Industrial Instrumentation
Ms. Sobia Anwar
Flow Sensors
Reasons for Flow Metering
Plant control, for product quality and safety
reasons.
Custody transfer, both interplant and selling to
outside customers.
Filling of containers, stock tanks and
transporters.
Energy, mass balancing for costing purpose
and health monitoring of heat exchangers.
Health monitoring of pipelines and on-line
analysis equipment, Government and
company legislation may dictate the use here
of such equipment.
Types of Flow Meters
Differential Pressure Meters.
Rotary Meters.
1. Displacement
2. Inferential
New Flow Meters.
1. Electromagnetic
2. Vortex Shedding
3. Ultrasonic
4. Tracer
5. Swirl
Mass Flow Meters.
Parts of differential pressure meters
1. Primary element
(Part of meter used to restrict the fluid flow in pipe
line to produce differential pressure)
They include
Orifice plate
Venturi tubes
Flow nozzles
Pitot tube etc.
Parts of differential pressure meters
1. Secondary element
(measure the differential pressure produced by
primary elements and convert them to
usable forces or signals )
Secondary elements;
Manometers
Bellow meters
Force balance meters etc.
Differential Pressure Meters
Orifice Plate
Dall Tube
Venturi Tube
Pitot Tube
Rota meter
Target meter
Averaging Pitot
Nozzle
Spring Loaded
Intake Meter
Elbow Meter
Bypass Meter
Obstruction Meters
Orifice Meters
Venturi Meters
Flow Nozzles
Flow through a Venturi Meter
In a venturi, 0.95 < C < 0.98
Advantage:
Pressure recovery
Uses little power
Flow through a Venturi Meter
0.98
2 x 105
Re
d 1 v 1
R = Based upon the conditions in the pipe approaching
the meter
e
Flow through a Orifice Meter
Flow through a Orifice Meter
P1 P2
d D
P1
P
Flow through a Orifice Meter
-Cheapest and Simplest
-But biggest pressure drop and power lost
(C~0.6 - 0.7)
-Side Note:
Pressure drop caused by friction and
turbulence of shear layer downstream of vena
contracta
10k
0.85
Re 5000
1 100k
C = CM
A2
2
1 −
A1
0.6
=d/D
0.1 0.8
Flow through a Nozzle
1 =m
Basic Equations:
m 2 a.) Continuity:
mass in = mass out
= Av
m b.) Bernoulli’s Eqn.
Total pressure is
constant throughout
1A1 v1 = 2 A 2 v 2
incompress ible
1 = 2 1
m 2
m
A 1 v1 = A 2 v 2 1 2
A1 A2
v1 v2
Flow through a Nozzle
Bernoulli
P0 = Total Pr essure = const .
1 2
= v + P
2
1 1
1 v1 + P1 = 2 v 2 + P2 = P0
2 2
2 2
P = static pressure
P0 = total pressure
1 2
v = dynamic pressure
2
Flow through a Nozzle
Rearranging the equation gives:
Flow through a Nozzle
Flow through a Nozzle
The velocity of fluid exiting the nozzle is determined
by the pressure difference and the area ratio.
Nozzle Flow meter and Orifice Plate
k Factor: The k factor in nozzle flow meters often accounts for the
specific geometry and flow conditions of the nozzle. It incorporates
various aspects, such as flow profile and velocity distribution, to
provide a more accurate flow measurement. The k factor is a lumped
correction factor that adjusts the theoretical flow rate derived from
Bernoulli’s equation to match actual conditions.
Discharge Coefficient: The discharge coefficient for an orifice
plate accounts for energy losses due to flow contraction and
turbulence as the fluid passes through the orifice. The coefficient
varies with factors like the Reynolds number and the geometry of
the orifice. It helps to correct the ideal flow calculations to reflect
the actual flow behavior, which can be more unpredictable due to
these losses.
Nozzles generally produce a more stable and predictable flow profile
compared to orifices, where flow separation and turbulence can vary
significantly. Thus, a simpler k factor can suffice for nozzles.
The Nozzle FlowMeter
Shorter and cheaper than venturi
But larger pressure drop.
Thus, more power lost in operating.
Differential Pressure Meters ( Cont‘d)
Elbow Flow meter Rota meter
Rotameter, variable-area-flowmeter
Force balance
Drag Force
Gravity
Buoyancy
(usually negligible)
use
m use = m cal
cal
Derived on next slide
Rotameter ( Cont‘d)
Rotameter m = A V
Equations
V2
F = D = Mg
2
2 Mg
V=
D
2 Mg 2 MgA2
m = A =
D D
For a fixed x-position, A is fixed. Then
m m
=
use cal
use
m use = m cal
cal
Pitot tubes
Pitot-Static Tubes
Rotary Meters ( Displacement Meters)
Displacement Meters
Gear
Oval wheel
Vane Meter
Gear (Roots)
Diaphragm Meter
Liquid Sealed Meter
Inferential Meter
Turbine Meter
Rotary Meters ( Displacement Meters)
Rotary meters, also known as rotary displacement flow meters, are
used to measure the flow rate of liquids and gases. They operate
based on the principle of positive displacement, which means they
measure the volume of fluid passing through the meter by trapping
a fixed amount of fluid and then releasing it.
