Gilflo ILVA flowmeters

for steam, liquids and gases

The Gilflo in-line variable area (ILVA) flowmeter ...

is a revolutionary development of the well established family of Gilflo flowmeters that has been used in industrial flowmetering applications for more than 30 years. Using the same unique operating principle but incorporating a number of significant design changes, the Gilflo ILVA flowmeter is perfectly suited for use with most industrial fluids including steam and gases. A comprehensive range of associated sensors and electronic instrumentation is available to compliment the Gilflo ILVA flowmeter range and make it one of the most adaptable flowmeters available.

Why install flowmeters?

The main justifications for installing flowmeters in any industrial plant are: n Product quality: By providing management information, they enable a plant to be operated at peak efficiency thus ensuring product quality is maintained in the most cost effective way. n Direct cost control: They can be used to cost raw materials or energy sources (such as compressed air) directly.

How the Gilflo ILVA flowmeter works

In common with other differential pressure flowmeters such as orifice plates and venturi meters, the Gilflo ILVA flowmeter primary element uses the theorem for the conservation of energy in fluid flow through a pipe. It operates on the well established spring loaded variable area (SLVA) principle where the area of an annular orifice is continuously varied by a moving cone. A centrally positioned cone is free to move axially against the resistance of a precision compression spring. This produces a variable differential pressure across the annular orifice which is sensed by a transmitter connected to integral tappings on the flowmeter body. The pressure difference can then be used to derive an instantaneous rate of flow based on Bernoullis Theorem.

Dp

The unique design of the Gilflo ILVA flowmeter greatly expands the capabilities of the differential pressure flow measurement. The key to the unique performance of the Gilflo ILVA flowmeter lies in the design of the orifice and cone to minimise upstream velocity profile effects and at the same time provide an exceptionally high turndown flowmeter based on practically achievable line velocities.

Installation benefits
The correct installation of any type of flowmeter is of prime importance if the manufacturers claims for accuracy and repeatability are to be achieved in practice. All types of flowmeter require a certain number of straight, uninterrupted lengths of meter size pipework upstream and downstream of the point of installation.

Gilflo ILVA

6D

3D

In real life, there are often space constraints that severely restrict where and how a flowmeter can be installed. It is therefore very important to look carefully at where the flowmeter is to be fitted as early as possible. The unique wafer design of the Gilflo ILVA flowmeter means that its installed length is much shorter than almost any other flowmeter. A Gilflo ILVA flowmeter can often be fitted into lines which were never designed to accept flowmeters. Gilflo ILVA flowmeter Turbine Vortex Orifice plate 0 2 10 20 Number of upstream diameters of straight pipe 30 6 diameters up to 20 diameters up to 30 diameters up to 30 diameters

The importance of turndown

DN150 Gilflo ILVA flowmeter 5 bar g saturated steam Vortex meter Benefit of large turndown at low flows

Gilflo ILVA flowmeter

0.6

Minimum velocity m/s

2.8

To ensure that the flow information gathered is accurate whatever the process conditions or demand, it is essential that a flowmeter is capable of meeting its specification over the full operating range from low standing or weekend loads, right up to the maximum demand of the process. As actual demands are often unknown or may vary widely, a flowmeter should have the largest turndown possible based on practical flow conditions. Great care should be taken that claims for turndown are based on realistic flow velocities. For instance, steam systems should be sized on a maximum flow velocity of about 35 m / s ... higher velocities will possibly cause erosion and noise problems in the system.

Turndown ratios with flow velocities limited to 35 m / s Gilflo ILVA flowmeter Turbine typically 10:1 Vortex up to 15:1 depending on operating conditions Orifice 4:1 0 20 40 60 80 100 100:1

Flowrate kg / h

1 000 Actual flowrate 750 500 Cumulative error

2 000 1 700 1 500 1 000

250 Threshold at 4:1 turndown 0 0 1 2 3 4 5 Hours elapsed 6

Orifice plate

500 0

This graph shows a typical demand curve for a distributed steam system with a high start-up load and variable demand through the day. An orifice plate meter with a 4:1 turndown is sized on the peak load of 1 000 kg / h. Any flowrates below 250 kg / h are 'lost' or, at best recorded with a significant error. In this case 1 700 kg have been 'lost'. The Gilflo ILVA flowmeter, with its 100:1 turndown eliminates this type or error.

