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POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

FLOW INSTRUMENTS

FLOWMETERS

Indicate flow rate. The different sensors include dial, in-line, ultrasonic, orifice plate, totalizing

meters, variable area, venturi, or with switch output. The different designs of the flowmeters

have a variety of applications.

Types of Flow Meter

A. Differential Pressure Flow Meter

B. Mass Flow Meter

C. Open Channel Flow Meter

D. Positive Displacement Flow Meter

E. Velocity Flow Meter

A. DIFFERENTIAL PRESSURE

The use of differential pressure as an inferred measurement of a liquid's rate of flow

is well known. Differential pressure flowmeters are, by far, the most common units in

use today. Estimates are that over 50 percent of all liquid flow measurement

applications use this type of unit.

Differential pressure flowmeters, like most flowmeters, have a primary and secondary

element. The primary element causes a change in kinetic energy, which creates the

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differential pressure in the pipe. The unit must be properly matched to the pipe size,

flow conditions, and the liquid's properties. And, the measurement accuracy of the

element must be good over a reasonable range. The secondary element measures

the differential pressure and provides the signal or read-out that is converted to the

actual flow value.

OPERATING PRINCIPLE

The basic operating principle of differential pressure flowmeters is based on the

premise that the pressure drop across the meter is proportional to the square of the

flow rate. The flow rate is obtained by measuring the pressure differential and

extracting the square root.

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1. ORIFICE

Orifices are the most popular liquid flowmeters in use today. An orifice is simply a flat

piece of metal with a specific-sized hole bored in it. Most orifices are of the concentric

type, but eccentric, conical (quadrant), and segmental designs are also available.

FUNCTION

Orifices, also called orifice plates, constrict fluid flow using a flat metal disc with a circular

hole in the center, as shown below. This constriction causes a pressure drop across the

plate. Pressure taps on both sides of the orifice measure the differential.

The left picture below shows an orifice plate installed between flanges in a pipe. Different

flow conditions are accommodated by changing the location of the orifice in the plate and the

way the edge is bored, as shown below on the right.

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USAGE

Orfice plates are the most common differential pressure meter in the chemical process

industry. Most gas, water, steam, and air applications are easily metered by orifice plates.

Orifices made of bronze or of steel, as shown below, can be used to meter lube oil, cooling

water systems, and compressed air flow. The bronze orifice on the left meters gases while

the one in the middle meters liquids.

ADVANTAGES

 No moving parts, low maintenance

 Low cost

 Small

 Available in a large variety of materials

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DISADVANTAGES

 Moderate accuracy of 2 - 4%

 Pressure drops are large relative to other differential pressure devices

 Requires lengths of straight pipe upstream and downstream

 Contraction of flow reduces accuracy of downstream pressure measurement

2. VENTURI TUBE

Venturi tubes are specially shaped pipe sections with tapered inlets and outlets, and straight

throats. As the pipe diameter decreases, the fluid velocity increases, causing a pressure drop

proportional to the flowrate across the venturi tube's throat.

Flow tubes operate on the same principle as venturi tubes, but differ in shape. Flow tubes

have no tapered entrance, but they do have a tapered throat as well as a long tapered exit.

In general, flow tubes are designed to be more compact than Venturi tubes.

FUNCTION

Venturi tubes and Flow Meters have the advantage of being able to handle large flow

volumes at low pressure drops. A venturi tube is essentially a section of pipe with a tapered

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entrance and a straight throat. As liquid passes through the throat, its velocity increases,

causing a pressure differential between the inlet and outlet regions.

USAGE

Venturi tubes such as the one below to the left are common in water and wastewater

treatment facilities, power plants, and chemical and petrochemical processing operations.

The flow tube to the right is designed to meter fluids such as cooling water, steam, and

combustion air.

ADVANTAGES

 Handle large flow volumes at low pressure drops.

 No moving parts, low maintenance.

 Accommodate liquids with high solids content.

 Shape is inherently self-cleaning.

 May be mounted horizontally or vertically.

