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Orifice Plate
Orifice Plate is the heart of the Orifice Meter. It restricts the flow and develops the Differential Pressure which is proportional to the square of the
flow rate. The flow measuring accuracy entirely depends upon the quality of Orifice plate, its installation and maintains.
When measuring wet gas or saturated steam a weep hole is drilled in a concentrically bored orifice plate. This is a small hole drilled on the orifice
plate such that its location is exactly on ID of the main pipe.
The Orifice plates are manufactured as per ISA / AGA/ API / ANSI standards and in various materials
such as SS304 /SS316 / SS316L /Hestoly C / Monel / PTFE coated.
Features Top
Despite Various Advances In Flow Measurement, Orifice Assembly Remains One Of The Most Used Flow Element.
This Is Because Of -
First Principle Device - Which Never Fails Suitable For All Pipe Sizes From 1/2 To 36
Suitable For Almost All Types Of Fluids Proven Solution For Flow Measurement
Very Nominal Cost Compared To Other Flow Because Of Proven Data Available, No Need Of
Elements Frequent Calibration Like Other Element
Size for Flanged Design : 25, 40, 50, 65, 80, 100, 150 ...250 mm
Material- Flanges & Carrier Ring : A105 / SS304/ SS316 / SS316L / CS & Other materials on request.
Orifice Plate : SS304, SS316, SS316L, Hast C, Monel, PP, PVC,PTFE, Coated or Clad with PP / HDPE / PTFE.
Gasket : CAF / SS Spiral Wound + CAF / PTFE / PVC / Rubber, Other materials as per special request.
Pressure Toppings : For 1" to 16" - Flange Taps / Corner Taps. Above 16" - D x D/2
2) Restriction Bore
Application :
This Type Is Not Used For Flow Measurement But For Dropping The
Pressure Considerably And Reducing The Flow Accordingly. The
Bore Is Not Beveled But Kept Straight. The Beta Ratio Has No Limit
As Accuracy Is Not The Goal
3) Eccentric Bore
Application :
Used For Measurement Of Flow For Fluids Containing Solids And Slurries.
It Is Also Used For Vapors And Gases Where Condensation Is Present. The
Eccentric Bore Is Offset To Where The Bore Edge Is Inscribed In A Circle
That Is 98% The Line Id.
4) Segmenta Bore
Application :
The Segmental Bore Is Located In The Same Way That The
Eccentric Bore Is. This Type Is Used Primarily For Slurries Or
Extreamly Dirty Gases Wher The Flow May Contain Impurities
Heavier Than The Fluid.
5) Quadrant Bore
Application :
Used For High Viscous Fluids Such As Heavy Cruid, Syrups And
Slurries. It Is Always Recommended For Flow Where Reynolds
Number Is Less Than 10,000.The Inlet Is Quarter Of A Circle And
The Plate Thickness Must Be At Least Radius Of The Inlet.
WNRF - Carrier Ring - Flange Taps WNRF - Carrier Ring - Corner Taps
Plate Carrier Ring - Flange Taps Plate Carrier Ring - Corner Tab
Pipe Taps (D X D / 2)
2 Ball Valve
3 Valve Manifold
4 Condensing
Dimensions of Restriction Orifice Plates for ASME B16.5 Raised Face Flanges
DIA
NPS L N P T
D3
1 25 0.42 2 30 2
1 40 0.64 3 30 3
2 51 1 6 30 3
3 76 1.5 8 40 3
4 102 1.5 10 40 5
6 152 1.5 15 40 5
8 202 3.5 15 40 7
10 253 3.5 19 45 7
12 302 3.5 20 45 10
14 341 6 20 45 10
16 392 6 21 50 11
18 443 8 23 50 13
20 494 8 25 50 16
24 595 10 29 60 18
1/2 48 54 54 64 64 70
3/4 57 67 67 70 70 77
1 67 73 73 80 80 86
1 86 96 96 99 99 118
TOLERANCES
D1 & D2 = 1%
D3 = 1 mm
D4 = 0/-0.4 mm
L = 0.1 mm
N = see note 6
P = 0.1 mm
S = 0.1 mm
T = see note 2
Notes:
1. MARKING
The Upstream side of the orifice tab shall be stamped at the indicated locations with:
- the word UPSTREAM
- the Tag Number
- the ASME flange class, followed by RF
- the nominal pipe size (NPS)
- the measured orifice D1 (in mm)
- the material of the orifice plate
- the type of orifice plate (Square, Restriction etc.)