Cumulative error kg

Flowrate below minimum of 250 kg / h (i.e. 1 000 kg / h 4)

Density compensation
It is rare for the pressure in a steam system to remain absolutely constant. Unless this variation is taken into account, flow measurement errors will occur. The automatic density compensation options completely eliminate these errors and allow accurate metering whatever the steam pressure. This is shown in the adjacent diagram.

1 000 Actual flowrate 800

Flowrate kg/ h

10 8 Actual system pressure

Pressure bar g

3 500 3 000 2 500 2 000 1 500 1 000 500

Cumulative error kg

600 400 200 Cumulative error 0 0 1 2 3 4 5 Hours elapsed 6 7 8

6 4 2 0

In the example above, a simple non-compensated flowmeter is set for 6 bar g. The actual pressure in the system varies through the day and unless this is allowed for, by the end of the day, very significant errors can arise. This is typical of many steam systems.

Gilflo ILVA flowmeters ... proven technology in a new package.

Thirty years experience and over 10 000 installations worldwide has firmly established the technology that gives Gilflo flowmeters their unequalled turndown and ultra compact installation. Now the Gilflo ILVA flowmeters uses this wealth of experience in a wafer design to give even lower cost of ownership. Designed and supported by Spirax Sarcos worldwide supported, the Gilflo ILVA flowmeter is the logical choice.

Range availability
n Sizes DN50 (2") to DN200 (8") n All stainless steel 316L body construction n Pressure rating to match flange specifications n Temperatures up to 450C

Applications
n Cost metering for energy management n Custody transfer n Process and control applications n Boiler load control

Flow direction

Commonly metered fluids

n n n n n n n n n 4 Saturated steam Superheated steam Condensate Natural gas Nitrogen Carbon dioxide Compressed air Ethylene Fuel oil

User benefits
All stainless steel construction. Alignment webs for easy installation. Precision cone. Suitable for most industrial fluids. Excellent turndown, up to 100:1. High pipeline unit accuracy, 1% of reading. Ultra compact installation, requires only six pipe diameters upstream and three downstream. Wafer design for easy installation. No expensive line size changes required to achieve low flow performance. Intrinsically safe for use in hazardous areas. Reliability proven over 30 years experience. Designed and manufactured by Spirax Sarco a ISO 9001 : 2000 approved company.

Wafer design fits between customer flanges.

Over-range stop prevents damage from surges or excessive flows.

Precision heavy duty nickel cobalt alloy spring operates up to 450C without creep.

Pressure tappings built into the flowmeter body for easy installation.

Gilflo calibration rig, Spirax Sarco, Cheltenham, England

Gilflo ILVA flowmeters ... system configurations and associated equipment

EL2230 temperature transmitter Gilflo ILVA n M240G (steam) and M250G (gas) flow computers provide complete information on flow, pressure and temperature. n Full density compensation. n Linearisation of Gilflo signal. F50C isolation valves EL2600 pressure transmitter M610 differential pressure transmitter n Wall or panel mounting. n Bright, easy to read display. n Alarm facilities for fluid flow, pressure and temperature. n 4 independent timers. n Analogue, pulse and EIA232C outputs available as standard.

M200 series flow computer

Gilflo ILVA

n M640 steam mass flow transmitter provides density compensated 4 - 20 mA output. n Linearisation of Gilflo signal. n Ideal for applications where density compensation is essential.

F50C isolation valves M640 Steam mass flow transmitter

n Suitable for use up to 74 bar g saturated steam. n HART 5.2 in-built. n Optional local display. n Intrinsically safe pipeline unit and mass flow transmitter.