DISADVANTAGE

 Require four or more pressure taps to accurately measure pressure differential.

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 Require lengths of straight pipe upstream and downstream.

 Accuracy depends on consistent flow profile.

 Less accurate at low flowrates.

3. FLOW NOZZLE

Flow nozzles are similar to orifice plates in that they contain a circular hole, smaller than and

concentric with the pipe diameter, that constricts fluid flow, causing a pressure differential. In

flow nozzles, however, the nozzle follows the hole, reducing the pressure differential across

the device. Flow nozzles are typically used to meter steam and gases or liquids with a small

degree of suspended solids.

FUNCTION

In flow nozzles, however, the nozzle follows the hole, reducing the pressure differential

across the device. Flow nozzles are typically used to meter steam and gases or liquids with

a small degree of suspended solids.

USAGE

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ADVANTAGES

 Can handle suspended solids

 For same flow rate, has significantly lower pressure drop than orifice plate

 May be mounted horizontally or vertically

 Less susceptible to erosion and corrosion than an orifice plate

DISADVANTAGE

 Unsuitable for viscous flow and sticky materials

 Requires consistently smooth flow profile, can't handle eddies or vortices

 Requires straight pipe runs up- and downstream

4. PITOT TUBE

Pitot tubes sense two pressures simultaneously, impact and static. The impact unit consists

of a tube with one end bent at right angles toward the flow direction. The static tube's end is

closed, but a small slot is located in the side of the unit. The tubes can be mounted separately

in a pipe or combined in a single casing.

Pitot tubes are generally installed by welding a coupling on a pipe and inserting the probe

through the coupling. Use of most pitot tubes is limited to single point measurements. The

units are susceptible to plugging by foreign material in the liquid. Advantages of pitot tubes

are low cost, absence of moving pa rts, easy installation, and minimum pressure drop

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ADVANTAGES

 Suitable for measuring steam

 Low pressure drop

 No moving parts, low maintenance

 Easy to install and ideal for retrofitting

 Inexpensive

DISADVATAGES

 Subject to clogging

 Limited to point measurements

5. ELBOW TAP

Elbow tap meters operate on the principle that when liquid travels in a circular path,

centrifugal force is exerted along the outer edges. Thus, when liquid flows through a pipe

elbow, the force on the elbow's interior surface is proportional to the density of the liquid

times the square of its velocity. In addition, the force is inversely proportional to the elbow's

radius.

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ADVANTAGES

 Simplified installation
 Inexpensive

DISADVANTAGE

 Low accuracy

6. TARGET

Target meters measure the force of a flowing stream on a target, usually a vane or disc,

suspended in the stream. The force on the target, measured by a strain gauge, is directly

proportional to the stream's velocity.

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ADVANTAGES

 Particularly useful for steam, corrosive materials and liquid flows with suspended

solids

 One of the only methods of measuring solids flow

 Low maintenance

 Easily adaptable to different fluids and flow rates by changing the target size and

material.

DISADVANTAGE

 Reduced accuracy in gas and liquid metering compared to other types of

flowmeters

7. VARIABLE-AREA (ROTAMETER)

FUNCTION

In variable-area meters, fluid flowing through a slightly tapered tube causes a float (as in the

animation below), piston, or vane to change position inside the tube, adjusting the area

available for fluid to pass through. The fluid velocity determines the final float position.

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ADVANTAGES

 Low pressure drop, which remains mostly constant across the operating range of

the meter.

 Easily read, installed, and maintained.

 Easily converted to handle flows of different fluids.

 Can be installed immediately before or after pipe fittings.

 Self-cleaning.

 Piston meters and vane meters can be mounted in any position.

 Low cost.

 Accurate within 2%

DISADVANTAGE

 Requires relatively clean fluid to prevent plugging.

 Rotameters must be vertically mounted.

 Usually only provides direct readings for air and water, calculations must be made

for other fluids.

 Rotameters are adversely affected by moderate to high viscosities.

 Can only be used on flows less than 200 gal/min and in pipes less than 3 inches in

diameter.

