PCCFL001

COMPLETE REVISION August 2006

Process Industry Practices Process Control

PIP PCCFL001 Flow Measurement Design Criteria

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time.

© Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP member companies and subscribers may copy this Practice for their internal use. Changes, overlays, addenda, or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP.

PRINTING HISTORY June 1998 Issued August 2006 Complete Revision Not printed with State funds

COMPLETE REVISION August 2006

Process Industry Practices Process Control

PIP PCCFL001 Flow Measurement Design Criteria Table of Contents 1. Introduction................................. 2 1.1 1.2

Purpose .......................................... 2 Scope ............................................. 2

2. References .................................. 2 2.1 2.2 2.3

Process Industry Practices............. 2 Industry Codes and Standards....... 2 Other References ........................... 3

3. Requirements.............................. 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9

General........................................... 3 Orifice Meter................................... 5 Flow Nozzle.................................... 6 Venturi (Classical and Proprietary Designs) ......................................... 7 Averaging Pitot Element................. 7 Integral Orifice ................................ 8 Turbine Meter ................................. 8 Positive Displacement Meter.......... 8 Magnetic Flow Meter ...................... 9

Process Industry Practices

3.10 Mass Meter (Coriolis) ..................... 9 3.11 Mass Meter (Thermal) .................... 9 3.12 Ultrasonic Meter (Transit Time & Doppler).......................................... 9 3.13 Vortex Meter................................... 9 3.14 Variable Area Meter ..................... 10

Tables Table 1 Minimum Straight Run Lengths for Orifice Runs and Other Flow Elements in Accordance with ISO 5167-2 Column B Table 2 Minimum Straight Run Lengths for Orifice Runs in Accordance with ANSI/API (ISO 5167-2, Column A) Table 3 Minimum Straight Run Lengths for Venturi Tubes and Flow Nozzles In Accordance with ANSI/API (ISO 5167-3)

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PIP PCCFL001 Flow Measurement Design Criteria

1.

COMPLETE REVISION August 2006

Introduction 1.1

Purpose This Practice provides requirements for the design of flow measurement systems.

1.2

Scope This Practice describes the design requirements for flow measurement systems that include head (differential pressure), velocity, oscillatory, electromagnetic and mass flow meters. This Practice does not cover: a. Restriction flow elements and flow switches b. Process isolation (root) valves, secondary transmitters, or process piping c. Custody transfer measurement requirements

2.

References Applicable parts of the following Practices, industry codes and standards, and references shall be considered an integral part of this Practice. The edition in effect on the date of contract award shall be used, except as otherwise noted. Short titles are used herein where appropriate. 2.1

2.2

Process Industry Practices (PIP) –

PIP PCCGN001 - General Instrument Design Checklist

–

PIP PCCGN002 - General Instrument Installation Criteria

–

PIP PCIDP000 - Differential Pressure Installation Details

–

PIP PNF00200 - Vent/Drain/Instrument Connection Details

Industry Codes and Standards •

American Gas Association (AGA)

•

American National Standards Institute (ANSI) –

•

American Petroleum Institute (API) –

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ANSI-2530/API-14.3/AGA-3/GPA-8185 - Natural Gas Fluids Measurement - Concentric, Square-Edged Orifice Meters Part 1 General Equations and Uncertainty Guidelines Part 2 Specification and Installation Requirements Part 3 Natural Gas Applications Part 4 Background, Development, Implementation Procedures and Subroutine Documentation

API Manual of Petroleum Measurement Standards (MPMS): Chapter 5 - Metering 5.2 Measurement of Liquid Hydrocarbons by Displacement Meters 5.3 Measurement of Liquid Hydrocarbons by Turbine Meters

Process Industry Practices

COMPLETE REVISION

PIP PCCFL001 Flow Measurement Design Criteria

August 2006

•

•

American Society of Mechanical Engineers (ASME) –

ASME B16.36 - Orifice Flanges

–

ASME MFC-3M - Measurement of Fluid Flow in Pipes Using Orifice, Nozzle, and Venturi

ISA, The International Society for Measurement and Control (ISA) –

•

International Organization for Standardization (ISO) –

2.3

ISO 5167-1 - Measurement of Fluid Flow by Means of Pressure Differential Devices

Other References –

3.

