Industrial Instrumentation: Dr. - Ing. Naveed Ramzan

PEC UET Lahore Dr. Shahid Naveed 15. Oktober 2014 / Dr.
Ing Naveed Ramzan 1

Industrial
Instrumentation
Dr. Ing. Naveed Ramzan
Flow Sensors
PEC UET Lahore Dr. Shahid Naveed 15. Oktober 2014 / Dr. Ing Naveed Ramzan 2

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.
Reasons for Flow Metering

Differential Pressure Meters.

Rotary Meters.
1. Displacement
2. Inferential

New Flow Meters.
1. Electromagnetic
2. Vortex Shedding
3. Ultrasonic
4. Cross Correlation
5. Tracer
6. Swirl
7. Fluidic

Point Velocity Meters.
Mass Flow Maters.

Types of Flow Meters

Orifice Plate
Dall Tube
Venturi Tube
Pitot Tube
Rota meter
Target mater
Averaging Pitot
Nozzle
Spring Loaded
Intake Meter
Elbow Meter
Bypass Meter

Differential Pressure Meters

Parts of differential flow 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.
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.

Parts of differential flow meters
Obstruction Meters
Orifice Meters

Venturi Meters

Flow Nozzles

Flow Through an Orifice Meter
P
1
P
2
P
P1
d
D
-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
CM
A
A
C =
(
(
(
(
(
(
|
|
.
|
\
|
2
1
2
1
1
0.6
0.85
|=d/D
0.1 0.8
R
e
100k
5000
10k
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
Back to the Nozzle
P
1
P
2
P
P
1
P
2
Shorter and cheaper than venturi
But larger pressure drop.
Thus, more power lost in operating.
The Nozzle Flowmeter
C
0.86
0.98
10
3
10
5
R
e
Obstruction Meters
Orifice Meters

Venturi Meters

Flow Nozzles

Flow through a Nozzle
2 2 1 1
2 1
2 2 2 1 1 1
2 1
v A v A
ible incompress
v A v A
Av m
m m
=
=
=
=
=

1
1
1
1
v
A
m
2
2
2
2
v
A
m
Basic Equations:
a.) Continuity:
mass in = mass out
b.) Bernoullis Eqn.
Total pressure is
constant throughout

pressure dynamic v
2
1
pressure total P
pressure static P
P P v
2
1
P v
2
1
P v
2
1
. const essure Pr Total P
Bernoulli
2
0
0 2
2
2 2 1
2
1 1
2
0
=
=
=
= + = +
+ =
= =
A
|
|
.
|
\
|
A
|
|
.
|
\
|
= =
A
|
|
.
|
\
|
=
P 2
A
A
1
1
YCA Q
Flow al Re For
Ideal
P 2
A
A
1
1
A v A Q
Rate Flow
P 2
A
A
1
1
v
2
1
2
2
2
1
2
2 2 2
2
1
2
2
AP
2 1
2
1
2
2
2
2
2
2
1
2
1
2
2 2
2
1 1
2
2 2 2 1
1
2
1
2
1
2
1
2
1
2
1

=
(
(
|
|
.
|
\
|
=
|
|
.
|
\
|
=
= = A
when
A
A
v
v
A
A
v
v v P P P
Y = Compressibility Factor
=1 for incompressible flow
or when AP<< P
abs
C= Discharge Coefficient
=f(Re) and
nature of specific flow meter

AP
P
Elbow Flow meter
Differential Pressure Meters ( Contd)
Rota meter

Rotameter, variable-area-flowmeter
Force balance
Drag Force
Gravity
Buoyancy
(usually negligible)
cal
use
cal use
m m

=
Derived on next slide
D
MgA
D
Mg
A m
D
Mg
V
Mg
V
D F
V A m
2
2
2 2
2
2
= =
=
= =
=
For a fixed x-position, A is fixed. Then

cal
use
cal use
cal use
m m
m m

=
|
|
.
|
\
|
=
|
|
.
|
\
|
Rotameter
Equations
Pitot Tube
Displacement Meters
Gear
Oval wheel
Vane Meter
Gear (Roots)
Diaphragm Meter
Liquid Sealed Meter
Inferential Meters

