Orifice plate flowmeters

The orifice plate is one in a group known as head loss devices or differential pressure flowmeters. In simple
terms the pipeline fluid is passed through a restriction, and the pressure differential is measured across that
restriction. Based on the work of Daniel Bernoulli in 1738 (see Tutorial 4.2), the relationship between the velocity
of fluid passing through the orifice is proportional to the square root of the pressure loss across it. Other
flowmeters in the differential pressure group include venturis and nozzles.

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

Fi
g. 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 β 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:

Fi
g. 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.

Ta
ble 4.3.1 Recommended straight pipe diameters upstream of an orifice plate for various � ratios and
preceding obstruction
Advantages of orifice plate steam flowmeters:
• Simple and rugged.
• Good accuracy.
• Low cost.
• No calibration or recalibration is required provided calculations, tolerances and installation
comply with ISO 5167.
Disadvantages of orifice plate steam flowmeters:
• Turndown is limited to between 4:1 and 5:1 because of the square root relationship between
flow and pressure drop.
• The orifice plate can buckle due to waterhammer and can block in a system that is poorly
designed or installed.
• The square edge of the orifice can erode over time, particularly if the steam is wet or dirty. This
will alter the characteristics of the orifice, and accuracy will be affected. Regular inspection and
replacement is therefore necessary to ensure reliability and accuracy.
• The installed length of an orifice plate flowmetering system may be substantial; a minimum of
10 upstream and 5 downstream straight unobstructed pipe diameters may be needed for accuracy.
This can be difficult to achieve in compact plants. Consider a system which uses 100 mm pipework, the β ratio is
0.7, and the layout is similar to that shown in Figure 4.3.4(b):

The upstream pipework length required would be = 36 x 0.1 m = 3.6 m

The downstream pipework length required would be = 5 x 0.1 m = 0.5 m

The total straight pipework required would be = 3.6 + 0.5 m = 4.1 m

Typical applications for orifice plate steam flowmeters:

• Anywhere the flowrate remains within the limited turndown ratio of between 4:1 and 5:1.

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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