ISA S20 - Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves

Miller, R.W., Flow Measurement Engineering Handbook

Requirements 3.1

General 3.1.1

Data 3.1.1.1 A data set shall be provided for each flow meter. 3.1.1.2 The data set may be provided in electronic or hardcopy format. 3.1.1.3 The minimum data set shall be in accordance with ISA S20, Specification Forms for Primary Elements, Sections 20.21, 20.22, 20.23, 20.24, and 20.25. 3.1.1.4 For flange tap orifice meters, gasket thickness shall be specified.

3.1.2

Instruments Sizing 3.1.2.1 Calculation methods and tools used shall be subject to owner’s approval. a. All calculation results shall be provided to the owner. b. Unless otherwise specified by owner, calculations for sizing of concentric, square-edged orifice meters shall be in accordance with ANSI-2530/API-14.3/AGA-3/GPA-8185. c. Nozzle, venturi, and other differential pressure device calculations shall be in accordance with Flow Measurement Engineering Handbook. d. For any other proprietary meter, the manufacturer’s sizing and calculation methods shall be used. 3.1.2.2 Head meter bore shall be sized to provide non-fractional maximum differential pressure calibration spans and give even scale flow display units.

Process Industry Practices

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COMPLETE REVISION

PIP PCCFL001 Flow Measurement Design Criteria

August 2006

3.1.2.3 In general, head type flow instruments shall be sized such that normal flow is between 65% to 80% of expected maximum. 3.1.2.4 The units of measurement for flow instruments shall be in accordance with the owner’s specifications in PIP PCCGN001. 3.1.2.5 Owner shall identify default metering uncertainty (1, 2 or undesignated) in the checklist PIP PCCGN001. 3.1.3

Installation 3.1.3.1 Unless otherwise specified by owner, the piping specifications PIP PNF00200 shall be followed. 3.1.3.2 Manufacturer’s installation requirements shall be followed as a minimum. 3.1.3.3 Meters in liquid service shall be installed so that meters are always full of liquid and trapping of gases is avoided. 3.1.3.4 In gas service, liquid trapping shall be avoided. 3.1.3.5 The use of strainers and eliminators shall be considered and evaluated to protect metering devices whose performance or integrity is compromised without such protection. 3.1.3.6 Thermowells shall be located a minimum of five nominal pipe diameters downstream of a meter. 3.1.3.7 Use of flow profile conditioning devices of any type shall be approved by owner. Comment: The use of flow profile conditioning may not be permitted if the meter is followed by rotating process equipment (compressors, pumps, turbines, etc.) that can be damaged if a part of the conditioning device breaks off and enters the equipment. 3.1.3.8 Meters shall be installed in a manner that minimizes mechanical vibration or stress on the meter.

3.1.4

Weather Protection 3.1.4.1 Winterproofing and weather protection shall be in accordance with PIP PCCGN002. 3.1.4.2 The impulse legs of differential pressure transmitters to head type flow meters shall require appropriate freeze protection.

3.1.5

Materials of Construction 3.1.5.1 All wetted component materials shall be compatible with the process fluid. 3.1.5.2 Meters shall be suitable for the environmental exposure including ambient temperature extremes and external corrosion conditions. 3.1.5.3 Piping and connections shall be in accordance with applicable piping specifications.

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PIP PCCFL001 Flow Measurement Design Criteria

August 2006

3.1.6

Electrical Classification Meter installations shall be in accordance with the specified electrical area classification.

