Post on 23-Jan-2021
FCRIBulletin
A RESOURCE FOR INDUSTRY VOL: 16 ISSUE: APRIL 2014
FLUID CONTROL RESEARCH INSTITUTE NABL Accredited ISO 9001Certified Establishment
(Under Ministry of Heavy Industries and & Public Enterprises, Govt. of India)
Kanjikode West, Palakkad – 678623, Kerala, India
Tel: +91-491-2566120/206/2569009/2569135; Fax: +91-491-2566326
MESSAGE FROM DIRECTOR Dear Readers,
With great pleasure FCRI re-launched the publication of FCRI bulletin from 2014 January issue. Bulletin
highlights the activities of the institute in the area of flow measurement and control. FCRI team
Welcomes Readers valuable support this and succeeding issues of the bulletin.
India was lagging behind
advanced nations in terms of
developing & pioneering
technologies in the field of fluid
flow metering and control. Also it is
acknowledged that one of the
greatest challenges facing the
Indian industry is the skill shortage, and with the
increasing activity in the process industry domain,
the impact of this shortage has been more critical
all around. With the launch of Fluid Control
Research Institute (FCRI), by the Ministry of Heavy
Industries and Public Enterprises, the scenario was
altered and considerable progress has been made
since then. Establishment of water, air and oil flow
measurement facilities and supporting standards
laboratories have contributed to massive savings for
Indian flow product and related industries in terms
of foreign exchange towards test/calibration
charges. It has also helped to improve the product
quality and confidence of end users of these flow
elements. A national level skill strategy is being
implemented by FCRI through training program.
With the re-launch of FCRI e-bulletin, it is intended to
showcase and make accessible various facilities
available at FCRI so that the resources can be fully
exploited by the Indian industry. This issue of the
bulletin focuses on the existing test resources and
also on the test facility recently added for
Environmental testing of Nuclear Power plant
elements and tests / calibrations performed in
various laboratories during October – December
2013. Environmental test facility for nuclear valves
has been specially calibrated to perform LOCA
(Loss of Coolant Accident) and MSLB (Main Steam
Line Break) tests apart from thermal aging tests
specified in ASME/ QME Standards. The capacity of
multi viscous facility has been enhanced from 300
lpm to1200 lpm. A sophisticated level test facility
upto 5 m and an online densitometer calibration
facility were also added during last year.
Dr. JACOB CHANDAPILLAI
Director
IN THIS ISSUE
International Participants for Course on
“Quality System Certification (ISO 9001) & Six Sigma
Practices For Organisations/Laboratories(Testing/
Calibration)”,February 03 – March 31, 2014
No. of Participants:17, Nominating Countries:
Bolivia, Cambodia, Kazakhstan, Myanmar, South Sudan,
Sri Lanka, Uganda, Vietnam, Zambia
1. General Highlights
2. LOCA/MSLB Test Facility
3. Thermal Aging Test Facility
4. Water Flow and Large Water Flow Lab.
5. Airflow Laboratory / CNG / CLATF
6. Oil Flow Laboratory
7. Physical Standards Laboratory
8. Environmental Qualification Laboratory
9. Electro Technical Laboratory
10. Training Department
11. Computational Fluid Dynamics
12. Data Acquisition System
13. General Purpose Laboratory
14. Centre for Water Management
1. GENERAL HIGHLIGHTS
Started commercial calibration in Large Water Flow Test Facility with a maximum Line Size of 2 mtrs.
Received an order from M/s .MCGM for Consultancy services for setting up of SCADA system for
measurement and display of sewage flow, sewage levels and various electrical parameters at
sewage pumping stations.
Received a Major Order for the Calibration of Mass Flow meters from M/s. Endresss and Hauser (India)
Pvt. Ltd.
Received an order for Consultancy Services towards setting up of Airflow Test Rig from M/s. Tata
Motors, Pune.
Performed the Model Approval of a CNG Dispenser belonging to M/s. Parker Hannifin at its newly
established CNG Facility.
Undertaken the calibration of a 900mm EMF belonging to M/s. Chennai Water Desalination Limited in
Large Water Flow Lab.
