Flow measurement
Introduction
Volume flow rate is the appropriate way of quantify the flow of all materials which
are in gaseous, liquid or semi-liquid slurry form ( where particles are suspended in
a liquid host).
Flow
measurement
becomes
weight measurement. The weight
is measured by means of a load
cell, which is then a strain gauge
measurement. Another popular
device for weight measurement of
moving systems like this is an
LVDT that measures the drop of
the conveyor at the point of
measurement because of the
material that it carries.
Orifice plates,
Venturi tubes ,
Flow nozzles,
Dall tubes and
Pitot tube.
Flow-restriction-type instruments are popular because they have no moving parts and
are therefore robust, reliable and easy to maintain.
P1 V1
P V
z1 2 2 z 2
2g
2g
Q A1V1 A2V2
Qi
P1 P2
2 g
A2
1 A2 / A1
If we assume
Qi
A2
A1
and the
A2
1
h P1 P2
2 gh
then
Qa
C
Qi
K
C
1 2
Qa KA2 2 gh
K is called flow coefficient
C and K versus Re
Standards tables can be used to obtain the value of the discharge coefficient and the
flow coefficient appropriate to the pipe diameter and fluid involved.
The discharge coefficient and flow coefficient depend upon the Reynolds number Re
Vav D
Re
Where
The Reynolds number is used to determine the point at which the flow goes from
viscous to turbulent and vice versa
Orifice plate
The oldest and most common form of pressure differential device for measuring the flow
rate is the orifice plate. There are three types of orifices plates namely concentric,
eccentric and segmental type.
The concentric type is used for clean fluids. In metering dirty fluids, slurries and
fluids containing solids eccentric or segmental type is used in such way that its lower
edge coincides with the inside bottom of the pipe.
The orifice plate is inserted into the main pipe between adjacent flanges, the outside
diameters of the plate being turned to fit within the flange bolts. The flanges are
either screwed or welded to the pipes.
The minimum flow area is known as the vena contracta. At the vena contracta
the minimum pressure is reached then there is a rapid recovery in the static pressure.
Vena contracta position varies with d/D ratio and it is difficult to locate the vena contracta
position.
Figure shows ranges for typical orifice coefficients versus the ratio of orifice diameter to
pipe diameter for different Reynolds number. For Reynolds number greater than 100000,
the value of K remains essentially constant.
Feature of OP
The edge thickness of the orifice must not be greater than 0.1d if d/D is less than or
equal to 0.2.
The material chosen for orifice plate is any rigid material of non-rusting and noncorrodible.
The common material used for fabricating orifice plate are stainless steel, phosphor
bronze, glass, ceramics, plastic, copper, aluminum, and tantalum.
Orifice plates are used for measuring the flow of gases, liquids or vapors but not
compressible fluids. Orifice plate is not suitable for measuring the flow of viscous
fluids.
Flow nozzle
The small hole in the thin wall orifice plate causes the flow stream to be squeezed
together, and the jet downstream from the orifice has a smaller diameter (vena
contracta) than the orifice diameter itself. The flow nozzle however is a smooth,
convergent section that discharges the flow parallel to the axis of the downstream pipe.
The downstream end of a nozzle approximates a short tube and has the diameter
of the vena contracta of an orifice plate of equal capacity.
Thus the diameter ratio for a nozzle is smaller and its flow coefficient is larger than
that of orifice, typical value 0.99 or greater. Pressure recovery is better than that of
an orifice.
Figure 6.7 Discharge coefficient function of Reynolds number for flow nozz
le
Recommended proportions and pressure tap locations for a long radius flow
nozzle (high ratio nozzle, as specified by the American Society of Mechanical
Engineers (ASME) code.
The upstream pressure is measured with a piezometer ring located one pipe
diameter upstream from the inlet face of the nozzle, and the throat pressure is
measured with a piezometer ring located one-half pipe diameter downstream from
the inlet face of the nozzle.
Flow nozzles are usually made of gun metals, stainless steel, or bronze.
Venturi tube
Pressure recovery is improved by extending the flow nozzle downstream in a
gradual and, divergent, conical section until the pipe diameter is again attained.
The conical type consists of a straight inlet section of the same diameter as the
pipe and in which the high pressure tap is located, a converging conical inlet
section in which the cross section of the stream decreases and the velocity
increases with a consequent increase in velocity head and decrease of pressure
head, a cylindrical throat which provides for the low pressure tap location of the
decreased pressure in an area where flow velocity is neither increasing nor
decreasing, and a diverging recovery cone in which velocity decreases and the
decreased velocity is head is recovered as pressure head.