Letter height approx. 4 mm
2. WELDING OF TAB
Tab may be integral with orifice plate up to and including 7 mm plate thickness.
In other cases full penetration joint to be applied.
3. FINISH OF PLATE
The upstream and downstream faces of the orifice plate to a diameter equal to D3 shall have a surface roughness Ra
0.8 m according to ASME B46.1.
The remaining annular part (between D4 and D3) of upstream and downstream faces shall have a surface roughness
Ra between 3.2 and 3.6 m according to ASME B46.1. This finish shall be obtained by machining with a round nosed
cutting tool having a 0.8 mm radius at a feed rate between 0.35 and 0.45 mm per revolution.
4. CONCENTRICITY
The centre of the orifice shall not differ from the centre of the plate by more than 0.1 mm for NPS 8 and 0.2 mm
for > NPS 8.
5. FINISH OF THROAT
The throat and outlet cone shall have a surface roughness Ra 0.4 m according to ASME B46.1.
All edges shall be sharp and free from burrs, so that when viewed with the naked eye no light is reflected by the
corners.
6. PLATE THICKNESS
The difference between any two measurements of plate thickness, for annular part D1-D3, shall not differ by more
than 0.001 DN in mm.
The plate shall not depart from flatness along any diameter by more than 0.01 D3.
Tolerance for N shall be:
N 6 mm +0.1/-0.25 mm
N > 6 mm +0/-1.5 mm
Thickness for annular part D3-D4, may be slightly less, max 0.05 mm, due to surface finishing difference
between D1-D3 and D3-D4. (see note 3)
General Notes:
Dimensions are in millimeters unless otherwise indicated.
Allowable pressure difference 20 bar for temperatures up to 400 C and D1/D3 0.1. The thickness of the plate
needs to be verified for strength in case the pressure difference is higher than 20 bar and/or the temperature is
beyond 400 C. Based on the outcome of the calculation the thickness of the plate needs to be adjusted.
DIA D1 & DIA D2 - to be specified by purchaser.
Material to be specified by purchaser.
The operation, advantages and limitations of different types of steam flowmeter, including orifice plate, variable area and vortex shedding devices.
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There are many types of flowmeter available, those suitable for steam applications include:
This Tutorial will review the above flowmeter types, and discuss their characteristics, their advantages and disadvantages, typical applications and typical
installations.
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With an orifice plate flowmeter, the restriction is in the form of a plate which has a hole concentric with the pipeline. This is referred to as the primary element.
To measure the differential pressure when the fluid is flowing, connections are made from the upstream and downstream pressure tappings, to a secondary device
known as a DP (Differential Pressure) cell.
Fig. 4.3.1
Orifice plate
Fig. 4.3.2
Orifice plate flowmeter
From the DP cell, the information may be fed to a simple flow indicator, or to a flow computer along with temperature and/or pressure data, which enables the
system to compensate for changes in fluid density.
In horizontal lines carrying vapours, water (or condensate) can build up against the upstream face of the orifice. To prevent this, a drain hole may be drilled in the
plate at the bottom of the pipe. Clearly, the effect of this must be taken into account when the orifice plate dimensions are determined.
Correct sizing and installation of orifice plates is absolutely essential, and is well documented in the International Standard ISO 5167.
Fig. 4.3.3
Orifice plate flowmeter installation
Installation
A few of the most important points from ISO 5167 are discussed below:
Pressure tappings - Small bore pipes (referred to as impulse lines) connect the upstream and downstream pressure tappings of the orifice plate to a Differential
Pressure or DP cell.
The positioning of the pressure tappings can be varied. The most common locations are:
From the flanges (or carrier) containing the orifice plate as shown in Figure 4.3.3. This is covenient, but care needs to be taken with tappings at the
bottom of the pipe, because they may become clogged.