 Cannot be used in systems where vibration is present.

CALIBRATION

TO CALIBRATE INSTRUMENT INVOLVES CHECKING THAT THE OUTPUT OF THE

GIVEN INSTRUMENT CORRESPONDS TO GIVEN INPUTS AT SEVERAL POINTS

THROUGHOUT THE CALIBRATION RANGE OF THE INTRUMENT. DIFFRENTIAL

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PRESSURE FLOW METER OUTPUT MUST BE CALIBRATED TO OBTAIN ZERO

PERCENT TO 100 PERCENT OUTPUT PROPORTIONAL TO THE ZERO PERCENT TO

100 PERCENT RANGE INPUT PRESSSURES. THIS IS ACCOMPLISHED BY

ADJUSTING SCREWS LOCATED AND CLEARLY MARKED AS ZERO AND SPAN THE

ANALOG TRANSMETER’S OUTER CASTING.

B. MASS FLOW METER

Mass flowmeters measure flow in one of two ways: inferentially or directly. Inferentially

means density and flowrate are measured independently. Coriolis and thermal meters,

shown, are both direct mass flowmeters.

The continuing need for more accurate flow measurements in mass-related processes

(chemical reactions, heat transfer, etc.) has resulted in the development of mass flowmeters.

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Coriolis Meter Thermal Meter

1. CORIOLIS

In coriolis meters liquid travels through a vibrating U-shaped or straight tube.

Coriolis mass flowmeters are true mass meters in that they directly measure mass flowrates,

as opposed to volumetric flowrates. These flowmeters operate based on the Coriolis

principle. The coriolis principle is the idea that something moving linear in a rotating frame

experiences acceleration.

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ADVANTAGES

 Devices can accommodate liquid, and liquid/solid flow.

 Can be constructed from a variety of materials.

 Measurement independent of flow conditions (temperature, pressure, density,

viscosity, flow profile, flow regime ).

 Straight-tube: minimal flow obstruction and pressure drop.

DISADVANTAGE

 Extreme temperatures may affect oscillating capabilities of tube.

 Cannot handle high solids content.

 U-tube: subject to clogging and disrupts flow.

 U-tube devices have relatively high pressure drops.

 More expensive than most flowmeters.

 Can't handle entrained gases.

 Sensitive to system vibration.

2. THERMAL

Thermal mass flowmeters use heat transfer to measure flowrate. The operation of thermal

mass flowmeters is based on the tendency of molecules to absorb heat.

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The most common type of thermal mass flowmeter is the heated tube. A portion of gas flow

is diverted through a sensing tube such as the one in the picture. The tube has two sensors

which conduct heat to the gas via a wire coiled around the tube, as shown in the schematic.

When flow occurs, gas molecules carry heat from the upstream coil to the downstream coil.

Thus, less heat is transferred from the second coil than from the first one, and a temperature

gradient is generated.

ADVANTAGES

• Unaffected by temperature, pressure, density, or viscosity within regular operating

limitations

• Can be calibrated to measure a variety of gases over a wide range of flowrates

• Easy to install and maintain , no moving parts

• Excellent low-flow sensitivity

• Do no restrict flow in any way

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DISADVANTAGE

• Extremely sensitive to solid particles, gas must be very clean

• Point measurements only, so provides no information on flow profile

• Special, much more expensive, designs required for liquid flow

CALIBRATION

Validation Using Resistance

This simple method measures the resistance across the velocity sensor. Since the velocity

sensor is most often a platinum resistance temperature detector, the measured resistance is

directly related to the temperature of the sensor. This temperature should be equal to the

space surrounding the velocity sensor once everything has come to equilibrium. This method

only measures the resistance of the platinum wire that is wrapped around the platinum

mandrel. This method does nothing to measure drift since the test doesn’t measure factors

related to heat transfer from the wire through the organic epoxy fillers and sheath out into

the flowing gas.

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C. OPEN CHANNEL FLOW METERS

In open channels, liquid flows with a free surface. Common examples of open channels are

tunnels, nonpressurized sewers, partially filled pipes, canals, streams, and rivers.