The pressure taps are located one quarter to one half pipe diameter up-stream of
the inlet cone and at the middle of the throat section.
Discharge coefficient
The discharge coefficient of venturi tube is between 0.95 and 0.98.
Venturi tube find wide application in large pipe line such as city water and
sewage lines, where large quantities of fluid are being pumped and the
power required to overcome the pressure drop of the measuring element is
important.
This meter is often used to measure large flows of combustion air at low
pressure where available pressure is limited.
it cannot be easily installed in an existing pipe line because of its length and
once tube is manufactured and installed it is impossible to change the range
of the flow installation instrument.
Dall tube
It is a modified version of Venturi tube which gives a higher differential pressure but a
lower head loss than the conventional venturi tube.
It consists of two conical reducers inserted into the fluid-carrying pipe. It has similar
internal shape to the venturi, except that it lacks a throat.
Like other flow meters the Dall tube is affected by disturbances upstream and it
needs a greater length of straight pipe upstream than a venturi tube.
The discharge coefficient for the Dall tube becomes variable below a Reynolds
number considerably higher than that at which venturi tube coefficient start to vary.
It is suitable for measuring the flow of fluids containing solids which could settle in the
throat slot.
The construction of Dall tube is easier and this gives an advantage to Dall tube in
cost over the venturi.
Its short length makes the engineering tasks of inserting it into the flow line easier.
Pitot tube
Pitot tube is mainly used for making temporary measurement of flow, although it is also
used in some instances for permanent measurement flow monitoring.
It measures the local velocity of flow at a particular point within a pipe rather than the
average flow velocity as measured by other type flowmeter.
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Velocity measurement
The difference between the tube (stagnation pressure) and static pressure of flow stream
will be measure of the velocity of stream.
Po Ps Vs Vo
2g
Since Vs = 0, therefore
P Ps Vo
h o
2g
The negative sign indicates that it is an increase in pressure and not a decrease.
2
Increase in head h Vo
therefore
2g
P Po
Vo 2 g s
2 gh
Vo C 2 gh
Pitot tubes have the advantage that they cause negligible pressure loss in the flow.
the installation procedure consists of the very simple process of pushing them down
a small hole drilled in the flow-carrying pipe.
Elbow meter
The principle of operation of elbow is shown in figure, which shows pressure taps
located on the inside (low pressure) and outside (high pressure) circumferential walls of
the elbow.
P
P
Q CA 2 g o z o i z i
Where C is the discharge coefficient, which must found experimentally for each
installation (changes from 0.56 to 0.88).
Venturi meter, flow nozzle, and orifice meter all contribute to the energy
losses in the system.
Elbow meters, however, do not introduce additional energy losses, since
they replace an elbow that is already being used in the system to
change the direction of flow.
Elbow meters, like the other obstruction meters, require a minimum of
10 to 30 pipe diameters of unobstructed upstream flow (to reduce large
scale turbulence) for satisfactory operation and accurate flow
measurement.
The fundamental difference between these crystal sensors and static-force devices
such as strain gages is that the electric signal generated by the crystal decays
rapidly. This characteristic makes these sensors unsuitable for the measurement of
static forces or pressures but useful for dynamic measurements.
This type of instrument normally only gives a visual indication of flow rate, and so is of no
use in automatic control schemes. However, it is reliable and cheap and used extensively
in industry. Variable area flow meters are commonly called rotameters.
F2 P2 A f
Wf Vf f
Wb V f
P1 P2 V f
Qa C
Af
A2
1
Where Af is the front area of the float, V f is the volume of the float,
f is the specific weight of the float and
P1 P2
2 g
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assuming that
and A2 the annular area and the expression of pressure drop across the float, we get
Qa CA2 2 gV f
A f
2
A2 D ay d 2
4
2
2 2
2
The tubes are constructed so that D a y d
A2
Day
2
K CDa
W Qa K f y
gV f
is the rotameter constant. It depends on the geometry of the tube and the float.
2Af
W Qa
K f
2
f 2
Type of Rotameter
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Since the majority of fluid applications of rotameters are for low viscosity
fluids, correction must be provided for the changes in fluid density or
specific weight.
These corrections are specially important for gas flows where changes in
operating temperatures and pressures cause significant changes in the
specific weight of the flowing medium.
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Turbine meters
The turbine flow meter works on the
basic principle of turbine. It consists of
a multi-bladed rotor (turbine wheel)
which is mounted at right angles to the
axis of the flowing fluid. The flowing
fluid invades the wheel causes it to
rotate at a speed proportional to the
fluid velocity, and hence to the
volumetric flow rate.
