Design and development for amelioration of primary water flow standard and calibration systems

The present study outlines the efforts made to improve national primary water flow standards and calibration systems through design and development. The facility has been designed and developed in accordance with ISO 4185 standard in the flow range 0.03 m³/h to 650 m³/h to calibrate various types of flow meters up to DN200 (Nominal diameter) using 12 kg, 300 kg, 3000 kg, and 6000 kg weighing systems. In the flow range up to 530 m³/h, the expanded uncertainty in flow meter calibration in totalized mode is found to be ±0.01% to ±0.025% (k = 2), whereas it is ±(0.03–0.05) % (k = 2) up to DN200 size (test rigs) for mass flow rate (MFR) and volume flow rate (VFR) in the flow range 0.1 m³/h to 650 m³/h. The measurement uncertainty achieved is comparable to that of state-of-the-art water flow measurement capabilities available at numerous National Metrology Institutes (NMIs). Thus, the present designed and developed system at CSIR-National Physical Laboratory (CSIR-NPL) is a solution to maintain traceability to the users and industries.     

Uncertainty analysis of the high pressure closed loop gas flow standard facility in NIM

High pressure air flow standard facilities, including the pVTt facility, sonic nozzle facility and closed loop facility were built in NIM at the end of 2014. The high pressure closed loop gas flow facility was the first closed loop facility in China. The system has 4 sets of 100 mm diameter turbine meters for the reference meters with a flow range of (40–1300) m³/h and a pressure range of (190–2500) kPa. To avoid uncertainties introduced during installation, the reference meters were designed to be calibrated in situ using the sonic nozzle facility. The uncertainty in the pressure measurement was reduced by installing an absolute pressure transducer in the manifold upstream of the reference meters, with differential pressure transducers used to measure the pressure drops across the reference flow meter and the test flow meter. The relative expanded uncertainty for the test meter can reach 0.20% (k = 2) as verified by comparison the sonic nozzle facility and the closed loop facility measurements.     

Influence of flow disturbances on the performance of industry-standard LNG flow meters

In the last decade significant progress has been achieved in the development of measurement traceability for LNG inline metering technologies such as Coriolis and ultrasonic flow meters. In 2019, the world's first LNG research and calibration facility has been realised thus enabling calibration and performance testing of small and mid-scale LNG flow meters under realistic cryogenic conditions at a maximum flow rate of 200 m³/h and provisional mass flow measurement uncertainty of 0.30% (k = 2) using liquid nitrogen as the calibration fluid. This facility enabled, for the first time, an extensive test programme of LNG flow meters under cryogenic conditions to be carried out to achieve three main objectives; the first is to reduce the onsite flow measurement uncertainty for small and mid-scale LNG applications to meet a target measurement uncertainty of 0.50% (k = 2), the second is to systematically assess the impact of upstream flow disturbances and meter insulation on meter performance and the third is to assess transferability of meter calibrations with water at ambient conditions to cryogenic conditions. SI-traceable flow calibration results from testing six LNG flow meters (four Coriolis and two ultrasonic, see acknowledgment section) with water in a water calibration facility and liquid nitrogen (LIN) in the LNG research and calibration facility under various test conditions are fully described in this paper. Water and LIN calibration data were compared and it was observed that the influence of removing the meter insulation on mass flow rate measurement accuracy can be more significant (meter error > ±0.50%) than the influence of many typical upstream disturbances when the meter is preceded by a straight piping length equal to twenty pipe diameters (20D) with no additional flow conditioning devices, in particular for ultrasonic meters. The results indicate that the correction models used to transfer the water calibration to cryogenic conditions (using LIN) can potentially result in mass flow rate measurement errors below ±0.5%, however, the correction models are specific to the meter type and manufacturer. This work shows that the target measurement uncertainty of 0.50% can be achieved if the expanded standard error of the mean value measured by the meter is smaller than 0.40% (k = 2). It is planned to repeat these tests with LNG in order to compare the results with the LIN tests presented in this paper. This may reveal that testing with an explosion safe and environmentally friendly fluid such as LIN produces representative results for testing LNG flow meters.     

Design,realization and uncertainty analysis of a laser-based primary calibration facility for solar cells at PTB

A completely newly designed multi-functional facility for the primary calibration of reference solar cells and the spectral characterization of all solar cell types has been developed and built at PTB. The new facility is based on the successfully applied Differential Spectral Responsivity (DSR) method that allows the determination of the absolute spectral responsivity and nonlinearity of solar cells with the lowest uncertainties. By using a tunable laser system, the new setup avoids the main problem of monochromator-based systems: the low optical power level of the monochromatic beam. Thus it enables a significant reduction of the uncertainty for the short circuit current under standard test conditions I_STC of solar cells. It enables the calibration of World Photovoltaic Scale (WPVS) reference solar cells with an uncertainty of 0.4% (k = 2), the lowest value stated by any WPVS laboratory.     

