04-06-2013, 02:58 PM
REPORT ON IN-PLANT TRAINING AT FLUID CONTROL RESEARCH INSTITUTE (FCRI) KANJIKODE WEST, PALAKKAD
REPORT ON IN-PLANT.pdf (Size: 408.92 KB / Downloads: 93)
INTRODUCTION
FLUID CONTROL RESEARCH INSTITUTE (FCRI), an esteemed organization dedicated to design and development of flow products and its calibration techniques was established in the year 1989. FCRI has been, established by Govt. of India with techno-economic inputs from the UNITED NATIONS DEVELOPMENT PROGRAMME (UNDP). The institute has grown into a fully fledged quality assurance centre for the core sector industry and is on par with similar establishments in developed countries.
FCRI is authorized by Department of Weights & Measures to conduct model approval tests on flow meters. FCRI is accomplished of NABL accredited laboratories for the calibration of flow meters in water, oil, and air media. The accurate and highly reliable services of FCRI are rendered to the major companies including GAIL, BPCL, BHEL, HPCL, ONGC, water supply boards etc.
Besides the fluid laboratories, FCRI also has three supporting labs. The Physical Standard Lab deals with the calibration of mass, volume, density, viscosity, material testing and pressure metrology; Electronics and Instrumentation Lab is for the calibration of electrical parameters and time and Noise & Vibration Lab undertakes noise evaluation of control valves, generator sets, pumps etc.
We 22 students of sixth semester Applied Electronics and Instrumentation Engineering, Govt. Engineering College, Kozhikode, selected FCRI for our in-plant training for 5 days from 19th June 2012 as part of our curriculum. FCRI is a research institute that deals with calibration and testing and provides third party certification for customer products.
PHYSICAL STANDARDS LABORATORY (PSL)
The Physical Standard Laboratory maintains the primary standards of length, mass, time, temperature, pressure/vacuum, volume, relative humidity and hardness. It also provides calibration services in the field of dimensional metrology. The laboratory is equipped with the most reliable and sophisticated reference instruments, operated under controlled environmental conditions of 20 degree Celsius and 50 Rh. The master equipments are traceable to National Physical Laboratory at New Delhi.
The laboratory is also equipped with reference instruments for force and torque. Calibration activities are carried out with established procedures in conformance with standard specifications.
OIL FLOW LABORATORY (OFL)
The Oil Flow Laboratory has the ability to calibrate any type of flow meter and is used for the bulk flow measurements viz positive displacement flow meters, turbine flow meters, mass flow meters etc. which are used to determine the total quantity of fluid. The Oil Flow Laboratory was commissioned in 1995. The calibration of OFL has been accredited by NABL. Legal Metrology, Weights & Measures unit, Department of Consumer Affairs has recognized FCRI for conducting Model Approval Test on flow measuring instruments and volume measuring instruments.
The Oil Flow Laboratory makes use of static gravimetric calibration system for measurement and calibration is done by “Standing start and stop method”. Turbine flow meters are connected at the end to get the pulse output. The diversion method used in WFL is not used here as it might cause back pressure problems in the pipeline. A maximum line size of 200mm and of maximum flow rate of 650m3/h is also maintained in the lab. The medium of flow is EXXSOL D80 with kinematic viscosity of 2.06 Centistokes at 250C and a specific gravity of 0.78. For a flow rate up to 100m3/h (450GPM) it is possible to change the medium of calibration to Hydrol 100 or Hydrol 220.
NOISE AND VIBRATION LAB
Noise and vibration laboratory of FCRI is well equipped for in-plant/site studies with the state of art equipment/instruments. It is used to conduct noise and vibration measurement/calibration. The laboratory caters to calibration of rpm indicators, tachometers, vibration pick-ups, sound level meters, accelerometers, measurement of valve noise, torque machine vibration monitoring, impact testing of specimens as per ASTM E 23, stress analysis of valve body, fatigue testing of engine valves and seismic testing.
The products calibrated at this lab include rotors, radial fans, wiper motor, compressors, automobiles, valves, engines, medical equipment, crackers, for shipping purposes, etc.
The services offered by noise and vibration laboratory include industrial/environmental/traffic noise surveys, valve noise measurements, machine vibration monitoring, strain measurements and dynamic response of structures.
PRIMARY STANDARD GALVIMETRIC SYSTEM (PSGS)
This type of calibration is performed by using the primary standard as the reference. It is an open loop system consisting of a huge spherical weighing vessel into which the compressed air is passed. Time rate of mass of air collecting in that vessel calculated which gives the mass flow rate. Finally air is emptied from the spherical weighing vessel to atmosphere. Maximum measurable unit of PSGS is 1000m3/h.
CLOSED LOOP AIR TEST FACILITY (CLATF)
It is the secondary type of pressure calibration method. As the name indicates it is the closed loop method. Initially the compressed air is passed through the blower to adjust the speed of flow and in turn to the heat exchanger. The heat exchanger is provided with a chiller plant parallel to maintain the temperature of 25 degree Celsius. A filter is also provided for filtering purpose. Unlike the primary or open loop method, it has three reference line with turbine meters and two test line where the test meters are connected. The air is then passed through the pre-filters and it is again channeled to the blowers. Hence maintain the closed loop.
PRIMARY AIR FLOW LABORATORY
Primary Air Flow Laboratory is called so because here we are taking the primary reference standard volume for calibration. The flow rate calibration in PAFL ranges up to 40m3/hr. This section is maintained at an ambient temperature range of 20+/-1 degree celcius, humidity 55+/-5. The conditioned atmosphere of PAFL maintains the metrological qualities of the master flow meters and there by provides high reliability of calibration and operating performance. Calibration is performed under Compression mode operation. This instrument has a 3point reproducibility and 5point repeatability.
CONCLUSION
Fluid Control Research Institute is the leading fluid research institute in South East Asia. It is a pride to our country and works for the development of the industries. The Test, Research and Calibration facilities are continually upgraded, updated and expanded to ensure they are among the best in the World. Regular Inter-comparison exercises, International Certifications and validations, stringent Quality Audits, skilled and trained manpower and overall professionalism have contributed to our high levels of reputation and credibility. FCRI has also undertaken projects in the area of software development related to analytical techniques, selection, estimation of requirement of flow meters etc. These softwares are also used by valve manufacturers, fertilizer industries and petrochemical plants. NEWTON, VAP 1.0, AUTOVALV, SAFEVALV etc are the software developed by FCRI.