Submitted a proposal for the supply of water meter test bench for Ministry of Industry and Trade, FIJI.
Silver Jubilee was Celebrated on 18th April, 2014.
FLUID CONTROL RESEARCH INSTITUTE VOL: 16 ISSUE: APRIL 2014
2. LOCA / MSLB CHAMBER
Fluid Control Research Institute (FCRI) specialists has qualified thousands of safety-related electrical and mechanical
components, including valves, cables, actuators, switches, relays, breakers, transmitters and transducers. FCRI recently
upgraded the valve test facility to perform Steam Event Simulation for Loss of Coolant Accident and Main Stream Line Break
(LOCA/MSLB) testing services meeting IEEE 323 requirements using qualified test facilities which enable testing for the new,
advanced reactor designs. MSLB/LOCA chamber simulates the harsh environment resulting due to LOCA/MSLB. This, tests the
ability of the equipment to perform its required safety function while being subjected to the pressure, temperature, and
humidity effects associated with the environment of a design basis accident. MSLB test on Cable and Terminal JB from were
Performed .The testing was conducted on the test items placed in MSLB chamber and required Temperature- pressure profile
was generated. During the test the test, Insulation Resistance values of the test items were monitored with insulation tester. Brief
Specification of the LOCA/MSLB test facility is as under:
Overall Dimension of chamber : 1000 mm dia and 1 meter depth
Inside dimension of Chamber : 950mm dia and 1 meter depth
Heating capacity : Ambient to 200°C
Heater Rating : 9 KW
LOCA / MSLB Chamber
3. THERMAL AGING CHAMBER
FCRI recently upgraded its test facility to perform Long term
thermal aging testing to monitor degradation of the Test
components using qualified test facilities which enable testing
for the new, advanced designs. Thermal degradation refers to
the change in chemical and physical properties of a material
that occur at elevated temperatures. Increased temperature
accelerates most of the degradation processes. It involves
aging the proposed component at three or more elevated
temperatures. After each heat cycle, samples are also
subjected to a repeated series of environmental exposures, such
as cold shock, mechanical stress and humidity.
Thermocouples and electronic
temperature controllers are used
to the test facility to maintain the
specified thermal aging
temperature. Temperatures are
maintained within +1°C of the
specified thermal aging
temperature.
Redundant Controllers are used to prevent overheating of the test samples in the event of a malfunction of the main
controller. Brief Specification of the Thermal Ageing test facility is as under:
Chamber Size : 32”×32”×32”
Chamber Size : High temperature
Temperature range : Ambient to 700°C
Heater Rating : 21KW
4. WATER FLOW LABORATORY
Cv Testing of 30” Control
Valve
Large Size Valves
Cv testing of large size valves
upto 30” size were tested for
M/s. Instrumentation Ltd., and
M/s. Severn Glocon (I) Pvt. Ltd.
Cv Testing of 30” Control Valve
Domestic meter regulator
2 nos. of domestic regulators
were tested for flow and
pressure loss for Ms. Nirmal
Industrial Controls Pvt. Ltd.,
Maharashtra.
Butterfly Valve
Torque test, Operation test
and actuator test were
carried out on a 14 inch
butterfly valve for Korea
Unicom Valve Co. Ltd.,
Korea.
Calibration of 30” Venturimeter
Venturimeters of size up to 30”
was calibrated for coefficient
of discharge and performance
was evaluated for various
Reynolds number for M/s.
Minco India Ltd., Goa.
Coefficient of discharge of the
venturimeter was determined
up to a flow rate of 4500 m3/h.
Calibration of 30”
Venturimeter
Calibration of 750 mm anubar
Calibration of annubars of sizes
600 mm and 750 mm were
carried out for M/s Emerson
Process Management, Navi
Mumbai.
6 Way Double Change Over Valve
6-way double change over
valve
Pressure drop test on a 6 way
double change over valve of
sixe 10” x 8” was done for M/s
Hawa Valves (I) Pvt. Ltd.,
Bangalore. Pressure drop
across the valve at various
opening were measured at
specific flow rates.