3.1.7

Head (Differential Pressure) Type Meters 3.1.7.1 Square root operation in calculating flows from head type meters shall be performed in only one device (i.e., transmitter, flow computer, control system, etc.). 3.1.7.2 For liquid, steam and heat transfer media services, pressure taps shall be located on the horizontal side of the piping or 45 degrees down from horizontal. The pressure tap sensing lines (impulse lines) shall be sloped down to the transmitter (minimum of 1” per foot). 3.1.7.3 For gas and vapor services, pressure taps shall be located on the vertical from the top of the piping, horizontal, or 45 degrees from vertical. The pressure tap sensing lines (impulse lines) shall be sloped up to the transmitter (minimum of 1” per foot).

3.2

Orifice Meter 3.2.1

Paddle type orifice plates shall be used.

3.2.2

The following minimum information shall be stamped or etched on the upstream side of the handle: a. Orifice plate tag number b. Material type c. Vent or drain hole size d. Inlet flow side e. Bore f.

3.2.3

Flange size in inches and ASME pressure rating

If an orifice meter is the selected flow element, and the orifice plate sizing dictates a meter run size less than a nominal 2 inch (50 mm), use either: a. A honed fabricated meter tube with corner taps b. An Integral Orifice (See Section 3.6 for requirements.)

3.2.4

Unless otherwise required by process service, orifice plate material shall be stainless steel minimum. Material type shall be specified in accordance with PIP PCCGN001.

3.2.5

Orifice plates shall be fabricated in accordance with ANSI 2530/API 14.3 Part 2.

3.2.6

Vent or drain holes in orifice plates shall be used only if approved by owner.

3.2.7

Flange type and material shall be in accordance with piping specifications. Orifice flanges shall be rated at a minimum of ASME Class 300 and shall be in accordance with ASME B16.36 and ANSI 2530/API 14.3/AGA-3/GPA8185.

Process Industry Practices

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COMPLETE REVISION

PIP PCCFL001 Flow Measurement Design Criteria

August 2006

3.2.8

Unless otherwise approved by owner, orifice “flange taps” shall be used for line sizes 2 inches (50 mm) and larger.

3.2.9

Corner taps shall be used for line sizes less than 2 inches (50 mm).

3.2.10 Unless otherwise required by piping specifications, orifice flange tap connections shall be 1/2 inch (12 mm) if used in ASME Class 600 service and below. 3.2.11 Unless otherwise required by piping specifications, orifice flange tap connections shall be 3/4 inch if used in ASME Class 900 service. 3.2.12 Connection type (threaded or socketweld) shall be in accordance with the piping specifications. 3.2.13 If used, other tap shall be in accordance with piping specifications. 3.2.14 Piping design for orifice runs shall be in accordance with the following: a. Orifice meters shall be installed in horizontal runs to minimize measurement inaccuracies. Vertical orifice runs shall be used only with owner’s approval. b. Orifice meter tap locations shall be as follows: 1) For “flange tap” designated orifice meters, the taps shall be located at 1 inch (25 mm) upstream and 1 inch (25 mm) downstream from the orifice plate face including gasket thickness. 2) For “pipe tap” designated orifice meters, the taps shall be located 2-1/2 internal pipe diameters upstream and 8 internal pipe diameters downstream of the orifice plate face. 3.2.15 Process Piping Connections 3.2.15.1 Primary orifice taps shall have a separate isolation (root) valve in addition to any manifolds. 3.2.15.2 Piping from taps to and through first isolation (root) valve shall be in accordance with applicable piping specifications. 3.2.15.3 Unused orifice taps shall be plugged in accordance with piping specifications. 3.2.16 Meter tube pipe and orifice flanges internal dimensional tolerances shall be in accordance with ANSI 2530/API 14.3/AGA-3/GPA-8185. 3.2.17 Straight run piping before and after an orifice plate flow element shall be no less than those specified in Table 1 for applications that require 1/2% uncertainty (flow control and monitoring) or Table 2 for applications that require no uncertainty and increased accuracy (custody transfer). 3.3

Flow Nozzle 3.3.1

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Unless otherwise required by service application and piping specifications, flow nozzles shall be designed to bolt between flanges.