Components: Typically consist of two rotors or gears that rotate
within a housing. As the fluid flows through, it fills the spaces
between the rotors and the housing.
Measurement: The rotation of the rotors is proportional to the
volume of fluid passing through. The number of rotations can be
converted into a flow rate.
Rotary Meters ( Displacement Meters)
Gear rotary meter
Oval wheel rotary meter
Vane rotary meter
Gear(Roots) rotary meter
Diaphragm rotary meter
Turbine Flow Meters
▪ Turbine flow meters are devices used to measure the flow rate of
liquids and gases by using a turbine wheel that rotates in response to
the flow.
▪ The flow of fluid passes through the meter, causing a turbine rotor to
spin. The rotational speed of the turbine is proportional to the flow
rate.
▪ The rotational speed is converted into an electrical signal, which can
be displayed as flow rate in various units.
Turbine Flow Meters
Turbine Flow Meters
Advantages
High Accuracy: Typically provides precise measurements, especially
in clean fluids.
Wide Range of Flow Rates: Can handle a variety of flow conditions.
Fast Response Time: Quick to react to changes in flow rates.
Limitations
Sensitivity to Viscosity: Performance can be affected by changes in
fluid viscosity.
Not Suitable for Dirty Fluids: Particulates and debris can impede
the turbine and affect accuracy.
Pressure Drop: May create a pressure drop in the system due to
flow restriction.
New Flow Meters
Electromagnetic
EM Meter
Vortex Shedding Meter
Vortex Generation Meter
Ultrasonic Flow Meters
New Flow Meters (Cont‘d)
Swirl Meter
▪ The meter consists of a specially designed flow path that
creates a swirling motion in the fluid as it passes through.
▪ As the fluid swirls, it generates a vortex pattern. The flow
meter uses sensors to measure the characteristics of this
vortex, such as the frequency and amplitude of the swirl,
which correlate to the flow rate.
▪ The data from the sensors are processed to calculate the
flow rate and display it in real-time.
New Flow Meters (Cont‘d)
Swirl Meter
New Flow Meters (Cont‘d)
Magnetic Flowmeter
Magnetic flowmeters, also known as magmeters, are widely used devices
for measuring the flow of conductive liquids. They operate based on
Faraday's law of electromagnetic induction, which states that a voltage is
induced when a conductive fluid flows through a magnetic field.
Basic Principle: When a conductive fluid flows through a magnetic
field, it generates a voltage proportional to the flow velocity. Electrodes
located on the flow tube detect this induced voltage.
Components:
• Magnetic Coils: Create the magnetic field.
• Electrodes: Measure the induced voltage.
• Flow Tube: Houses the fluid and creates a path for flow
measurement.
New Flow Meters (Cont‘d)
Magnetic Flowmeter
New Flow Meters (Cont‘d)
Magnetic Flowmeter
Advantages
High Accuracy: Provides precise flow measurements, often within
±0.5% of reading.
Versatile: Works well with a variety of fluid types and can handle
fluctuating flow conditions.
Minimal Pressure Drop: The design allows for a smooth flow path,
resulting in low pressure loss.
Limitations
Conductivity Requirement: Must measure conductive fluids; non-
conductive fluids (like oils or gases) cannot be measured.
Installation Considerations: Requires proper installation to avoid
errors, including ensuring that the flow is fully developed and that the
meter is mounted correctly.
Electrode Corrosion: In some applications, electrodes can corrode over
time, especially in aggressive fluids.
Coriolis Mass Flowmeter
Coriolis mass flowmeters are advanced instruments used to measure
the mass flow rate of fluids (liquids and gases) based on the Coriolis
effect. They are known for their high accuracy and versatility across
various applications.
Coriolis Effect: When a fluid flows through a vibrating tube, the flow
causes a shift in the tube's oscillation pattern due to the Coriolis force.
This shift is directly proportional to the mass flow rate of the fluid.
Measurement Principle: The device typically consists of a U-shaped
or straight tube that is vibrated at a specific frequency. As fluid flows
through, the tubes experience a phase shift in their oscillation and
change in frequency, which is measured by sensors. This phase shift
and frequency change is used to calculate both mass flow rate and
density.
Coriolis Mass Flowmeter
Coriolis Mass Flowmeter
Advantages
High Accuracy: Capable of measuring mass flow with an accuracy of
±0.1% to ±0.5%, depending on the specific model and application.
Direct Mass Measurement: Measures mass flow directly, rather than
volumetric flow, which is useful for applications where density changes
may occur.
Wide Range of Applications: Suitable for various fluids, including
viscous liquids, slurries, and gases.
Minimal Pressure Drop: The design allows for minimal disruption to
the flow, resulting in low pressure losses.
Limitations
Cost: Generally, more expensive than traditional flowmeters due to
their complexity and advanced technology.
Sensitivity to Vibration: External vibrations can affect accuracy, so
installation considerations are crucial.
Size and Weight: Coriolis meters can be bulkier compared to other
flow measurement technologies.
Discussion & Questions?