Uncertainty evaluation of the 20 kN m deadweight torque standard machine

A deadweight-type torque standard machine of 20 kN m rated capacity (20 kN m-DWTSM) has been designed and developed by the National Metrology Institute of Japan (NMIJ) at the National Institute of Advanced Industrial Science and Technology (AIST). Each uncertainty contribution comes mainly from the performance of each mechanical part of the 20 kN m-DWTSM. Authors evaluated the uncertainty of the mass of the linkage weights, local acceleration of gravity, influence of air buoyancy on deadweight loading, initial moment-arm length (including CMM measurement and temperature compensation), and sensitivity of the fulcrum. This report deals especially with evaluation of the remaining contributions, namely the influence of arm flexure and reference line variation at the end of the moment-arm on best measurement capability (BMC). Estimation of BMC in the 20 kN m-DWTSM gave a relative expanded uncertainty of less than 7.0 · 10⁻⁵ (k = 2) for the calibration range from 200 N m to 20 kN m.     

Range expansion of the reference torque wrench calibration service to 5 kN m at NMIJ

The reference torque wrench (RTW) calibration service within the range from 5 N m to 1 kN m has been provided to industry by the National Metrology Institute of Japan (NMIJ) in the National Institute of Advanced Industrial Science and Technology (AIST). Reflecting the strong demand from Japanese industry, the calibration range was extended to 5 kN m. First, a high-precision torque transducer in the form of a torque wrench with a rated capacity of 5 kN m was developed in order to establish a calibration method for such a large RTW. Second, the calibration method was investigated using a deadweight type torque standard machine with a rated capacity of 20 kN m as a reference standard. Aimed expanded calibration range is from 200 N m to 5 kN m. As a result of calibration experiment using three transducers having different rated capacities, a relative expanded uncertainty of less than 7.0 × 10⁻⁵ could be obtained at a certain calibration point in the best case.     

New air speed calibration system at NMIJ for air speeds up to 90 m/s

National Metrology Institute of Japan (NMIJ) has established a high air speed standard facility and has been providing a calibration service since 2015. The facility has an air speed range of 40 m/s to 90 m/s with a relative expanded uncertainty (k = 2) of 0.63%. The purpose of this primary standard is mainly to contribute to the improvement of meteorological observation research and to the evaluation of flow field inside a turbo machine and around a high speed vehicle. The reference air speed is derived from the national primary gas flowrate standard of Japan. A conversion device from flowrate to air speed is installed in the test line of the closed-loop calibration facility. The reference air speed at the nozzle exit of the conversion device is obtained by comparing the integral of the air speed profiles and the reference volume flowrate. The total pressure tube used as a transfer standard is then calibrated against the reference air speed at the center of the nozzle exit. The Eiffel-type wind tunnel, which is a working standard for the daily calibration service, is calibrated using this total pressure tube. The present paper describes the calibration system, the traceability chain, and an uncertainty analysis using a validation method.     

Analysis of viscosity effect on turbine flowmeter performance based on experiments and CFD simulations

Viscosity effect is one important factor that affects the performance of turbine flowmeter. The fluid dynamics mechanism of the viscosity effect on turbine flowmeter performance is still not fully understood. In this study, the curves of meter factor and linearity error of the turbine flowmeter changing with fluid viscosity variations were obtained from multi-viscosity experiments (the viscosity range covered is 1.0×10^–6 m²/s–112×10^–6 m²/s). The results indicate that the average meter factor of turbine flowmeter decreases with viscosity increases, while the linearity error increases. Furthermore, Computational Fluid Dynamics (CFD) simulation was carried out to analyze three-dimensional internal flow fields of turbine flowmeter. It was demonstrated that viscosity changes lead to changes of the wake flow behind the upstream flow conditioner blade and the flow velocity profile before fluid entering turbine rotor blade, which affect the distribution of pressure on the rotor blades, so impact the turbine flowmeter performance.     