Flow measurement through open channels is based upon the head, or depth, of the fluid.

As liquid flows across weirs or flumes (the two main types of open channel measurement

devices) the head changes. The difference in head across the device indicates the

flowrate.

Flow measurement through open channels is based upon the head, or depth, of the fluid.

As liquid flows across weirs or flumes (the two main types of open channel measurement

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devices) the head changes. The difference in head across the device indicates the

flowrate.

ADVANTAGE

 Easy to construct

 Simple to determine flow with proper equations

 Parshall flumes produce one-fourth the head loss of a weir designed to handle the
same flow range

 Parshall flumes are accurate in a wide range of conditions

DISADVANTAGE

 Devices must be installed in the stream in a location where there is no disruption of


steady flow by upstream or downstream blockages

 Require consistant flow profiles

 Specific constraints on pipe/channel sizes and grades

D. POSITIVE DISPLACEMENT FLOW METERS

Positive Displacement flow meters are the only flow measuring technology to directly

measure the volume of fluid that passes though the flow meter. It achieves this by trapping

pockets of fluid between rotating components housed within a high precision chamber.

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This can be compared to repeatedly filling a beaker with fluid and pouring the contents

downstream while counting the number of times the beaker is filled.

Rotor rotational velocity is directly proportional to flow rate, since the flow of fluid is causing

the rotation.

Positive Displacement Flow Meter

• Oval Gear & Impeller

• Reciprocating Piston

• Nutating Disk

• Rotary Vane

• Helical Rotor

1. Oval Gear & Impeller

Oval gear meters and impeller meters, operate in the same manner, but differ in the shape

of the gears. Fluid flowing through the measuring chamber causes the gears to turn,

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displacing an exact volume of fluid. A magnetic or mechanical device counts the number of

turns, determining the volumetric flowrate.

Oval Gear

Impeller

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The industrial oval gear meters pictured on the left are used for a variety of applications

including petroleum based fluids, water solutions, and liquids compatible with the materials

of construction. Pictured on the top is a handheld oval gear meter that is used in applications

that require an accurate measurement of dispensed liquid volume. Examples of applications

include petroleum, chemical, fuel management, lubrication, solvents and food product

industries

ADVANTAGES

 High accuracy and repeatability

 Handles viscous flow

 Cost-effective

 Accuracy unaffected by changes in viscosity

 Requires little maintenance

DISADVANTAGES

 Typical construction materials susceptible to corrosion by water based fluids

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2. RECIPROCATING PISTON

Fluid enters a reciprocating piston meter, also known as an oscillating piston meter,

through an inlet port. The port leads to a precisely measured gap created by a piston in a

round chamber.

As the piston oscillates around the chamber, it displaces an exact volume of fluid.

The piston meter to the left is part of a system that handles diesel exhaust fluid. In the middle

picture, a piston meter is used in renewable fuel applications. Piston meters are good for low

volume measurement applications such as fueling light aircraft and helicopters, shown on

the right. Other industries that use these flowmeters include chemical, pharmaceutical,

petrochemical, and food and beverage.

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ADVANTAGES

 High accuracy and repeatability.

 Only one moving part to cause wear.

 Can be made of materials to ensure sanitary needs of food and beverage

processing.

DISADVANTAGES

 Can only be used with relatively clean liquids.

3. NUTATING DISK

A disc attached to a sphere is mounted inside a spherical chamber. As fluid flows through

the chamber, the disc and sphere unit nutates . The nutation causes a pin, mounted on the

sphere perpendicular to the disc, to rock.

Each revolution of the pin indicates a fixed volume of liquid has passed.

ADVANTAGES

 May be constructed from a variety of materials.

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 High accuracy and repeatability.

DISDVANTAGES

 Accuracy is adversely affected by viscosities below the meter's designated


threshold.

4. ROTARY VANE

A rotary vane meter is composed of a circular rotor mounted inside a round compartment

that contains a number of sliding vanes, which isolate fixed volumes of liquid between the

rotor and the wall of the compartment.