Multi Sensor Ultrasonic Flow
Meter
R & D project of M/s G E, Hyderabad
Special test of multi sensor ultrasonic flow meter
were conducted for GE as a part of their R & D
project. The main focus of the study was to
analyze the stability of the meter when
subjected to continuous flow over a period of
time.
RRSL Test Facility
Established transfer standard flow measurement
facility
Transfer standard flow measurement facilities
have been established at Regional Reference
standards Laboratory (RRSL), Faridabad and
Regional Reference Laboratory, Bangalore. The
entire facility has been designed, fabricated and
erected by FCRI.
Testing of spray nozzle
Spray nozzles of size 1.5” were tested for pressure drop ar various flowrates. The nozzle is screwed onto the holding body with a 1.5”
Class 300 Flange end connection for water entry. Water enters the inner chamber of the nozzle through the flange. Nozzle consists of
3 main parts: a) Nozzle Body with a seat b) Control Plug resting on the body seat c) Spring. In order to maintain constant pressure
inside the nozzle, the plug is loaded by a spring calibrated in function of water-steam diff. pressure. Hence, any load variation in the
water pressure is immediately compensated by the axial movement of plug, thus, changing the orifice section (annular area) of the
nozzle.
Testing of spray nozzle
2 FCRI PUBLICATIONS, FLUID CONTROL RESEARCH INSTITUTE
FLUID CONTROL RESEARCH INSTITUTE VOL: 16 ISSUE: APRIL 2014
5. AIR FLOW LABORATORY
FCRI has established air flow facilities covering areas related to industrial gases. A full-fledged low pressure calibration facility has been in existence since 1989
operating at near atmospheric pressure with flow rates upto 10000 m3/h. Various types of flow meters of sizes upto 400 mm are evaluated with measurement
uncertainties, which are in par with international institutions.
Model approval tests of Gas regulators
Model approval tests of Gas regulators were
done as per EN 88-1 & EN 334 for M/s. Jetex
carburetors & M/s.Raychem RPG limited, Pune.
Following tests were conducted on Gas
regulators for Model approval tests as per EN 88-
1& EN 334, Leak Tightness Test, Torsion &
Bending, Rated Flow Rate Test, Pressure
Regulator performance, Endurance Test, Lock-
up Pressure test, Lock-up test, Accuracy Test.
Determination of accuracy class lock up
pressure, class of lock up pressure zone, the
maximum accuracy flow rate and the minimum
flow rate related to given range of inlet pressure
& Determination of lock up pressure.
Model Approval tests on Diaphragm gas meters:
A wide range of domestic gas meters were calibrated for various
companies. Samples of diaphragm gas meters used for domestic gas
metering were subjected to Type Approval tests in accordance with
BS 4161 Part 5, 1990 "Gas meters, specification for diaphragm meters
for working pressure up to 7 bar" and BS EN 1359 : 1999, "Gas meters -
Diaphragm gas meters". Model approval test of Diaphragm gas
meters were done as per IS 14439 for M/s. Raychem RPG limited,
Pune. Following tests were conducted on Diaphragm gas meters for
Model approval tests as per IS 14439,General inspection & Initial
Performance test, Durability test (2000 hrs) Final Performance test.
Calibration of Gas Meters
Calibration of Ultrasonic flow meters for M/s.GE
India Industrial Pvt.Ltd,Pune
Calibration of 2 nos of 8” NB Ultrasonic flow meters
were done at AFL for M/S.GE India Industrial
Pvt.Ltd, Pune. Calibration of these Bi directional
flow meters was done at both forward & reverse
conditions. Calibration of ultrasonic Flowmeter
Calibration of 18”NB Annubar, for M/s.
Hydronuematics
Calibration of 18”NB Annubar was carried out
for M/s. Hydronuematics, Goa. This is the largest
flow meter tested in the facilility so far.
Calibration factor was established for the 18”NB
Annubar.
Calibration of 18” NB annubar
6. OIL FLOW LABORATORY
Testing of level measurement probes
Testing of level measurement probes
were done for M/s. Gilbarco Veeder
Root India Ltd, Mumbai and M/s.