The speed of rotation is monitored by constructing the flowmeter such that it behaves as
variable reluctance tachogenerator. This is achieved by fabricating the turbine blades
from ferromagnetic material and placing a permanent magnet and coil inside the meter
housing. A voltage pulse is induced in the coil as each blade on the turbine wheel moves
past it, and these pulses are measured by a pulse counter, the pulse frequency and
hence flow rate can be deduced.
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Pulse or Voltage Output, Flow rates from 0.1 GPM to 60 GPM, 0.25" to 1.0" Pipe
CRFO & CRFA Rotor Flow Indicator & Transmitter
DESCRIPTION
This
flow
transmitters
combine
visual
confirmation of flow with a pulse or conditioned
0-10 V output proportional to flow rate. As liquid
passes through the meter body, a magnetic rotor
spins at a rate proportional to flow. This causes a
series of magnetic fields (the rotor vanes) to
excite a Hall Effect sensor, producing a series of
voltage pulses. The output pulses (CRFO) are at
the same voltage level as the input (4.5 - 24
VDC) with a frequency proportional to the flow
rate. The output signal can be utilized by digital
rate meters, totalizers, or other electronic
controllers. CRFA Type analog sensors condition
the output signal to 0-10 VDC.
Typical
applications
include
water
purification/dispensing
systems,
chemical
metering equipment, lasers and welders, water
injection systems, semiconductor processing
equipment, chillers and heat exchangers.
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SPECIFICATIONS
Wetted Materials:
Body: Nylon 12
Turbine: Nylon 12 Composite
Bearings: PTFE/15% Graphite
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Turbine flow meters are used in food processing industry metering of milk, cheese, cream,
syrup, vegetable oils, etc. and also in oil industry automation.
Special form of turbine meter is the bidirectional type, for use in pipes where the flow is liable
to reversed on occasions.
1) turbine meters of sizes above 50 mm, have excellent short term repeatability. If they are
recalibrated at fairly frequent intervals they can be extremely accurate,
5) high cost
6)bearing problems occur with liquids of poor lubricating quality and liquid containing a high
proportion of suspended solids,
7) Calibration characteristic sensitive liquid viscosity variation, the effect is greater in small
turbine meters,
8) the small sizes do not perform well as large sizes because the bearing friction is greater in
small meters.
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e Blv
This emf e is detected by electrodes placed in the conduit walls. Then, the flow rate Q is
given by
Q D 2 / 4 v
Since
v e / Bl
Then
Q D 2 e / 4 Bl D / 4 Be K m e
By measuring emf e, the flow rate is calculated. The typical voltage signal measured
across the electrode is 1 mV when the flow rate is 1m/s.
Either an alternative or direct magnetic flux may be used. However, if amplification of the
output is required, the advantage lies with the alternating field.
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The disadvantages
1)can be used only for fluids which have
reasonable conductivity. Water based liquids
(reasonable conductivity, e.g. above 10
microsiemen/cm)
can
be
handled
comfortable but hydrocarbon and most
organic liquids( low conductivity e.g. in the
range 0.1 microsiemen/cm) cannot be
metered easily and need sophisticated and
costly electronic devices,
2) The size and cost of the field coils and
circuitry do not increase in proportion to the
size of pie. Consequently small size meters
are bulky and expensive
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SPECIFICATIONS
Wetted Parts: measuring tube and
electrodes, stainless steel; process
connections, Delrin or PVDF
Max. Pressure: 6 bar
Medium Temperature: -10 to +40C
Max. Inaccuracy: +/- 1.5% of actual value
Min. Conductivity: 20 S/cm
Supply Voltage: 24 VDC +/- 10%
Max Current Consumption: 50 mA
Output Signal: flow proportional frequency, square
wave
Electrical Protection: IP 65
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St
V
D
Where St is a calibration constant called the Strouhal number, V flow velocity and D the
obstruction diameter.
Experimental studies indicate that the Strouhal number is relatively constant St = 0.2 over
a very wide range of Reynolds numbers (300 to 150000), then
V 5 fD
So by measuring the frequency f the flow velocity
can be calculated.
The above equation indicates also that small
diameter of obstructing body should be used in
designing the sensor, since they give a higher
frequency for a given flow velocity.
Various thermal, magnetic and ultrasonic
techniques are used to sense the frequency of
vortex formation.