M750 display unit

Gilflo ILVA

n M750 display unit provides local display of total flow and rate of flow. n Suitable for steam and most industrial fluids and gases.

F50C isolation valves M610 differential pressure transmitter

n Ideal for applications where fluid density is constant. n User configurable. n Linearisation of Gilflo signal. n Retransmission options of rate and / or total flow available.

M750 display unit

Note: The illustrations above are schematic only. Refer to Installation and Maintenance Instructions for further details.

n Bright, easy to read display. n Panel mounting as standard.

Calibration of Gilflo ILVA flowmeters

All Gilflo ILVA flowmeters are calibrated on a high accuracy flow facility at Spirax Sarcos manufacturing plant in Cheltenham, England. Designed and built by Spirax Sarco engineers in conjunction with UK National Engineering Laboratories, it ensures that every flowmeter meets the highest possible standard of accuracy. Some basic features of the flow facility are: n n n n n n n Facility size capability: DN50 to DN300. Reference methods: gravimetric and transfer standard electromagnetic meters. Flow capacity: up to 19 000 litres/min water. Pipework: all 316L stainless steel with upstream and downstream pipework straight runs in excess of recommended lengths. Flowmeter location: clamping arrangements ensure flowmeters are concentric to pipework to ensure accurate calibration. Fully automatic data collection: archiving of all flow data electronically for future reference / recalibration. Calibration documentation: full calibration documentation is available with every flowmeter.

Sizing and selection of a Gilflo ILVA flowmeter

It is important to select the correct size of Gilflo ILVA flowmeter for a particular application. First principles can be used as follows, determine the equivalent water flowrate (litres/min) based on the maximum anticipated actual flow, then select the Gilflo ILVA best suited to the application using the tables below. Alternatively consult Spirax Sarco.

Equivalent water flowrate QE

Mass flow units Liquids QE = qm SG Volumetric units QE = QL SG Where: QE = Equivalent water flowrate (litres/min) qm = Mass flowrate (kg/min) QL = Maximum liquid flowrate (litres/min) QS = Maximum gas flowrate at standard conditions (litres/min) QF = Maximum gas flowrate at actual flow conditions (litres/min) SG = Specific gravity DS = Density of gas at standard conditions (kg /m3) DF = Density of gas at actual flow conditions (kg /m3) PS = Standard pressure = 1.013 bar a = 1.033 kg / cm2 a = 14.7 psi a PF = Actual flow pressure in same absolute units as PS TS = Standard temperature (K) = C + 273 TF = Actual flow temperature (K) = C + 273

Gases and steam actual flow conditions Gases standard conditions

QE = qm 1 000 DF qm

QE = QF

DF 1 000

QE =

DS PF TS x x 1 000 PS TF

QE = QS DS x PS x TF 1 000 PF TS

Using the value of QE as determined above, select the correct Gilflo flowmeter from the table below: Table of QE Flowmeter type DN50 DN80 DN100 DN150 DN200 Maximum QE litres / minute 149 585 1 800 2 900 5 700 Maximum DP Wg 200 200 200 200 200 Example: Determine which Gilflo pipeline unit is required to measure the flow of compressed air when: 1: Estimated maximum rate of flow = 500 s m /h at 7 bar g and 20C Note: Standard conditions = 1.013 bar a, 0C giving a standard density of 1.29 kg / m DS P T 2: Calculate QE from QE = QS x S x F PF TS 1000 QE = (500 x 16.667) x QE = 110 litres / min. 1.29 1.013 293 x x 1000 8.013 273

From the table, it can be seen that a DN50 Gilflo ILVA flowmeter would be suitable for this application. Note: 1 m / h = 16.667 litres/ min.

