO2 N2 Ideal Gas Method SGi Zf Liquid SG Method SG Density H20 Molecular Weight Method MW Zf NBS NRC Steam Eqn NX 19 Detailed Real Gas Method SGr Zair Redlich Kwong Redlich Kwong Wichert Aziz FLOWEL 3 0 Devices Supported Orifice Plate Standard Orifice Plate Standard Drain Vent Orifice Plate Conical Entrance Orifice Plate Quadrant Edged Orifice Plate Eccentric Orifice Plate Segmental Orifice Plate 1d 6d Thick Orifice Plate 6d 20d Thick Orifice Plate Restriction Honed Orifice Meter Run Venturi Cast Venturi Machined Venturi Welded Nozzle ISA 1932 Nozzle ISA 1932 Drain Vent Nozzle Long Radius High Ratio Nozzle Long Radius Low Ratio Venturi Nozzle Venturi Nozzle Toroidal Throat Venturi Nozzle Cylindrical Throat Density Calculation Methods Requires Optional Fluid Prop Calc Soave Redlich Kwong Peng Robinson Lee Kesler BWR Thompson Brobst Hankinson or COSTALD Modified Rackett Modified Antoine NBS Ammonia Eqn NBS Nitrogen Eqn NBS Argon Eqn NBS Oxygen Eqn IUPAC Carbon Dioxide NBS Hydrogen NBS Methane NBS Ethane NBS Ethylene NBS Propane NBS i Butane NBS n Butane Information Fax Differential Pressure Tap Configu rations Supported Corner Flange Radius Flange 180 deg Offset Flange 90 deg Offset Vena Contracta Vena Contracta 180 deg Offset Vena Contracta 90 deg Offset Pipe Wall Ven
12. cas Viscosity Eqn gases only e Isentropic Exponent Methods Ideal Gas heat Ca pacity Ratio Real Gas with Redlich K wong Correc tion and Real Gas with Lee Kessler Correction e Vapor Pressure Method Antoine e Bubblepoint Methods Soave Redlich Kwong and Peng Robinson For a detailed listing of methods please see the Flowel Features section You may purchase Flowel with or with out the optional Property Calculator See our price list for current prices and terms Evaluating Flowel For a small fee we also offer a 30 Day Trial of Flowel This trial includes all software user manual network files technical support and the Property Calculator Option Should you decide to buy Flowel we apply the cost of the trial towards your first purchase You keep the user man ual regardless of purchase FLOWEL 3 0 Information Fax Page 7 of 9 Flowel Feature List Fluid States Supported gas gas wet gas critical flow liquid liquid critical flow Fluid Database Unlimited User Definable Mixtures water steam natural gas AGA 8 85 natural gas AGA 8 92 ammonia argon carbon dioxide ethane ethylene hydrogen i butane methane n butane nitrogen oxygen propane approx 600 other fluids Density Calculation Methods AGA 8 1985 Detailed AGA 8 1985 SG CO2 N2 AGA 8 1985 SG HV CO2 N2 AGA 8 1985 SG HV CO2 AGA 8 1985 HV CO2 N2 AGA 8 1985 SG CH4 CO2 N2 AGA 8 1992 Det
13. essed through a series of screens It was an inflexible but simple user interface Flowel version 1 used the equations from L K Spink s book Principles and Practice of Flow Meter Engineering For many years this work was the most widely accepted reference on flow measurement Later the American Gas Association AGA 3 and the International Standards Or ganization ISO 5167 released new standards that super seded Spink s work Released in 1988 Flowel version 2 incorporated these new standards Information Fax Page 1 of 9 PRINCIPLES od PRACTICE Fite WATE PSC INES Spink s classic work on Flow Meters The new methods were more accurate and more compli cated Many instrument engineers were using programs like Flowel to perform flow calculations On average us ers were more familiar with computers and less familiar with flow equations In Flowel version 2 we provided these users with a suitable user interface For simple cal culations Flowel provided a simple linear screen se quence For more complicated situations such as ones in volving AGA 8 gas compressibility calculations Flowel provided setting sheets Today the challenge is not calculation speed Most of us are familiar with computers and no one performs manual flow calculations As a result instrument specialists are unfamiliar with the latest standards These standards are more accurate cover more situations and are often more complex