Orpak systems India Pvt Ltd., Pune.
The probes were tested in gasoline
and diesel medium. These probes are
used for the automation of level and
temperature measurement in the
storage tank at retail petrol and
diesel outlets.
Level Measurement Probes
Testing of venturimeters for GE, Bangalore
The assembly configuration comprise of
80mm pipe, reference flow meter and a
vertical loop that goes up to a height of
3000mm, followed by Venturimeter ,
followed by a height of around 500mmm
before the bend. The experiment was
conducted with various viscosity oils 2cst,
32cst, 68cst, and 100cst and 200cst oils. On
line data was logged to the Data
Acquisition system continuously.
Testing of Venturi Meter
Calibration of Ultrasonic Flow Meter
Testing of ultrasonic flow meter for GE,
Hyderabad
To study the prototype ultrasonic flow meter
developed by GE, endurance tests were
conducted for 16 hours. Four ultrasonic flow
meters were assembled in series and the
experiment conducted. A special turbine flow
meter used in the helicopter to check the fuel
consumption, available fuel in the storage tank
was tested for its accuracy .The test was for
Aeronautical Development Agency,
Bangalore.
Testing of Turbine Flowmeter
Automobile sector
Positive displacement flow meters
used to verify the fuel consumptions
of medium and heavy vehicles at
test tracks were certified for
companies like ARAI - Pune,
International centre for Automotive
Technology New Delhi, VRDE-
Maharashtra, Automotive test
systems-Chennai, Nissan Ashok
Leyland- Chennai.
Enhancement of the flow capacity of
multi viscous facility
A new multiviscous facility is being
commissioned for a flow upto 1200
lpm. The existing facility is upto
300lpm. The new primary calibration
system works on gravimetric
method. The oils available for
calibration will be 2cst, 15cst, 100cst
and, 220cst up to 1200 lpm and
32cst, 68cst and 460 cst upto 300
lpm. The same facility can be utilized
for the model approval
of PD meters, turbine flow meters,
mass flow meters etc. as
recommended in OIML R117.The
budgeted uncertainty of the
system will be better than +/-0.1%.
It is expected to be
commissioned before 31st March
2014.
New sophisticated level testing facility.
A new facility for testing / calibrating
level measuring probes / instruments
upto a height of five meters is being
commissioned. The level calibration
can be done in petrol, Diesel, Diesel –
water interface l and Petrol –Water
interface as per the client
requirement. The facility can utilized
for the calibration of level,
temperature and density indication of
the probes. The budgeted uncertainty
will be better than 0.1mm for level,
0.1deg.C and 0.1kg/m^3 for density
Density calibration facility.
A new facility for calibrating density meters
and mass flow meters for density is being
commissioned. The facility will be
exclusively for the calibration of mass flow
meters and density meters of various sizes
in different densities ranging from 650kg/m3
to 1000kg/ m3 in fluids like water( 1000kg/
m3) , Exxsol D80 (780 kg/ m3) and ether
(650kg/m3) .The budgeted uncertainty is
better than 0.1kg/m3 of reading.
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FLUID CONTROL RESEARCH INSTITUTE VOL: 16 ISSUE: APRIL 2014
7. PHYSICAL STANDARDS LABORATORY
A lot of 32 pressure transmitters for Reliance Infrastructure, Noida, Provings rings and E2 class Dead Weights for M/s VSSC,
Thiruvananthapuram, a lot of 10 nos. of 500 kg weights for M/s Endress & Hauser, Aurangabad, a lot of 150 glasswares for
M/s Govt. Analyst Lab, Thiruvananthapuram, a lot 70 torque wrenches for M/s VSSC, a lot of pressure, torque, dimensional
and force instruments for M/s Air Force Station, Sulur, a lot of pressure gauges and Dead Weight Tester for M/s NTPC,
Alappuzha, a lot of 5 litre, 20 litre, 50 litre and 100 litre capacity Volume Measures for M/s. Tokheim India (Pvt) Ltd., Mumbai,
a lot each of pressure instruments for M/s BHEL and CINDA Engg., torque and pressure gauges for M/s Air Force Station,
Bidar and a lot 20 precision pressure instruments for M/s HAL, Bangalore.