One pipe diameter on the upstream side and 0.5 x pipe diameter on the downstream side.This is less convenient, but potentially more accurate as the
differential pressure measured is at its greatest at the vena contracta, which occurs at this position.
Corner tappings - These are generally used on smaller orifice plates where space restrictions mean flanged tappings are difficult to manufacture. Usually on pipe
diameters including or below DN50.
From the DP cell, the information may be fed to a flow indicator, or to a flow computer along with temperature and/or pressure data, to provide density
compensation.
Pipework - There is a requirement for a minimum of five straight pipe diameters downstream of the orifice plate, to reduce the effects of disturbance caused by the
pipework.
The amount of straight pipework required upstream of the orifice plate is, however, affected by a number of factors including:
The ratio; this is the relationship between the orifice diameter and the pipe diaameter (see Equation 4.3.1), and would typically be a value of 0.7.
Equation 4.3.1
The nature and geometry of the preceding obstruction. A few obstruction examples are shown in Figure 4.3.4:
Fig. 4.3.4
Orifice plate installations
Table 4.3.1 brings the ratio and the pipework geometry together to recommend the number of straight diameters of pipework required for the configurations
shown in Figure 4.3.4.
In particularly arduous situations, flow straighteners may be used. These are discussed in more detail in Tutorial 4.5.
Table 4.3.1
Recommended straight pipe diameters upstream of an orifice plate for various ratios and preceding obstruction
This can include the boiler house and applications where steam is supplied to many plants, some on-line, some off-line, but the overall flowrate is within
the range.
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Turbine flowmeters
The primary element consists of a multi-bladed rotor which is mounted at right angles to the flow and suspended in the fluid stream on a free-running bearing. The
diameter of the rotor is slightly less than the inside diameter of the flowmetering chamber, and its speed of rotation is proportional to the volumetric flowrate.
The speed of rotation of the turbine may be determined using an electronic proximity switch mounted on the outside of the pipework, which counts the pulses, as
shown in Figure 4.3.5.
Fig. 4.3.5
Turbine flowmeter
Since a turbine flowmeter consists of a number of moving parts, there are several influencing factors that need to be considered:
In larger pipelines, to minimise cost, the turbine element can be installed in a pipework bypass, or even for the flowmeter body to incorporate a bypass or shunt, as
shown in Figure 4.3.6.
Bypass flowmeters comprise an orifice plate, which is sized to provide sufficient restriction for a sample of the main flow to pass through a parallel circuit. Whilst
the speed of rotation of the turbine may still be determined as explained previously, there are many older units still in existence which have a mechanical output as
shown in Figure 4.3.6.
Clearly, friction between the turbine shaft and the gland sealing can be significant with this mechanical arrangement.
Fig. 4.3.6
Bypass or shunt turbine flowmeter
o Clearances between the turbine wheel and the inside of the pipe are very small.
o Entrained debris can damage the turbine wheel and alter its performance.
o Entrained debris will accelerate bearing wear and affect accuracy, particularly at low flowrates.
The most common float material is grade 316 stainless steel, however, other materials such as Hastalloy C, aluminium or PVC are used for specific
applications.
On small flowmeters, the float is simply a ball, but on larger flowmeters special shaped floats are used to improve stability.
A tapered tube, which will provide a measuring scale of typically between 40 mm and 250 mm over the design flow range.
Usually the tube will be made from glass or plastic. However, if failure of the tube could present a hazard, then either a protective shroud may be fitted
around the glass, or a metal tube may be used.
With a transparent tube, flow readings are taken by observation of the float against a scale. For higher temperature applications where the tube material
is opaque, a magnetic device is used to indicate the position of the float.
Because the annular area around the float increases with flow, the differential pressure remains almost constant.