Flow characteristics of back supported V-cone flowmeter (wafer cone) using PIV

The present experimental study has been carried out to evaluate the performance and flow characteristics of the Wafer cone flowmeter using Particle Image Velocimetry (PIV). Two equivalent diameters (β) of 0.62 and 0.72 with combination of two vertex angles (ϕ) namely 30°and 45°are used for the evaluation of the performance of the flowmeter in the range of Reynolds number of 3 × 10³ to 8.19 × 10⁴. The investigation shows that the coefficient of discharge seems to be independent of β-value with the increase in vertex angle. Further, the appropriate location of the downstream pressure tap is also estimated for the cone configuration of β = 0.62 and ϕ = 30°. It is observed that the downstream pressure tap location of 0.8D distance gives a higher value of discharge coefficient compared to 0.0D distance with the error being also lower marginally. PIV data has been analysed for the cone configuration of β = 0.62 and ϕ = 30°at four Reynolds numbers of 3028, 6057, 52755 and 74488 in terms of axial velocity and turbulent intensity. The measurements reveal an interesting phenomenon in terms of the rapid decay of turbulent kinetic energy on the downstream of the cone. This may be due to the interference of the cone wake with the support wake resulting in fast decay. This unique phenomenon leads to the reduction in the requirement of the downstream straight length for the Wafer cone flow meter, unlike other obstruction type flowmeters.     

Pressure measurement technique and installation effects on the performance of wafer cone design

The present study explores novel pressure averaging technique for wafer cone flowmeter design and its robustness in the presence of double 90° bend (out-of-plane) and gate valve as a source of upstream flow disturbance. The wafer cone flowmeter is tested in a circular pipe (inside diameter of 101 mm) with water as the working medium for the flow Reynolds number ranging from 1.19×10⁵ to 5.82×10⁵. Influence of the half cone angle (α) on the coefficient of discharge (C_d) of wafer cone flowmeter is studied with this new pressure averaging technique. Half cone angles considered in this study are 30° and 45° with a constant constriction ratio (β) of 0.75. The upstream static pressure tap is located at 1D upstream of the wafer cone. The downstream pressure averaging technique comprises eight circumferential holes of diameter 2 mm on the maximum diameter step of the wafer cone. The pressure taps are communicated through the support strut which serves as a downstream static pressure tap. The disturbance causing elements are individually placed at 1.5D, 5.5D, 9.5D and 13.5D upstream to the wafer cone flowmeter. The wafer cone flowmeter is also tested with gate valve opening of 25%, 50% and 75% for all the arrangements considered. The 30° cone is found to be better than 45° cone for the range of Reynolds number covered in the present study. The results show that the 30° wafer cone flowmeter with novel downstream pressure averaging technique is insensitive to the swirl flow created by a double 90° bend (out-of-plane) and requires an upstream length of 9.5D with a gate valve as a source of flow disturbance.     

Uncertainty evaluation of a 10N·m dead weight torque standard machine and comparison with a 1kN·m dead weight torque standard machine

A 10N·m dead weight torque standard machine (10-N·m-DWTSM) has been developed and evaluated since 2006 at the National Metrology Institute of Japan (NMIJ), a part of the National Institute of Advanced Industrial Science and Technology (AIST). Previously, the lengths of a moment arm, made of a low-thermal-expansion alloy (Super Invar), and the sensitivity limit of the fulcrum were evaluated. However, it is known that mechanical parts made of Super Invar vary in size with time. Therefore, the sensitivity limit of the fulcrum should be investigated under real calibration conditions. In this study, the moment arm lengths and the sensitivity limit of the fulcrum were re-evaluated. The moment arm lengths were found to have increased by an average of 6.3 μm in five years. The relative combined standard uncertainty of the moment arm length, w_arm, was re-evaluated in consideration of the uncertainty of the secular length change and was found to be 1.8 × 10⁻⁵. The sensitivity limit of the fulcrum was investigated by using a highly accurate, small-rated-capacity torque measuring device. The relative combined standard uncertainty due to the sensitivity limit of the fulcrum was 2.5 × 10⁻⁵ in the 0.1–10N·m torque range. The uncertainty budget table of the 10-N·m-DWTSM was completed. The relative expanded uncertainty of torque realized by the 10-N·m-DWTSM, W_tsm, was evaluated in the 0.1–10N·m torque range and was found to be 6.6 × 10⁻⁵, with a coverage factor, k, being equal to 2. In addition, the 10-N·m-DWTSM was compared with the existing 1-kN·m-DWTSM at NMIJ by using small-rated-capacity torque measuring devices at 5N·m and 10N·m torque steps. Two loading conditions were adopted in this comparison. The comparison results showed good agreement within the uncertainties in all cases. Thus, the torque realized by the 10-N·m-DWTSM was shown to be equivalent to that achieved by the 1-kN·m-DWTSM.     