Site calibration
Weighing balances at Roots Industries Ltd, Coimbatore,
Governnent Analyst Lab, Kozhikode, Kochi and
Thiruvananthapuram, The State Farming Corpn.of Kerala Ltd,
Punalur, Kollam, SHM Shipcare, Cochin , The Pipettemann -
Micropipette calibration Laboratory, Coimbatore, HLL
Lifecare Limited,TVM , Yamuna Roller Flour Mills Pvt.Ltd,Thrissur,
Scientific And Industrial Testing Research, Coimbatore, Excell
Assay And Hallmarking Centre , Thrissur630mm x 630mm
Surface Plate at Isotech Metrology Solutions, Kanjikode
Altitude Chamber for M/s Goodrich Aerospace Services,
Bangalore, Volume vessel calibration at Steel max Rolling Mills
Ltd., Kanjikode
Calibration of 50l volume Prover
Services to foreign companies
Standard weights for M/s BSMD-
MOIC, Kingdom of Bahrain,
Pressure instruments for M/s Al –
Futtaim Exova LLC- Post Dubai,
Dimensional verification of large
orifice plates for M/s National
Petroleum Construction Co.,
UAE.
Valve actuator test as per UL
1091
8. ENVIRONMENTAL QUALIFICATION LABORATORY
Environmental Qualification Laboratory of FCRI is involved in doing service in the area of Noise& Vibration testing and calibration and strain measurement. It is
serving across the sectors from Transportation, Power engineering to medical instrumentation. It facilitates testing of a very wide range of products including
temperature/ humidity & HVAC equipment, electrical / electronic measuring & indicating instruments, electrical switch-gear / control-gear enclosures, Telemetry/
wireless-communication equipment, audio-visual equipment, new products developed for space / aerospace, military and outdoor applications, etc. Some of
the major assignments conducted during this period are
Railway sector
Customer: Bombardier Transportation
India Ltd., Vadodara
Product : CRW panel
Standard followed: IEC 61373: 2010
"Railway Applications – Rolling stock
equipment – Shock and vibration tests
Type of tests: Simulated long life testing
Functional Random vibration testing
Shock testing
Testing of CRW panel
Aviation sector
Customer: Souriau India Pvt. Ltd.,
Cochin
Product: Connectors
Standard followed: MIL-STD-1344,
method 2005 " Test standard for
electrical connectors"
Type of tests
Random testing - 44 g rms
Sine testing - 20g
Testing of connectors
Testing of grading capacitor
Power sector
Customer: ALSTOM T&D India Ltd., Hosur
Product: Grading capacitor
Standard followed: IEC 62146-1, “Grading
capacitors for high-voltage alternating current
circuit-breakers – Part 1: General"
Type of tests
Resonance search test - Initial Shock testing
Resonance search test - final Testing of connectors
9. ELECTRO TECHNICAL LABORATORY (ETL)
The state of the art electro technical calibration facilities includes Electronic Standard Cells, Standard Resistors, Multifunction Transfer
Standard, Multifunction Calibrators, CRO calibrator, Transconductance standards, AC/DC Current Shunts, LF Power Standard, RLC
Standard , Cesium and Rubidium Frequency Standard, LF & RF Standard Sources etc.
Thermal Calibration Lab
Thermal Calibration lab has facility for Fixed point calibration of SPRTs, HTPRTs and standard thermocouples probe and comparison
calibration of all types of laboratory and industrial grade temperature measuring devices as per ITS-90 . ITS-90 Fixed Point Calibration
(-38.8344°C to 961.78°C).
The state of the art primary
calibration facility includes, DC
Bridge, Standard resistors, DMM-8½
digit, Multichannel scanner, Quartz
sheathed SPRTs & HTSPRTs, TPW
cell, Large sealed Fixed point cells
point cells( Mercury point to Silver
Point) with dedicated
maintenance baths and furnaces,
PC with dedicated software for
the generation of calibration
reports with temperature table.