Fig. 4.3.7
Variable area flowmeter
Fig. 4.3.8
Variable area flowmeter installed in a vertical plane
Top
Fig. 4.3.9
Spring loaded variable area flowmeters
However, another important feature is also revealed: if the pass area (the area between the float and the tube) increases at an appropriate rate, then the
differential pressure across the spring loaded variable area flowmeter can be directly proportional to flow.
or
In Option 1 (determining the displacement of the float or 'flap'). This can be developed for steam systems by:
Fig. 4.3.11
Spring loaded variable area flowmeter monitoring the position of the float
Fig. 4.3.12
Typical installation of a spring loaded variable area flowmeter measuring steam flow
In Option 2 (Figure 4.3.10), namely, determining the differential pressure, this concept can be developed further by shaping of the float to give a linear relationship
between differential pressure and flowrate. See Figure 4.3.13 for an example of a spring loaded variable area flowmeter measuring differential pressure. The float
is referred to as a cone due to its shape.
Fig. 4.3.13
Spring Loaded Variable Area flowmeter (SLVA) monitoring differential pressure
Fig. 4.3.14
Typical installation of a SVLA flowmeter monitoring differential pressure
Top
However, unlike other SLVA flowmeters, the DIVA does not rely on the measurement of differential pressure drop across the flowmeter to calculate flow,
measuring instead the force caused by the deflection of the cone via a series of extremely high quality strain gauges. The higher the flow of steam the greater the
force. This removes the need for expensive differential pressure transmitters, reducing installation costs and potential problems (Figure 4.3.15).
The DIVA has an internal temperature sensor, which provides full density compensation for saturated steam applications.
2% of actual flow to a confidence of 95% (2 standard deviations) over a range of 10% to 100% of maximum rated flow.
0.2% FSD to a confidence of 95% (2 standard deviations) from 2% to 10% of the maximum rated flow.
As the DIVA is a self-contained unit the uncertainty quoted is for the complete system. Many flowmeters claim a pipeline unit uncertainty but, for the whole system,
the individual uncertainty values of any associated equipment, such as DP cells, need to be taken into account.
The turndown of a flowmeter is the ratio of the maximum to minimum flowrate over which it will meet its specified performance, or its operational range. The DIVA
flowmeter has a high turndown ratio of up to 50:1, giving an operational range of up to 98% of its maximum flow.
Pitot tubes
In large steam mains, the cost of providing a full bore flowmeter can become extremely high both in terms of the cost of the flowmeter itself, and the installation
work required.
A Piot tube flowmeter can be an inexpensive method of metering. The flowmeter itself is cheap, it is cheap to install, and one flowmeter may be used in several
applications.
Pitot tubes, as introduced in Tutorial 4.2, are a common type of insertion flowmeter. Figure 4.3.18 shows the basis for a Pitot tube, where a pressure is generated
in a tube facing the flow, by the velocity of the fluid. This 'velocity' pressure is compared against the reference pressure (or static pressure) in the pipe, and the
velocity can be determined by applying a simple equation.
Note that a square root relationship exists between velocity and pressure drop (see Equation 4.2.13). This limits the accuracy to a small turndown range.
Equation 4.2.13
Where:
The bluff body causes a blockage around which the fluid has to flow. By forcing the fluid to flow around it, the body induces a change in the fluid direction and thus
velocity. The fluid which is nearest to the body experiences friction from the body surface and slows down. Because of the area reduction between the bluff body
and the pipe diameter, the fluid further away from the body is forced to accelerate to pass the necessary fluid through the reduced space. Once the fluid has
passed the bluff body, it strives to fill the space produced behind it, which in turn causes a rotational motion in the fluid creating a spinning vortex.
The fluid velocity produced by the restriction is not constant on both sides of the bluff body. As the velocity increases on one side it decreases on the other. This
also applies to the pressure. On the high velocity side the pressure is low, and on the low velocity side the pressure is high. As pressure attempts to redistribute
itself, the high pressure region moving towards the low pressure region, the pressure regions change places and vortices of different strengths are produced on
alternate sides of the body.
The shedding frequency and the fluid velocity have a near-linear relationship when the correct conditions are met.
The frequency of shedding is proportional to the Strouhal number (Sr), the flow velocity, and the inverse of the bluff body diameter. These factors are summarised
in Equation 4.3.2.
Fig. 4.3.21
Vortex shedding flowmeter
Equation 4.3.2
Where:
f = k x u
Where:
Hence:
Then the volume flowrate qv in a pipe can be calculated as shown in Equation 4.3.3:
Equation 4.3.3
Where:
A = Area of the flowmeter bore (m)
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