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Flow Instruments: Polytechnic University of The Philippines
Flow Instruments: 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
A. DIFFERENTIAL PRESSURE
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
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
OPERATING PRINCIPLE
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
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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
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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
ADVANTAGES
Low cost
Small
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DISADVANTAGES
Moderate accuracy of 2 - 4%
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
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,
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
DISADVANTAGE
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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
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
USAGE
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ADVANTAGES
For same flow rate, has significantly lower pressure drop than orifice plate
DISADVANTAGE
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
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
Inexpensive
DISADVATAGES
Subject to clogging
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
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ADVANTAGES
Particularly useful for steam, corrosive materials and liquid flows with suspended
solids
Low maintenance
Easily adaptable to different fluids and flow rates by changing the target size and
material.
DISADVANTAGE
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.
Self-cleaning.
Low cost.
Accurate within 2%
DISADVANTAGE
Usually only provides direct readings for air and water, calculations must be made
Can only be used on flows less than 200 gal/min and in pipes less than 3 inches in
diameter.
CALIBRATION
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ADJUSTING SCREWS LOCATED AND CLEARLY MARKED AS ZERO AND SPAN THE
Mass flowmeters measure flow in one of two ways: inferentially or directly. Inferentially
means density and flowrate are measured independently. Coriolis and thermal meters,
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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1. CORIOLIS
Coriolis mass flowmeters are true mass meters in that they directly measure mass flowrates,
principle. The coriolis principle is the idea that something moving linear in a rotating frame
experiences acceleration.
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ADVANTAGES
DISADVANTAGE
2. THERMAL
Thermal mass flowmeters use heat transfer to measure flowrate. The operation of thermal
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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
limitations
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DISADVANTAGE
CALIBRATION
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
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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
Parshall flumes produce one-fourth the head loss of a weir designed to handle the
same flow range
DISADVANTAGE
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
Rotor rotational velocity is directly proportional to flow rate, since the flow of fluid is causing
the rotation.
• Reciprocating Piston
• Nutating Disk
• Rotary Vane
• Helical Rotor
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
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
include petroleum, chemical, fuel management, lubrication, solvents and food product
industries
ADVANTAGES
Cost-effective
DISADVANTAGES
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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,
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ADVANTAGES
processing.
DISADVANTAGES
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
Each revolution of the pin indicates a fixed volume of liquid has passed.
ADVANTAGES
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DISDVANTAGES
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
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
clean.
DISADVANTAGES
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
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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
Common applications of the helical rotor meter involve the measurements of highly viscous
meters.
ADVANTAGES
Especially well suited for measurement of highly viscous and hard to meter
fluids.
Unaffected by flow profile and does not require straight lengths of pipe.
DISADVANTAGES
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based 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
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 flowmeters are popular because they give a direct measure of fluid velocity, the
characteristic most commonly associated with flowrate. These flowmeters, however, are
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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.
• Ultrasonic
• Electromagnetic
• Vortex-shedding
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
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In both cases the angular velocity of the rotor is proportional to the velocity of the fluid.
ADVANTAGES
Low mass of rotor allows rapid response and ability to measure pulse flow.
DISADVANTAGES
Flashing or bubble formation may occur if the downstream pressure of a liquid stream
is too low.
2. ULTRASONIC
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The principle behind ultrasonic flowmeters is the variation between transmitted and
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
Measures flow of fluids and slurries that ordinarily cause damage to conventional
sensors
locations
sensor fouling
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conductivity
Easy installation.
DISADVANTAGES
3. ELECTROMAGNETIC
When a conductor moves at right angles to a magnetic field, a voltage difference is induced
ADVANTAGES
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electrical conductivity
DISADVANTAGES
Will not work in partially full pipes, even if electrodes are wetted
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
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
turbulent.
DISADVANTAGES
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REFERENCES
Behal, A., Bacikova, H. (February 13, 2013). Calibration Basics. Retrieved from
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
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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