Comparison Calibration
(-70°C to 1200°C)
The comparison calibration facility of
thermal lab is well equipped with a
range reference SPRTs, PRTs, TCs and
dedicated digital temperature
indicators. A range of highly stable
heat sources like LN2 comparison
bath, Stirred alcohol & oil baths, dry
block calibrators, thermocouple
calibration furnace, Zero point well
etc. can cover the temperature
range from Boiling point of LN2 to
1200°C.
RH Calibration
(10% to 95% & 5°C to 70°C)
The self contained relative humidity
generator that measures and controls
humidity with high accuracy based on
“two pressure “ generation principle
have a large working volume to
accommodate most of the humidity
probes, chart recorders, humidity-
Loggers /transmitters and higrometers
commercially available in industry for
calibration. ETL has well established
quality system complying with ISO/IEC
17025. The laboratory is accredited by
the National Accreditation Board for
Testing & Calibration Laboratories
(NABL), Department of Science and
technology, Govt. of India. The
reference standards maintained in the
laboratory are traceable to national
standards.
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FLUID CONTROL RESEARCH INSTITUTE VOL: 16 ISSUE: APRIL 2014
10. TRAINING PROGRAMMES
It is now widely recognized that support and involvement from engineering industry can be hugely beneficial for students and young people to equip with the skills
and knowledge relevant to the current demand of engineering business. FCRI in partnership with professional engineering institutions is working to join the dots
through its customized training courses and career inspiration programme for tomorrow’s engineers. By working together, we can take the best of what the
engineering community has to offer and ensure sustained interventions, underpinned by robust career information and resources under one roof. We can apply
meaningful evaluation to the Programme, allowing us to reliably measure the impact of our combined efforts Training Programmes in the area of Flow
measurement & control, Calibration, Testing, Instrumentation engineering and related fields are conducted for Indian and Foreign nationals by FCRI. Training
programmes conducted by FCRI provide a platform for interaction between FCRI engineers and engineers from various fields outside.
Customized training programmes
We conduct national training programmes, Bi-
monthly and Customized Programmes in which
Indian nationals from various technical fields
and organizations Participate. Officials from
Organisations like ONGC, GAIL, Weights &
Measures Dept. (LM), Reliance etc participate
in our customized courses. New Customized
courses for Indian Navy, Emerson, NPCIL etc are
in the pipeline. We have courses for Fresh
Engineering graduates also. For budding
engineers from various universities and colleges,
we allow Industrial Visit and In-plant training to
have R&D / Industrial exposure.
International Training Programmes are conducted
under the aegis of ITEC / SCAAP / Colombo Plan of
the Ministry of External affairs, Govt. of India, and
Under self Financing Scheme. More than 65 Such
International training programmes have been
conducted which benefitted 700 foreign nationals
from 70 countries. We have four such Programmes like
Oil & Gas, Flow Measurement, Digital Library Practices
& IT, Instrumentation and Control & DAS in Fluid Flow,
Quality System Certification & Six Sigma Practices.
Training programme for foreign nationals
Presently two International Training Programmes
namely viz.