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The flow tube contains a small flat-faced pin called a bluff body that spans the internal
bore. As fluid moves across the bluff body, vortices or eddies are formed and shed
alternately from one side then the other. The vortices form at a rate that is directly
proportional to flow. The formation of the vortices is directly behind the bluff, and the
spacing is the same at all flow rates. The frequency is sensed outside of the flow tube by
directing a beam of ultra-high frequency sound from a transmitter in one leg of the yoke,
through the flow tube wall, through the liquid, and out again to a receiver in the other leg
of the yoke. The received signal is demodulated and the vortex shedding frequency is
computed by a microprocessor and transformed into a 4-20 mA signal.
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In ultrasonic flow meters, the measurement of flow rate is determined by the variation in
parameters of ultrasonic waves. There are two types of ultrasonic flow meters currently
in use:
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The non-contact ultrasonic flow meter is a noninvasive flow meter available in two formats:
transit time and Doppler. Both technologies
feature clamp on designs with transducer
arrangements that can detect in-situ fluorites
from outside the pipe work, without any
interruption to flow or process. Transit time flow
meters, or also known as 'time of flight' meters
are mainly consigned to the measurement of
clean liquids, although many flow measurement
devices have a maximum tolerance of 5%
solids. The principle behind this type of nonintrusive clamp-on (strap on) flow meter is that
acoustic waves with a frequency of >20kHz are
emitted from one transducer to the other side of
the pipe back to the opposite transducer
requires less time than when traveling in the
opposite direction. The differential transit time of
the synchronized signals is proportional to the
flow rate of the fluid.
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)b(
)a(
)c(
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Tf
L
C V cos
L
Tb
C V cos
2VL cos
T T f Tb 2
C V 2 cos 2 ( )
Since V is very small compared to C. Hence,
T T f Tb
2VL cos
C2
In this method, C need to be known and also its value might change due to various factors
like temperature, density etc., hence affect the accuracy.
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Ff
1
L
T f C V cos
1
L
Fb
Tb C V cos
F F f Fb
2V cos
L
The change in frequency is independent of C and thus not subjected to errors due to
Fmeasurement of
changes in C and the V can be calculated from
This method is practical and forms the basis of many commercially available
ultrasonic flow meters.
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In the sing around method, two signals of different frequencies are multiplied
giving an output with sum and difference of frequencies. The difference
frequency is then extracted by filtering.
In the up and down method, the two frequencies are separately
counted for 5 to 20 seconds and then the difference is found out.
In these type of flow meters the transducers are mounted outside the pipe by
mechanical clamping or by adhesive bonds.
This method requires clean fluid to minimize signal attenuation or dispersion.
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Doppler principle
Since the particles are traveling at the fluid velocity, the frequency Fr of the reflected
wave according to Doppler principle is given by
Fr Ft
Since
C V cos
C Vcos
Ft Fr 2 Ft
Assuming Ft,
V C
( Ft Fr )
( F Fr )
C t
( Ft Fr ) cos
2 Ft cos
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y t (t ) A sin(2Ft t )
y r (t ) A sin( 2Fr t )
F Ft Fr
Fr Ft F
y r (t ) A sin[2 ( Ft F )t ]
Let
2
2
F
y 2 cos(2
t ) A sin( 2Ft t ) as F Ft
2
The modulated signal is the addition of the transmitted wave and the reflected wa
This technique is also used for laser Doppler velocity measurement sys
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Advantage
The advantage of ultrasonic flow meters are:
1) no obstruction by the meter to the flow & the flow pattern is not
disturbed,
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They are most widely used for the application where the highest degree of
accuracy and good repeatability are required.
These devices work on the principle that as the liquid flows through the meter,
it separates the flow of liquid into separate known volumetric increments
which are counted and totaled. The sum of the increments give the
measurement of the total volume of liquid passed through the meter.
The mechanical parts of the meter are in the flowing stream and extract
energy from the stream to drive the meter components. The loss of energy
results in pressure drop.
The presence of solid particles in the fluid cause rapid wear and loss of
accuracy.
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Type of fluid,
lubricity of the fluid,
proportion of contamination,
required accuracy,
maximum flow rate,
rangeability,
allowable pressure drop.
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In this section only nutating disc and lobed impeller will be discussed,
for details about positive displacement flow meter see reference [].
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q A B V a b ia Ra
2
a and f
The quantity
a f
Ra R0 [1 (Ta T0 )]
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1.
2.
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i
V C
i0
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Some problems arise when hot wire or hot film sensors are used in
liquids which carry dirty particles, lint or organic matter.
These materials quickly coat the hot wire or film and cause
significant reduction in heat transfer and lead to change in the
calibration.