Process Industry Practices

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PIP PCCFL001 Flow Measurement Design Criteria

August 2006

3.3.2

In high pressure (1000 psig or higher) applications, the flow nozzle shall be welded directly into the pipe.

3.3.3

Tap connections shall be installed 1 inside pipe diameter upstream and 1/2 inside pipe diameter downstream in accordance with ASME-MFC-3M.

3.3.4

Minimum straight run pipe length requirements shall be in accordance with Table 3. Comment: Where owner approves additional metering uncertainty, minimum piping run lengths may be in accordance with ASME-MFC-3M.

3.3.5 3.4

Unless otherwise required by process service or piping specifications, flow nozzles shall be type 316 SS.

Venturi (Classical and Proprietary Designs) 3.4.1

Classical venturis shall be fabricated in accordance with ASME MFC-3M.

3.4.2

Venturi meter materials and construction shall be compatible with the process fluid and applicable piping codes.

3.4.3

Flow calculations for proprietary venturi meters shall be provided by manufacturer.

3.4.4

Minimum straight run pipe length requirements shall be in accordance with Table 3. Comment: Where owner approves additional metering uncertainty, minimum piping run lengths may be in accordance with ASME-MFC-3M.

3.5

Averaging Pitot Element 3.5.1

Unless they are bi-directional, averaging pitot tube elements shall be permanently marked to indicate proper installation position and flow direction.

3.5.2

Unless otherwise required by process services, averaging pitot tubes shall be type 316 SS.

3.5.3

Minimum straight run pipe length requirements shall be in accordance with pitot element manufacturer’s recommended lengths.

3.5.4

For a removable element, the process valve shall have the proper inside diameter to allow passage of the element. The valve shall meet applicable piping specifications.

3.5.5

Removable elements shall have blow out prevention.

3.5.6

Extra heavy flow elements and/or double ended support shall be used in large diameter pipes or ducts or if high flow velocity can cause the element to deflect or vibrate. Manufacturer’s installation recommendations shall be followed.

3.5.7

Elements shall be purged when installed in dirty services.

Process Industry Practices

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PIP PCCFL001 Flow Measurement Design Criteria

3.6

3.7

COMPLETE REVISION August 2006

Integral Orifice 3.6.1

Process line block and bypass valves or transmitter isolation valves (root valves or manifold) shall be installed for applications that require servicing while on-line.

3.6.2

Integral orifices shall be sized and installed in accordance with manufacturer’s recommendations. Manufacturer shall provide meter sizing and flow calculations.

3.6.3

Minimum straight run pipe length requirements shall be in accordance with manufacturer’s recommended lengths.

3.6.4

Unless otherwise required by process services, wetted metal parts shall be type 316 SS. Other wetted components shall be compatible with the process.

3.6.5

A strainer shall be specified if needed to avoid plugging of the orifice.

Turbine Meter 3.7.1

Turbine meters shall be installed so that the meters are always: a. In single phase flow b. Liquid full in liquid applications

3.7.2

The installation setup shall be designed to avoid creating a pressure drop condition for the fluid to flash in the meter. Comment: Flashing will damage the meter and severely impact measurement.

3.8

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3.7.3

Turbine meters shall be marked to indicate proper flow direction.

3.7.4

In-line type turbine meters 1 inch (25 mm) and above shall be flanged.

3.7.5

A strainer shall be installed upstream of the turbine meter system. Dual strainers shall be provided if the process flow cannot be interrupted for maintenance.

3.7.6

Strainers shall be installed far enough upstream to prevent the distortion of flow profile at the turbine meter.

3.7.7

For high-accuracy applications, liquid turbine meters shall be installed in accordance with API MPMS, Chapters 5 and 6.

Positive Displacement Meter 3.8.1

Manufacturer’s recommended installation requirements shall be applied as a minimum.

3.8.2

For high-accuracy applications, liquid positive displacement meters shall be installed in accordance with requirements of API MPMS, Chapters 5 and 6.

3.8.3

The meter shall be installed so that the fluid passing through the meter is in a single phase and the meter is liquid full.