14. ia and else where Use one product for all of your customers e Flowel provides a variety of specification sheet for mats including one based on the International Society for Measurement and Control ISA S 20 standard Cus tomize Flowel specification sheets with your company logo Flowel supports laser printers so your reports look great Some of the world s largest engineering companies use Flowel They report that Flowel has dramatically in creased productivity and decreased errors Equipment Vendors Generate Revenue ocz3o lt o zJ 4 35 Some revenue generating ideas for Equipment Vendors As margins on equipment continue to drop vendors need new services and products Flowel offers some interesting possibilities e Sell flow calculations to your customers Your cus tomers may not need a sophisticated product like Flowel but would appreciate Flowel s accuracy Dis Page 3 of 9 tinguish yourself from the competition with Flowel generated flow graphs fluid composition reports and uncertainty calculations e na small market it may take time to recoup your in vestment in Flowel As an option you may purchase Flowel through a lease arrangement that dramatically reduces your initial investment Call for more details e For your larger customers become a Flowel reseller It s a great way to encourage equipment sales both you and your customers use the same sizing software Please call us for more details
15. ing standards e We test every calculation in Flowel against an inde pendent source to verify accurate and correct imple mentation In every test case we provide a reference to an independent source If no sources are available in literature or from regulatory bodies we provide an independent calculation performed in MathCad or Flowel 2 The Flowel Validation document consists of multiple volumes and describes over 20 000 tests and sample calculations Before a release of a new version of Flowel we re run all 20 000 calculations and verify their accuracy Flowel supports Quality Assurance reviews Flowel generated specification sheets indicate calculation methods gt J 5 Property Method AGA 8 1992 LUCAS Viscosity Lee Kesler k Flowel Specification Sheets indicate calculation methods Designers For designers that specify orifice plates nozzles and ven turis Flowel offers productivity As a designer the main enemy of your productivity is incomplete information With Flowel you can stop searching for obscure equations and fluid properties You get devices old standards new standards fluid properties and more For occasional users Flowel provides an intuitive user interface with guided screen progressions There is no need to remember special key strokes or peculiar rules Flowel prompts you for all needed information and warns you when special circumstances require your attention
16. n Sequences In Flowel each user choice affects subsequent options For ease of use it is im portant that Flowel presents choices in the right order For example instrument engineers do not specify the process fluid Therefore Flowel initially presents fluid related choices followed by meter run choices and fi nally offers choices related to sizing Page 6 of 9 System Architecture The diagram below illustrates the various modules that compose Flowel ae ees Fluid Properties DLL T C a _ Be eee Yi BF EE BI Va i E N foe E A whe oS Watcom I Flowel R Database We gt GUI lt gt Calculation Engine J ii PowerBuilder C z A Su N Unit D Flowel Database Converter DLL j C Nu The Fluid Properties library contains routines used for the calculation of density compressibility viscosity isen tropic exponent and vapor pressure The Flow Calculation library contains routines used for the calculation of bore size differential pressure and flow rate The Unit Con verter library contains all routines used to convert values from one measurement unit into another unit Kenonic Controls Ltd writes these libraries in the C program ming language Kenonic Controls Ltd writes the Flowel graphical user in terface in the PowerBuilder basic programming lan guage PowerBuilder is a development environment product sold by Powersoft Corporation