The center of the rotor is offset from that of the compartment. This keeps the rotor in constant

contact with the wall of the compartment opposite that of the liquid pockets, to prevent

backwashing.

Rotary vane meters are often used in the petroleum and agricultural industries due to their

rugged construction. As with many positive displacement flowmeters, they also function as

batchers .

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The more vanes in the rotor, the higher the accuracy of a rotary vane meter at low flowrates.

ADVANTAGES

 Sweeping action of vanes prevents buildup of sediment and keeps compartment

clean.

 Wide choice of construction materials.

 High accuracy and repeatability.

 Low pressure drop over entire range of flow measuring capabilities.

DISADVANTAGES

 Relatively complex design increases cost.

5. HELICAL ROTOR

In helical rotor meters, two nested rotors create pockets of fixed volume. The counter-rotation

of the rotors carries the pockets of liquid axially down the length of the rotors.

The rotation rate and number of rotations, determined by the flowrate, is measured using

electronic sensors. Helical rotor meters are made of cast iron, cast steel or bronze depending

on the material flowing through it.

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The rotation rate and number of rotations, determined by the flowrate, is measured using

electronic sensors. Helical rotor meters are made of cast iron, cast steel or bronze depending

on the material flowing through it.

Common applications of the helical rotor meter involve the measurements of highly viscous

materials such as concrete or molasses. Pictured below is an example of one of these

meters.

ADVANTAGES

 Especially well suited for measurement of highly viscous and hard to meter

fluids.

 Highest accuracy and repeatability of any positive displacement flowmeter.

 Unaffected by flow profile and does not require straight lengths of pipe.

 Low pressure drop.

 Rotor action is self-cleaning.

DISADVANTAGES

 Can only meter liquids.

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 Typical materials of construction will corrode in the presence of water or water-

based fluids.

 Cannot handle abrasive fluids.

CALIBRATION

o Standing-start-and-finish method

o Flying-start-and-finish method

Standing-start-and-finish method

The weight of liquid is noted along with the time taken to fill the tank. The reading from the

flowmeter is also noted. Temperature and pressure of the liquid at the flowmeter are also

noted during the fill.

Flying-start-and-finish method

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Flying-start-and-finish methods are used primarily for flowmeters with slow response times

and where flow rate is the primary measurement rather than quantity passed.

Velocity Flow Meter

Velocity flowmeters are popular because they give a direct measure of fluid velocity, the

characteristic most commonly associated with flowrate. These flowmeters, however, are

among the most sensitive to process conditions.

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Since velocity flowmeters operate under the assumption of a constant velocity profile, they

are inaccurate for flows in the laminar regime. This inaccuracy occurs because there is a

large difference between the fluid velocity at the wall and at the center of the pipe. This

property makes velocity flowmeters especially sensitive to piping geometry and Reynolds

number.

E. VELOCITY FLOW METER

• Turbine & PaddleWheel

• Ultrasonic

• Electromagnetic

• Vortex-shedding

1. TURBINE & PADDLEWHEEL

When fluid flows past a turbine meter, such as the one pictured below, the meter's vaned

rotor rotates. The same occurs in a paddlewheel, except the paddlewheel's blades are

perpendicular to the direction of flow.

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In both cases the angular velocity of the rotor is proportional to the velocity of the fluid.

ADVANTAGES

 One meter can be manufactured to handle a wide range of flowrates.

 May be constructed of a variety of materials to handle a variety of fluids.

 Paddlewheels provide a more cost-effective alternative when less accuracy is

required or with viscous flow.

 Low mass of rotor allows rapid response and ability to measure pulse flow.

DISADVANTAGES

 Can cause large pressure drops.

 Flashing or bubble formation may occur if the downstream pressure of a liquid stream

is too low.

 Require lengths of straight pipe upstream and downstream.

2. ULTRASONIC

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The principle behind ultrasonic flowmeters is the variation between transmitted and

received sound waves as a result of fluid flow.