(1) Instrumentation & Control and Data Acquisition
System in Fluid Flow in Process and Petroleum
Engineering (Jan 15- Mar 15 2014)
(2) Quality System Certification (ISO 9001) & Six Sigma
Practices for Organisations/Laboratories
(Testing/Calibration) (Feb 03 – Mar 31 2015) and
One Post Graduate Certificate Programme on
“Fluid Flow, Instrumentation Engineering and DAS
in Process Industries” are going on
Forthcoming National Training Programs for the year 2014
Series Name of the Program Duration Date
150 Principles of Data Acquisition & SCADA 4 Days 11-14 March ‘14
151 Liquid Hydrocarbon Flow Measurement and
Custody Transfer 3 Days 9 - 11 April ‘14
152 Water Transmission & distribution
Engineering 2 Days 5-6 June ‘14
153 On the Job Training for Field Engineers on
Flowmeters & Calibration Techniques 5 Days 7 - 11 July ‘14
154 Basics of Computational Fluid Dynamics 2 Days 17 - 18 July ‘14
155 Metrology, Pressure, Thermal & Electro Technical
Measurements and Calibration 2 Days 7-8 August ‘14
156 Gas flow Measurement/Natural Gas Custody
Transfer as per AGA Standards 3 Days 8-10 October ‘14
157 Control Valves & Actuators 3 Days 10 – 12 December ‘14
Programs Completed 2013-2014
Quarter No. of
courses
No. of participants
National training programs
Quarter I 40 230
Quarter II 32 405
Quarter III 31 227
Sub Total 103 862
International training programs
Quarter I 0 0
Quarter II 1 16
Quarter III 2 29
Sub Total 3 45
Grand Total 106 907
Forthcoming Inter National Training Programs for the year 2014
Sl. No. Title of the Training programme Duration Date of training course
1 Oil, Water and Gas Flow Measurement and Control Techniques &
Standards 12weeks
August 01, 2014 to
October 31, 2014
2 Digital Library Practices and Information Technology Application for
Advanced Knowledge Management 6 weeks
November 20, 2014 to
January 05, 2014
3 Instrumentation & Control and Data Acquisition System in Fluid Flow
in Process & Petroleum Engineering 8 weeks
January 15, 2015 to
March 15, 2015
4 Quality System Certification (ISO 9001) & Six Sigma Practices for
Organizations/Laboratories (Testing/Calibration) 8 weeks
February 03, 2015 to
March 31, 2015
11. COMPUTATIONAL FLUID DYNAMICS
Strainers are widely used in the water transmission and distribution systems to filter out particles and prevent
erosion damages to the pipelines and damages to the downstream mechanical equipment like condensers,
heat exchangers, pumps, compressors, meters, etc . Design of these components has to be done such that the
required pressure drop is consistently achieved to minimize operational costs for the operating agency. Design
performance improvements on manufactured strainers have proved to be very costly as their manufacture is
often expensive and time consuming. It is here that the Institute has been able to help the water transmission
and distribution sector by use of CFD software tools on preliminary drawings of the strainers, the performance of
the strainers are evaluated and in case the pressure drop is not within the desired limits, design modifications
tried till the value is within limits.
The finalized design is then manufactured thereby saving considerable amount of time and money for the
manufacturer and the Industry. FCRI has undertaken pressure drop estimation and Improvement of design of
strainers for sizes ranging from 150 mm to 750 mm using computational fluid dynamics (CFD). Strainers evaluated
were of straight through Conical and T Type Basket strainers with single and duplex configurations. In some cases
the CFD analysis was carried out, the strainer manufactured and then tested in the water flow laboratory of the
Institute. The result of the CFD analysis and the laboratory tests carried out at the Institute matched very well and
was within 2%.CFD Analysis was done for different conditions like when the strainer is clogged and when it is
clean. The performance of the strainer over various flow rates was also studied.
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FLUID CONTROL RESEARCH INSTITUTE VOL: 16 ISSUE: APRIL 2014
12. CONSULTANCY FOR IMPLEMENTATION OF SCADA SYSTEM FOR MCGM
Consultancy services of FCRI has been availed by M/s.
Municipal Corporation of Greater Mumbai (MCGM) for
setting up of SCADA system for measurement and display of
sewage flow, sewage levels and other parameters from the
sewage pumping stations and monitoring centrally at two
locations in Mumbai city. There are in all about 50 numbers
of sewage pumping stations which collect and pump
approximately 2750 MLD of sewage. The scope of work
includes site study and survey of pumping stations, design
and implementation of a SCADA system, management of
project execution, validation and training, etc.
Training on Data Acquisition & SCADA
The project is a first of its kind in terms of number of sites
on a SCADA for sewage flow operations, and includes a
large number of technical and other challenges. A four-
day National level Course on “Principles of Data
Acquisition and SCADA” was conducted during 19-22
November 2013 and was attended by well over 30
participants from Industry and Engineering Institutions.
The course was designed specifically considering needs
of Graduate Engineers who wish to understand as well
as apply principles of Data Acquisition systems and
SCADA.