Sizing the Gilflo ILVA flowmeter for saturated steam - capacities kg / h

Steam pressure bar g Maximum flow DN50 Minimum flow Maximum flow DN80 Minimum flow Maximum flow DN100 Minimum flow Maximum flow DN150 Minimum flow Maximum flow DN200 Minimum flow 1 300 3 1 179 12 3 629 36 5 847 58 11 492 115 3 416 4 1 632 16 5 023 50 8 092 81 15 905 159 5 503 5 1 976 20 6 080 61 9 795 98 19 252 193 7 577 6 2 264 23 6 967 70 11 224 112 22 061 221 10 12 671 727 7 7 2 635 2 855 26 29 8 108 8 784 81 88 13 062 14 152 131 142 25 674 27 816 257 278 15 804 8 3 156 32 9 709 97 15 643 156 30 746 307 20 918 9 3 603 36 11 085 111 17 859 179 35 101 351 25 1 020 10 4 003 40 12 317 123 19 843 198 39 002 390 30 1 113 11 4 371 44 13 449 134 21 667 217 45 587 426 40 1 283 13 5 039 50 15 505 155 24 980 250 49 098 491

Note: Maximum flowrates are calculated at a differential pressure across the Gilflo ILVA pipeline unit of 498 mbar (200" H20). Minimum measurable flowrate is 1% of maximum.

Gilflo spring design

The design and manufacture of the spring in the Gilflo ILVA flowmeter is fundamental to its accuracy and long term performance. n Made from 'aerospace' alloy Inconel X750 which is widely used in jet engine turbine components due to its exceptional high temperature performance. n During manufacture, all springs are age hardened at 650C for 4 hours. n All springs are 'hot set' at 460C after manufacture to eliminate any possibility of relaxation at high temperatures. n Design stress levels range from 11% to 30% UTS ... most springs are designed to stress levels of around 60%. n In service, all Gilflo ILVA flowmeters incorporate over-range stops to prevent over stressing the spring in overload conditions. n Many thousands of installations have proved the integrity of the design and manufacture of the spring.

Specification
Operating principle Limiting conditions Sizes available Spring loaded variable area with differential pressure output proportional to rate of flow. To ANSI 600 (carbon steel) pressure / temperature envelope. DN50, DN80, DN100, DN150 and DN200 EN 1092 PN16, PN25, PN40 BS 10 Table H ANSI B 16.5 Class 150, 300, 600 JIS 20 KS 20

Flange specifications

Body and internals: Stainless steel 316L Spring: Inconel X750 Installation Normally horizontal. For vertical (flow downwards) applications, consult Spirax Sarco. When used in conjunction with an M200 series flow computer or M750 display unit or M640 steam mass flow transmitter, pipeline unit accuracy is better than 1% of actual flow from 5% to 100% of Accuracy maximum rated flow. For flows from 1% to 5% of maximum rated flow, the pipeline unit accuracy will be better than 0.1% FSD. Repeatability Better than 0.25%. Unrecovered pressure drop Less than 200 inches water gauge (498 millibar) at maximum flowrate. Materials of construction

Dimensions / Weights
Size DN50 DN80 DN100 DN150 DN200 A 35.0 45.0 60.5 75.0 85.0 B 63 78 103 134 161 C 130 160 208 300 360

(approximate in mm and kg) D 103 138 162 218 273 E 17.5 22.5 37.5 37.5 42.5 Weight 2.0 3.9 8.3 14.2 23.6

E Note: Pressure tappings are threaded " NPT. (2 off located at 180)

In addition to the ILVA range, Spirax Sarco can supply Gilflo flowmeters for special requirements in sizes from DN50 to DN400. These are of flanged, pressure vessel type construction and can be manufactured to meet most international standards construction and inspection. Please consult Spirax Sarco for details. A B Some of the products may not be available in certain markets. C
Spirax-Sarco Limited, Charlton House, Cheltenham, Gloucestershire, GL53 8ER UK. Tel: +44 (0)1242 521361 Fax: +44 (0)1242 573342 E-mail: Enquiries@SpiraxSarco.com Internet: www.SpiraxSarco.com
Copyright 2003 Spirax Sarco is a registered trademark of Spirax-Sarco Limited

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MI Issue 4