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Introduction
Flowmeters are process instruments that measure a fluids linear or non-linear flow at volumetric or mass flow rates
A fluid can either be a liquid or a gas
Introduction
Fluid properties:
Liquid or gas Temperature and pressure Density Viscosity Chemical properties Presence of other phases
Introduction
Installation considerations:
Orientation Flow direction Upstream/downstream pipe work Location for servicing Location of valves Effects of local vibration Electrical connections Effects of unsteady flow
Introduction
Performance considerations:
Accuracy Repeatability Linearity Rangeability (turndown) Pressure drop Output signal characteristics Response time
Introduction
Economic considerations:
Cost of ownership (i.e. purchase, installation, operation, maintenance, calibration, meter life, spares) Pressure loss
Environmental considerations:
Ambient temperature effects Humidity effects Safety factors Electrical interference
Fluid goes through a chamber with a unit that repeatedly fills and discharges a fixed volume
The total volumetric flow rate can then be calculated from the rate of filling and discharging the discrete volumes
Fluids generally need a degree of lubricity Clean, non-abrasive, medium to high viscosity liquids Good for batch operation, low-tech plants Often used in oil and gas refining, chemical, pulp and paper
Nutating Disc
Rotating Valve
Oscillating Piston
Oval Gear
Advantages:
Moderately inexpensive No Reynolds number constraints No upstream/downstream requirements High accuracy 0.25 to 1% of rate Can measure very low and very viscous flows
Disadvantages:
Moving parts Can create large pressure drops Maintenance is necessary; must disassemble to unplug if using a dirty fluid and subject to deterioration Measures discrete fluid flows instead of actual flow rate May take up a lot of space
Flow goes through a section with different cross section areas that cause pressure and velocity variations
Employ Bernoulli equation by observing relationship between pressure drop and velocity to get volumetric flow
Most common method to measure flow Smart transmitters simplify use Accuracy: 2% of full scale Line size: greater than Rangeability: 4:1 Common Applications:
Most gases and low viscosity fluids Used for chemical, oil and gas refining, power, and transfer of natural gas
Orifice Plates
Calculate mass flow: mactual = KAt*(2(p1-p2))0.5
Venturi Tube
Flow Nozzle
Advantages:
Well known system of measurement Versatile Line size flexibility Inexpensive initially Highly repeatable East to maintain Economical to correct sizing mistake
Disadvantages:
High installation costs Moderate system accuracy An abrasive or sticky process will erode accuracy and increase maintenance cost Moderate rangeability High relative pressure loss
Uses flow to turn a turbine rotor Magnetic sensor transmits a voltage pulse to a processor Axial-vane rotor is free turning Rotor continuously moving under pressure of the liquid
Accuracy in the range of +/0.25% with 10:1 turndowns.
Turbine flow meters are widely used for both liquid and gas applications Typical applications include:
Oil and gas, refining, chemical, semiconductor, agricultural, pharmaceutical, food beverage dispensing, photo development, process control, and more
High degree of accuracy at low cost, especially when combined with a flow computer Flexibility in connecting to associated electronic readout devices for flow control and computer interface Wide flow rangeability Construction materials that permit use with many process fluids Simple, durable, field-repairable construction Operation over a wide range of temperatures and pressures
Poor interchangeability from unit to unit Bearings depend on lubricity and cleanliness of process fluid Turbine blades are susceptible to wear and must be frequently calibrated Liquid applications may be suspect to problems involving cavitation, specific gravity, and viscosity Intended for clean fluid applications
Nonmagnetic tube surrounded by coils Must pump conductive liquids Flow rate inferred by sensing linear velocity Principle of operation based on Faradays Law, E=kBDV 30:1 rangeability Accuracy 0.5% of volumetric rate Line size of 0.15 to 60
Turbine flow meters are widely used for corrosive, dirty, or slurry-like liquids Typical applications include:
Wastewater applications or any dirty liquid which is conductive or water based (large water flows) Pulp & paper industry, acid flows or other highly corrosive liquids, abrasive fluids such as mining ore slurries and pulp stock Also ideal for applications where low pressure drop and low maintenance are required
Relatively unaffected by changes in liquid density or viscosity (compatible with wide range of process fluids) Liquid turbulence has a very limited affect Suitable for high viscosity and slurries Low maintenance, high accuracy and rangeability No pressure loss Obstructionless flow Flow profile has minimum effect on measurement accuracy (Re# constraints and little flow conditioning needed)
Measures conductive liquids only High initial cost 4-wire device (requires external power source) Must be lined with non-conductive material (lower temperature and pressure limits) Grounding problems Unstable zero with empty meter
Use transmitted sound waves to determine flow rate Measures liquids and gases with different designs Accuracy 1-5% for microprocessor-based units Rangeability 20 to 50:1 Can be divided into 2 types
Sonic transducers are mounted diagonally on opposite sides of a pipe Requires clean liquid and uniform flow profile Rangeability: 10:1 Accuracies:+/- 1% of rate Advantages:
Established 1843 by Christian Doppler Measures the shift in frequency due to motion of particles or bubbles in the process pipe Turndowns: 10:1 Accuracy: +/- 1% of rate Not suitable for clean liquids Requires straight pipe runs for installation Pipe must have good acoustical properties
Oldest method to measure flow, used by Romans to measure flow in their aqueducts Any time the fluid flows with a free surface Examples: aqueducts, log flumes, channels, etc. Flow measured by inserting a calibrated restriction to the channel Two types of restrictions
Weirs Flumes
Liquids and some gas applications Doppler flowmeters require entrained gas or particles to reflect ultrasonic energy Where non-wetted sensors are applicable Existing installations where pipe modifications are difficult or uneconomical Where exotic materials make other flowmeter uneconomical Large pipes where in-line meters are uneconomical Temporary installations Typical applications include:
Some designs allow measurement to be made external to the pipe (utilize no wetted parts) Low maintenance
Fluid changes (% solids, bubbles, etc) affect measurement Proper installation is critical Longer upstream/downstream straight piping requirements Minimum Reynolds number constraint 4-wire operation (external power source) Low user confidence Only mixed success in industrial flow applications
Oscillatory Flowmeters
Two types:
Fluidic Flowmeter
Vortex Shedding
Vortex shedding is caused by fluid flowing around an object Blunt object placed in the flowing stream The frequency of the vortices is measured The relationship between flow and frequency is: V = k*d*f The frequency is directly proportional to the flow rate.