Ultrasonic flowmeters send sound waves through a stream via transducers, a variety of which

are shown here. The returning sound wave provides information about the stream's flowrate.

ADVANTAGES

 Non-invasive, so no pressure drop

 Measures flow of fluids and slurries that ordinarily cause damage to conventional

sensors

 Responds quickly to changes in velocity

 Eliminates local mechanical and electrical noise, permitting use in a variety of

locations

 Accommodates flow in either direction

 Non-contact, lack of moving parts greatly reduce maintenance requirements and

sensor fouling

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 Works with a variety of pipe sizes and flow conditions

 Measures independently of temperature, pressure, density, viscosity, and electrical

conductivity

 Easy installation.

DISADVANTAGES

 Excess solids or entrained gases may block ultrasonic pulses

 Requires steady flow, can't handle wide and/or rapid fluctuations

3. ELECTROMAGNETIC

The operation of electromagnetic flowmeters is based on Farraday's Law.

When a conductor moves at right angles to a magnetic field, a voltage difference is induced

in the conductor that is proportional to the conductor's velocity.

ADVANTAGES

 Low pressure drop

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 No moving parts means less wear, no routine maintenance

 Insensitive to density, viscosity, pressure, temperature and flow profile

 Usable for a variety of otherwise difficult to meter fluids

 Accurate (error range of 0.5%)

 Relatively low cost

 Measures independently of temperature, pressure, density, viscosity, and

electrical conductivity

 Measures forward and reverse flow

 Can be used with pipes of varying sizes

DISADVANTAGES

 Can only meter liquids

 Liquids must be conductive

 Nearby electromagnetic noise causes interference

 Will not work in partially full pipes, even if electrodes are wetted

 Requires lengths of straight pipe upstream and downstream

 Allowing sludges and greasy fluids to flow too slow causes buildup, which affects

measurement

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4. VORTEX-SHEDDING

When fluid flows past a blunt (non-streamlined) object, turbulence forms at the sides of the

object in the form of eddies, or vortices. As the eddies flow downstream, they separate, or

shed, from the blunt object and grow in size.

Vortex-shedding meters use the principles of turbulence to measure flowrate.

These vortices shed alternately from each side of the object and swirl in opposite directions.

The rate of shedding and size of the vortices is directly proportional to the flowrate of the

fluid. This phenomenon is the same as that which makes a flag flap in the wind.

ADVANTAGES

 Accurate regardless of temperature, pressure, density and viscosity when flow is

turbulent.

 Suitable for measuring liquids, gases and steam.

 Excellent for metering steam flow.

DISADVANTAGES

 Flow must be turbulent.

 Ineffective for slurries and viscous flow.

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REFERENCES

Behal, A., Bacikova, H. (February 13, 2013). Calibration Basics. Retrieved from

https://www.venturi- calibrationservices.com/calibration- basics.html

Mauter, E., Palazzolo, J., et al. (January 22, 2015). Positive Displacement Flow meter

Retrieved fromhttp://flowmetrics.com/guide-positive-displacement-flow-meters/

http://encyclopedia.che.engin.umich.edu/Pages/Flowmeters/PositiveDisplacement/

PositiveDisplacement.html

Rudolf, T., Rodrigo, S., et al. (June 26, 2016). Flow Meter. Retrieved from

http://www.maxiflo.co.kr/english/technology/flowmetertypes.htm

Robert, P., Prats, C., Domingo, J., et al. (September 16, 2017). Flow Measurement

Retrieved from https://www.slideshare.net/ErFarukBinPoyen/flow-measurement-

part-ii

Wesorick, S., Chen, H., Roberts, A. (November 05, 2015). Differential Pressure. Retrieved

fromhttp://encyclopedia.che.engin.umich.edu/Pages/Flowmeters/DifferentialPressur

e/DifferentialPressure.html

Kaplan, K., Roberto, T. (July 21, 2014) Velocity Flow Meter. Retrieved form

http://encyclopedia.che.engin.umich.edu/Pages/Flowmeters/Velocity/Velocity.html

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