Evaluation of newly developed 50 N dead-weight type force standard machine using tuning-fork type force transducer

A 50 N dead-weight type force standard machine (DWM) was developed by the National Metrology Institute of Japan to expand the lower end of calibration force from 10 N to 1 N. The weights of the DWM consisted of a loading frame and a linkage-weight stack. The loading frame applied a gravitational force of 1 N to a force transducer under calibration. The calibration and measurement capability of the 50 N DWM was verified to be 2 × 10⁻⁵ relative using a tuning-fork type force transducer in accordance with ISO 376. The equivalence between the 50 N and 500 N DWMs was confirmed by performing an intralaboratory comparison using the tuning-fork type force transducer. Moreover, the competence of the transducer for the evaluation of DWMs was demonstrated.     

Evaluation of flowmeters for heat metering

Heat flowmeters are expected to be reasonably priced, be very reliable, and have high measurement accuracy. Various types of heat flowmeters have been developed and they are widely used in large residential and industrial buildings. In this study, three types of heat flowmeters (turbine, electromagnetic and ultrasonic) were tested for accuracy, effect of installation position and vibration, durability and performance in the field for several installation positions and in the presence of vibration. We used a liquid flow standard system and a customized durability test system in accordance with the International Organization of Legal Metrology (OIML) R 75-2 heat meter testing method. The field test was conducted in eight different locations from winter to summer. All flowmeters were calibrated before and after the field test, and the measurement deviation and the relative expanded uncertainty were calculated. The mean deviations obtained were–0.21%,–0.07%, and 0.11%, with the relative expanded uncertainties 0.48%, 0.17%, and 0.40% for turbine, electromagnetic, and ultrasonic flowmeters, respectively. The results of position and rotation tests, mean deviations by rotation angles at 90°, 180°and 270°relative to 0°(horizontal position) were–1.24%,–1.07% and–0.80%, respectively. For the vibration tests at 1 m/s² and 5 m/s² vibration acceleration, the turbine flowmeter, the electromagnetic flowmeter and the ultrasonic flowmeter showed deviations that ranged from −0.2% to −0.5%, −0.6% (2.6 m³/h), and 0.0% (negligible), respectively. In the durability tests, the accuracy of all three types of heat flowmeters remained at ±1% or less, showing sufficient durability. In the field test, the deviation of the turbine flowmeter and the ultrasonic flowmeter showed ±2.5% or less deviation. However, the electromagnetic flowmeter seems to be inaccurate below 6.9% of the maximum flow rate.     

Accurate determination of spring constant of atomic force microscope cantilevers and comparison with other methods

We present calibration results of commercial AFM cantilevers using the KRISS nanoforce calibrator (NFC) that can determine traceably spring constants with an uncertainty better than 1%, along with the results obtained from other four calibration methods: the dimensional method, the cantilever-on-cantilever method, the Sader method, and the thermal noise method. Two types (contact and tapping mode) of beam-shaped AFM cantilevers with nominal spring constants of 0.9 N m⁻¹ and 42 N m⁻¹, respectively, were investigated in this study. Because of its small uncertainty, the NFC method was used to assess the uncertainties of other four methods through comparisons between values obtained from other methods and those from the NFC method for the same cantilever. Results from other methods were generally in good agreement with those from the NFC method within the uncertainties of other methods claimed in other literatures, but values obtained from the Sader method were differed by up to 40% from the NFC values, which is 2 times worse than the known uncertainty.     

A new mass & time primary standard for natural gas in China and the uncertainty evaluation

A new mass-time primary standard for high pressure natural gas, which is based on electromagnetic balance and hydraulic fast-acting valves, was set up at the beginning of 2017 in Chengdu, China. The full load of the electromagnetic balance is 3 tons and the measurement uncertainty of mass is better than 1.0g(k = 2). The opening and closing time of the hydraulic fast-acting valves can achieve 33 ms±3 ms.The operation pressure and flowrate range of the facility is (4–60)bar.a and (5–410)m³/h respectively. In accordance with the preliminary tests, the estimate uncertainty of sonic nozzles calibration is between 0.10% and 0.12%(k = 2). The operation principle, testing results and the uncertainty evaluation are presented in the paper as well as some improving ideas.     