Different objects manufactured to produce stable vortices Vortices are measured by:
High frequency pressure transducers Measuring variations in heat transfer from a heated resistor Ultrasonics
Pros Good accuracy (+/0.5%) and rangeability (40:1) No moving parts, less to break Moderate costs Can handle liquid, gas, and steam Low pressure drop Not affected by fluid density changes
Cons Intrusive, obstruct flow If using ultrasonics to measure the vortices, straight runs of pipe are needed Re < 20,000 (high) for linear performance Sensitive to increasing Viscosity Expensive in larger sizes
Common Applications
Low viscosity fluids Pressurized gases Steam and other utility fluids Pressurized gases with high densities Single-phase fluids (no particulate matter)
Fluidic
As fluid enters device, flows along one interior wall Some fluid diverted back to inlet (feedback flow) causing the fluid to be pushed against other wall The flow shifts from side to side creating oscillations Oscillations sensed by an electronically heated thermistor on one side Alternating flow causes the thermistor to be cooled, this signal is directly proportional to velocity
Pros Accuracy between 0.5% and 1.0% of rate Minimum maintenance Inexpensive
Cons Can only be used on clean low-viscosity fluids Re 3,000 (requires turbulent flow) Only used in pipes 4 or less diameter
Target Flowmeters
Target Flowmeter
Use an object that is placed in the fluid flow Object mounted at right angle Force exerted on the target is measured by strain gauges Gauges produce electronic output that is proportional to the square of flow rate Optimum size of target depends on liquid being studied
Drawbacks
While accuracy is good at low scale, at full scale the accuracy can vary as much as 5+% Straight pipe length requirements
Mass Flowmeters
Inferred mass (uses density to convert volumetric to mass flow) Direct Mass (actually measure mass)
Thermal Mass
Measures heat loss from a heat source Measures temperature rise as flow passes a hot tube Mass flow is inferred from known physical properties of fluid Usually used for gas applications
Coriolis
Operates on gyroscopic principle Based on coriolis forces (angular velocity of earth imparts force on a moving object) Fluid flows through U- or S-shaped tube which vibrates at its natural frequency
Coriolis
Motion of fluid in the tubes resist this vibration (the tubes twist) Velocity of the tube deflection is proportional to mass flow
Pros Extremely accurate (0.15%) Directly measures mass No Re constraints Low maintenance Can measure density, temperature, mass and volumetric flow
Cons High initial capital costs Small pipe diameters needed cause large pressure drop Not recommended for measurements involving gases
Angular Momentum
Measures the force required to resist the angular momentum of flowing fluid This force proportional to mass Device consists of: Motor Impeller (imparts the momentum) Turbine to resist the angular momentum torque is applied The torque needed to resist rotation of the turbine is transmitted to a display
Drawbacks
Only clean liquids can be used Lots of moving parts that often require maintenance Expensive
Sources
http://www.manufacturing.net/ctl/article/CA185726 http://www.efunda.com/designstandards/sensors/flowmeters/flowmeter_pd.cfm http://www.efunda.com/designstandards/sensors/flowmeters/flowmeter_dp.cfm www.manufacturing.net/ctl/article/CA325984 http://www.jlcinternational.com/gas_liquid_turbine_flowmeters.htm http://www.ddc-online.org/inout/inout_chapt02_ana_06flow.aspx http://www.omega.com/prodinfo/magmeter.html http://www.envitech.co.uk/Product_Images/FlowMeter4210.jpg http://www.seilenterprise.co.kr/English/Technology/flowmetertypes.htm http://www.efunda.com/designstandards/sensors/flowmeters/flowmeter_tar.cfm http://www.omega.com/literature/transactions/volume4/images/10_Fig_01_l.GIF