3.8.4

Inlet and/or outlet ports shall be plainly marked to indicate proper flow direction.

3.8.5

A strainer shall be considered upstream of the meter. Process Industry Practices

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PIP PCCFL001 Flow Measurement Design Criteria

August 2006

3.8.6 3.9

Meters in line sizes 1-1/2 inches (37 mm) and above shall be flanged body style.

Magnetic Flow Meter 3.9.1

Magnetic flow meters shall be installed with piping designed in accordance with manufacturer’s recommendations.

3.9.2

Magnetic flow meters shall be installed so that the meter is always liquid full. Comment: The preferred installation is vertical with flow up.

3.10

3.9.3

Materials of construction shall be compatible with the process fluid.

3.9.4

Magnetic flow meters shall be grounded in accordance with manufacturer’s recommendations.

3.9.5

The meter factor data shall be provided by the manufacturer.

Mass Meter (Coriolis) 3.10.1 Mass flow meters shall be installed with piping designed in accordance with manufacturer’s recommendations. 3.10.2 Mass flow meters shall be installed so that the meter is always liquid full in liquid applications. 3.10.3 Mass flow meters shall be installed so that the meter is self-draining in gas applications. 3.10.4 Materials of construction shall be compatible with the process fluid. 3.10.5 The meter factor data shall be provided by the manufacturer. 3.10.6 The meter shall be sized so the maximum full scale flow rate is in the upper one-third of the meter range, unless pressure drop considerations require a larger meter.

3.11

Mass Meter (Thermal) Use of mass (thermal) meters shall be approved by owner and installed in accordance with manufacturer’s recommendations.

3.12

Ultrasonic Meter (Transit Time & Doppler) Use of ultrasonic meters shall be approved by owner and installed in accordance with manufacturer’s recommendations.

3.13

Vortex Meter 3.13.1 Meters shall be installed with piping designed in accordance with manufacturer’s recommendations. 3.13.2 Meters shall be installed so that the meter is always liquid full in liquid applications. 3.13.3 Meters shall be installed so that the meter is self-draining in gas applications. 3.13.4 Materials of construction shall be compatible with the process fluid.

Process Industry Practices

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PIP PCCFL001 Flow Measurement Design Criteria

COMPLETE REVISION August 2006

3.13.5 The meter factor data shall be provided by the manufacturer and be based on the actual piping schedule. 3.13.6 Welds on mounting flanges shall be ground smooth. 3.13.7 Proper gasket sizing shall be followed to avoid protrusion into the process piping. 3.14

Variable Area Meter 3.14.1 Meters shall be installed in a vertical position and piped in accordance with manufacturer’s recommendations. 3.14.2 Meters shall be accessible for easy reading, maintenance, or repair. 3.14.3 The capacity of the selected meter shall be such that normal flow rate falls in middle one-third of chart or scale range. 3.14.4 For process flows, scales shall be graduated in percent units. Meter factor for maximum flow at 100% shall be engraved on scale. 3.14.5 Scales for purge meters shall read directly in Standard Cubic Feet per Hour (SCFH) of air for gas service or Gallons per Hour (GPH) of water for liquid service. 3.14.6 Glass tube meters shall only be used on air, inert gas and water at temperatures of 140° F (60° C) or less and pressures of 100 psig 7 bar(g) or less. Owner’s approval shall be required for use of glass tube meters in other services. 3.14.7 For purge meter applications, a check valve shall be installed on the outlet of the meter to prevent back flow.