Static pressure measurement error for wall taps with high Reynolds number turbulent pipe flow

An experimental study on a static pressure measurement errors in wall taps was conducted using a high Reynolds number actual flow facility (Hi-Reff). The bulk Reynolds number Re_D examined was up to 1.3 × 10⁷ and tap Reynolds number Re_t was up to 8.5 × 10⁴. The behavior of the static pressure measurement error at high Reynolds numbers was clarified experimentally. The static pressure measurement error normalized by wall shear stress increases with Reynolds number and reaches an asymptotic value. Its maximum value is 7.1 at Re_t = 8470. The asymptotic value increases with the size of the tap diameter up to 6 mm and then becomes constant for tap diameters exceeding 6 mm. The universal curve reported in previous studies is observed for only a limited range of tap Reynolds numbers of below 700 and of tap diameters below 4 mm.     

Improved system for the automatic calibration of standard resistors in the meg-ohm range

An automated measuring system has been developed to improve the calibration of high value standard resistors in the meg-ohm range at the National Institute for Standards (NIS), Egypt. This system is suitable for the calibration of the standard resistors from 100 kΩ to 100 MΩ using the DMM-based method by the substitution technique where the unknown resistor and the standard resistor are indirectly compared in the same position using a dummy resistor as a short-term reference standard. The system operation is automatically controlled by using a Lab VIEW program which is especially developed for this purpose. The uncertainty for the high value standard resistors measurement of this system is estimated. The performance of this system is also evaluated by comparing the measurement results obtained from this technique with those obtained by the direct comparison DMM-based method. It is found that the measurement uncertainty of with this method spans from 4.1 × 10⁻⁶ to 27 × 10⁻⁶, while it spans from 40 × 10⁻⁶ to 110 × 10⁻⁶ for the direct comparison method. The relative differences of the deviation from nominal values of the working standards resistors measured by the two methods are found to be within their expanded uncertainties.     

Calibration of laser Doppler vibrometer and laser interferometers in high-frequency regions using electro-optical modulator

We proposed a new primary calibration method of a laser Doppler vibrometer (LDV) using the optical modulated excitation of an electro-optical modulator and validated this approach by comparing mechanical modulated excitation with homodyne laser interferometer at the National Metrology Institute of Japan (NMIJ). The velocity sensitivity of the LDV was evaluated with the uncertainty budget at a high-frequency range up to 1 MHz, which is indicated as the upper limit of 50 kHz in ISO (International Organization for Standardization) 16063–41. As the results, we confirmed that velocity sensitivities between optical and mechanical modulated excitations are flat within their uncertainty from 100 Hz up to 1 MHz. Moreover, in order to evaluate the accurate phase shift of the accelerometer up to 20 kHz using optical modulated excitation, we also revealed the reliability of two time shifts between homodyne and heterodyne laser interferometers.     

Development and validation of a dynamic primary standard for unsteady liquid flow calibration

LNE-CETIAT liquid flow laboratory is the French Designated Institute for liquid water flow rate from 1 g h⁻¹ to 50 t h⁻¹. Historically, its primary standards are based on the flying start and stop gravimetric method. The best relative expanded uncertainty for liquid mass flow rate is 0.05% (k = 2). In the scope of the Joint Research Project Metrowamet and its mission to maintain and develop the French standards for liquid flow, LNE-CETIAT has developed and validated a dynamic primary standard for unsteady liquid flow calibration. This paper will first present the developped system, which is composed of a dynamic flow generator and a dedicated measuring system together with its own software for data acquisition and processing. The validation, realized by intra and inter-laboratory comparisons for static and dynamic flows, is presented in the third chapter. Finally, the validation of the measurement and calibration capabilities, based on internal tests and inter-laboratory comparisons are presented.     

Development and evaluation of the calibration facility for high-pressure hydrogen gas flow meters

The calibration facility with the multi-nozzle calibrator was developed for the calibration of flow meters to be used with high-pressure, high-flow-rate hydrogen gas. The critical nozzles installed in the multi-nozzle calibrator were calibrated with traceability to the national standard. The relative standard uncertainty of the mass flow rates produced from the calibration facility is 0.09% when the flow rate is between 150 g/min and 550 g/min. In this study, the Coriolis flow meter was calibrated for a pressure range of 15–35 MPa. The relative standard uncertainty of the flow rates obtained from the Coriolis flow meter was 0.44% for the case of the worst fluctuations in the output of the flow meter; based on the calibration curve, this is 0.91%. The present result shows that there is a maximum 3% difference between the output of the Coriolis flow meter and the mass flow rates of the multi-nozzle calibrator, even though the Coriolis flow meter was calibrated using water. Therefore, for the development of a calibration facility that can calibrate a flow meter under the same conditions as those encountered in actual use, it will be important to develop a new flow meter.