17. s and plant closures Ineffective quality programs mean lost markets and higher costs Many operating com panies use Flowel for a cost effective answer to these problems Engineering Contractors On Time and On Budget fe Task 9 3 Kickoff Study NE Design Procure Construct Start Up S Contractors work under time and budget constraints Contractors that provide instrument engineering services must deliver design documents that are on time on budget and meet customer specifications Authored by an engi neering contractor Flowel has a number of features spe cifically designed for contractors FLOWEL 3 0 Information Fax e Use Flowel to reduce training time and required skill levels We consistently receive reports that Flowel in sulates users from the complexities of flow calcula tions Consult on line help for assistance Pick up the phone for fast answers from a knowledgeable Flowel technical support engineer e Flowel helps you track costs Print out job reports showing the number of instruments in a given project and the number of calculations expended on each in strument To document charges attach job reports to invoices e Flowel supports your customers standards Flowel in cludes the methods and devices used in existing and new facilities It provides the methods used in Europe North America South America East As
18. turi only Throat Venturi only Flow Measurement Standards ISO 5167 1980 ISO 5167 1991 AGA 3 1990 AGA 3 1985 ASME MFC 3M ASME MFC 7M BS 1042 General Viscosity Methods Requires Optional Fluid Prop Calc IAPS 1975 Viscosity Eqn for wa ter steam only Lucas Viscosity Eqn for gases only Isentropic Exponent Ratio of Spe cific Heats Cp Cv Requires Optional Fluid Prop Calc Ideal Gas Heat Capacity Ratio Real Gas with Redlich Kwong Cor rection Real Gas with Lee Kesler Correction Vapor Pressure Requires Optional Fluid Prop Calc Antoine Bubblepoint Requires Optional Fluid Prop Calc Soave Redlich Kwong Peng Robinson Page 8 of 9 Material Tables Unlimited User Definable 316 SST 316L SST Hastelloy C 276 Monel 400 Carbon Steel 301 SS 304 SS 310 SS 316 SS 330 SS Measurement Units NCFS NhLi day NhL hr FLOWEL 3 0 347 SS Hastelloy B Hastelloy C Iconel X annealed Haynes Stellite 25 Copper Yellow Brass Aluminum bronze Beryllium Copper 25 Cupronickel 30 K Monel 347 SS NIMPBPD SLiday NIMPBPH SL hr NIMPGPD SL min NIMPGPH SL sec NIMPGPM Sm3 day NIMPGPS Sm3 hr NL day Sm3 min NL hr Sm3 sec NL min SUSBPD NL sec SUSBPH Nm3 day SUSGPD Nm3 hr SUSGPH Nm3 min SUSGPM Nm3 sec SUSGPS NUSBPD ton day NUSBPH ton hr NUSGPD ton min NUSGPH ton sec NUSGPM tonne day NUSGPS tonne hr SCFD tonne min SCFH tonne sec SCFM USBPD SCFS USBPH ShLiday U
19. use Flowel to quickly re calculate fluid properties Create an unlimited number of fluids both pure and mixed Associate any fluid with any device No need to call a process engineer or look for references e Changes in flowing rates pressures or temperature are common Use Flowel to easily re calculate beta ratios or orifice sizes Note the change in the Flowel data base for the next shift FLOWEL 3 0 Information Fax User Interface Flowel presents users with thousands of possible options Yet users report that the Flowel user interface is very easy to use Flowel achieves usability by closely following a few principles Ding a aw a krengen means 12 SE ce Mines Recon fi m mi m C Ce Ce a ed e Simple Navigation Users new to Windows often be come lost Flowel provides a graphical summary screen that is always present and a logical progression of dialog windows e Visual Cues There are no hidden functions in Flowel Users initiate actions by clicking buttons or by select ing menus There are no special keys to memorize e Intelligent Selection Lists Flowel supports thousands of different combinations of devices fluids and meth ods Flowel makes your choices manageable by using intelligent selection lists It only presents options that apply to your situation For example if you select gas critical flow we only present flow elements that are applicable to critical gas flow e Guided Scree
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