13. GENERAL PURPOSE LABORATORY
Changes in temperatures and pressure in valves and process control elements causes thermal effects specially thermal deformation process elements subjected
to such extreme operating temperature and pressure are normally subjected to an accelerated life test or endurance test before being imparted into service to
validate the design. This is being used to prove the design and analyse the reliability of the components constituting the entire system. These tests are normally
performed in specially designed test rigs as per the international standards and designed for the required operating pressure.
Fugitive emission testing of valves
A control valve was tested in the HPHT
loop which is capable of testing upto
200 bar and 325°C. Endurance testing
was conducted on the valve with a test
pressure of 100 bar and 295°C on the
upstream side. The valve was subjected
to leak test by applying the requisite
pressure and temperature at the
upstream side with downstream side
open to the atmosphere.
Mechanical cycles were
performed and the above valve
was checked for leak tightness at
differential pressures upto 100 bar.
Fugitive emission testing of valves
AON/OFF valve of size 8”x ASME Class
150 with Wafer ends was tested for
fugitive emission at 10 bar operating
pressure at elevated temperature of
177°C using Helium as the Test fluid with
3000 numbers of mechanical cycles and
three thermal cycles under the leak rate
category of 100 ppm as per standard
method for the Evaluation of External
leakage of manual and automated On-
Off valves ANSI/ISA 93.00.01-1999.
Helium mass spectrometer with sniffing
probe method was used to measure the
leakage flow rate from the stem seal and
body bonnet seal. During the test
leakage rate was within allowable limit.
The Valve was tested for the leakage
category of 100 ppm, temperature class
of the valve room temperature to 177°C.
14. CENTRE FOR WATER MANAGEMENT (CWM)
Centre for water management (CWM), a state of the art test
lab for flow product, mainly domestic and bulk water meters,
offer different kinds of services like flow product assessment,
in-situ measurement/calibrations, analysis/design and
consultancy service related to flow problems especially in
water distribution networks, surge etc. In this facility, accurate
measurement of flow in terms of volume is determined by
gravimetric system. A flow rate up to 300 m3/hr, through 150
mm pipeline, can be achieved in the laboratory with overall
uncertainty in volume better than 0.03 %.
Assistance is being offered to different water Utilities
during bulk purchase of water meters. A Model
approval program is launched to help the
manufacturers to improve the quality of their meters.
Details of models passed the endurance test will be
made available in FCRI website. This is expected to help
water boards to verify the models submitted by suppliers
and proceed with quick purchase with acceptance
tests on randomly sampled meters and applying the
prescribed acceptance criteria.
Centre for Water Management has also started a water
metering scheme for delivering good quality water meters to the
customers. Many water boards have made it mandatory to
install water meters, which passed the routine tests, for getting
water supply connection. We often see the meters purchased
from the local markets failing the tests and the customer lose
their money. In order to ensure that the customer gets good
quality meters, FCRI has introduces a water metering scheme.
Under this scheme FCRI supplies water meters, which pass the
testing as per IS/ISO standards, to the user for installing at their
location for a period of 5 years. The risk of losing money in buying
and testing meters directly from the market is eliminated here.
Around 3000 water meters of various sizes are tested at
CWM every year. The test facility is accredited by NABL and
recognized by Bureau of Indian Standards. Testing of water
meters of all sizes are conducted as per Indian and
International standards. Tests include Hydrostatic Pressure
Test, Accuracy Test, Pressure Loss Test, Temperature
suitability Test and Endurance Test (continuous and
discontinuous flow test). Most of the water boards in India
insist endurance tests and acceptance tests at FCRI during
their bulk purchase of meters. This has ensured reasonable
life for meters in the field and has yielded substantial
increase in the revenue of water boards.
CWM Test Facility
FOR FURTHER DETAILS PLEASE CONTACT
DIRECTOR
FLUID CONTROL RESEARCH INSTITUTE (Under Ministry of Heavy Industries & Public Enterprises)
Kanjikode West, Palakkad – 678 623, Kerala, India
Tel: +91-491-2566120/206/2569009; Fax: +91-491-2566326,
Email: fcri@fcriindia.com, Website: www.fcriindia.com
6 FCRI PUBLICATIONS, FLUID CONTROL RESEARCH INSTITUTE
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