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Process Industry Practices

COMPLETE REVISION

PIP PCCFL001 Flow Measurement Design Criteria

August 2006

Table 1 Minimum Straight Run Lengths for Orifice Runs and Other Flow Elements in Accordance with ISO 5167-2 Column B Beta Ratio Upstream disturbance

Dimension

0.2

0.4

0.5

0.6

0.67

0.75

3

3

9

13

20

20

Note 4

Note 4

10

18

18

18

Note 4

Note 4

10

18

20

22

18

18

18

18

20

20

Note 4

Note 4

5

5

6

8

Note 4

8

9

11

14

18

6

6

6

7

9

12

2

3

3

3.5

3.5

4

A

Single elbow A S

Two elbows in same plane 30D>S>10D A S

Two elbows in same plane 10D>S A

Two elbows in different planes 30D>S>5D A

Reducer A

Expander A

Full Bore Ball or Gate valve, fully open Downstream Length for all pictured disturbances

Process Industry Practices

B

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PIP PCCFL001 Flow Measurement Design Criteria

COMPLETE REVISION August 2006

NOTES for Table 1 - PCCFL001: (1) Meter run lengths shown are for ½% additional uncertainty as shown in ISO-5167-2, Column B. For additional information refer to ISO-5167-2 for Orifice Plates and ISO-5167-3 for Venturis. (2) Any flow conditioner shall be installed in the straight length between the primary element and the upstream disturbance, or the fitting closest to the element. The installation location shall be per applicable standard. (3) Interpolate pipe diameters for intermediate beta ratios. (4) Data are not available for straight run lengths for ½% uncertainty (see ISO 5167-2).

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Process Industry Practices

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PIP PCCFL001 Flow Measurement Design Criteria

August 2006

Table 2 Minimum Straight Run Lengths for Orifice Runs in Accordance with ANSI/API (ISO 5167-2, Column A) Beta Ratio Upstream disturbance

Dimension

0.2

0.4

0.5

0.6

0.67

0.75

6

16

22

42

44

44

10

10

18

30

44

44

10

10

22

42

44

44

19

44

44

44

44

44

5

5

8

9

12

13.5

6

12

20

26

28

36.5

12

12

12

14

18

24

4

6

6

7

8

A

Single elbow A S

Two elbows in same plane 30D>S>10D A S

Two elbows in same plane 10D>S A

Two elbows in different planes 30D>S>5D A

Reducer A

Expander A

Full bore Ball or Gate Valve Fully Open Downstream Length for all pictured disturbances

Process Industry Practices

B

7

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PIP PCCFL001 Flow Measurement Design Criteria

COMPLETE REVISION August 2006

NOTES for Table 2 - PCCFL001: (1) Meter run lengths shown are for 0% additional uncertainty as shown in ISO-5167-2, Column A. For additional information refer to ISO-5167-2 for Orifice Plates and ISO-5167-3 for Venturis. (2) Any flow conditioner shall be installed in the straight length between the primary element and the upstream disturbance, or the fitting closest to the element. The installation location shall be per applicable standard. (3) Interpolate pipe diameters for intermediate beta ratios.

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PIP PCCFL001 Flow Measurement Design Criteria

August 2006

Table 3 Minimum Straight Run Lengths for Venturi Tubes and Flow Nozzles in Accordance with ANSI/API (ISO 5167-3) Upstream Straight Run Required Piping Configuration

Additional Uncertainty

Single 900 bend upstream

Two 900 Bends in the Same Plane

Two 900 Bends in Different Planes

Reducer 2D to D over a Length of 1.5D to 3D

Expander 0.5D to D over a Length of 1.5D to 3D

Globe Valve Fully Open

Full Bore Ball or Gate Valve Fully Open

Downstream Run Required

Beta Ratio 0.2

0.4

0.5

0.6

0.7

0.5%

6

7

7

9

14

0%

10

14

14

18

28

0.5%

7

9

10

13

18

0%

14

18

20

26

36

0.5%

17

18

20

24

31

0%

34

36

40

48

62

0.5%

Note 1

Note 1

5

5

7

0%

5

5

6

9

14

0.5%

8

8

9

11

15

0%

16

16

18

22

30

0.5%

9

10

11

13

16

0%

18

20

22

26

32

0.5%

6

6

6

7

10

0%

12

12

12

14

20

0.5%

2

3

3

3.5

3.5

0%

4

6

6

7

7

NOTES for Table 3 - PCCFL001: (1) For additional information on Orifice Plates refer to ISO-5167-2.

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