Rotary Meters ( Displacement Meters)
Turbine Meter
Hoverflo Meter

Devices which are used to
measure mass or
volumetric flow rate of
gas or liquid by using a
rotating element.
15/10/2014 27
What are Rotary Meters ( Displacement Meters)
Types of Rotary Meters

Positive Displacement Rotary Meters

Inferential Rotary Meters

15/10/2014
28
Types of Rotary Meters ( Displacement Meters)
Positive displacement
flow meters, also
know as PD meters,
measure volumes of
fluid flowing through
by counting repeatedly
the filling and
discharging of known
fixed volumes.

15/10/2014 29
PD Rotary Meters ( Displacement Meters)
Principle of Operation
POSITION 1. As the bottom impeller rotates in a
counterclockwise direction towards a horizontal position,
fluid enters the space between the impeller and cylinder.
POSITION 2. At the horizontal position, a definite volume
of fluid is contained in the bottom compartment.
15/10/2014 30
POSITION 3. As the impeller continues to turn, the
volume of fluid is discharged out the other side.
POSITION 4. The top impeller, rotating in opposite
direction, has closed to its horizontal position confining
another known and equal volume of fluid.
15/10/2014 31
Principle of Operation
Oval Gear
Nutating Disk
Oscillating Piston
Multi Piston
Rotating Impellers
Rotating Valve
Birotor
Roots Meter
Helix Meters
15/10/2014
32
Nutating Disk
A nutating disc meter has
a round disc mounted on
a spindle in a cylindrical
chamber.
By tracking the
movements of the
spindle, the flowmeter
determines the number of
times the chamber traps
and empties fluid.

15/10/2014 33
Oval Gear
Two identical oval rotors mesh
together by means of slots around
the gear perimeter.
The oval shaped gears are used to
sweep out an exact volume of the
liquid passing through the
measurement chamber during each
rotation.
15/10/2014 34
Oval Gear
The flow rate can be calculated by measuring the rotation
speed.
15/10/2014 35
Roots Meter
The roots meter is
similar in many
respects to the oval
gear meter.
Two-lobed impellers
rotate in opposite
directions to each
other within the body
housing.
15/10/2014 36
Roots Meter
These peanut-shaped gears sweep out an exact volume of
liquid passing through the measurement chamber during
each rotation.
The flow rate can be calculated by measuring the rotation
speed.
15/10/2014
37
Rotating Impeller
15/10/2014
38
Birotor
15/10/2014
39
Advantages

High accuracy over a wide range of viscosities and flow
rates up to 2000 cP with proper clearances.
Extremely good repeatability on high viscosity fluids,
very low slippage, long life if little or no abrasive material
in the fluid
Low pressure drop
Functions without external power

Rotary Meters ( Displacement Meters)

Advantages
Special construction available for high viscosities and
temperatures
Can register near zero flow rate
Measures directly, not an inferential device, for more
consistent results
Easy to repair and economical.

15/10/2014
41
Disadvantages
Increased maintenance compared to other meters, more
moving parts
May become damaged by flow surges and gas slugs
Chance of corrosion and erosion from abrasive materials
Derated flow rate capacity for high viscosities and
temperatures
Relatively high cost for large sizes

15/10/2014
42
The inferential type meters are so-called
because rather than measuring the actual
volume of fluid passing through them,
they infer the volume by measuring
some other aspect of the fluid flow and
calculating the volume based on the
measurements
15/10/2014 43
Inferential Meters

Turbine Meters
Paddle Wheel
Insertion Type
15/10/2014
44
Inferential Meters
The inferential type meters are so-called
because rather than measuring the actual
volume of fluid passing through them,
they infer the volume by measuring
some other aspect of the fluid flow and
calculating the volume based on the
measurements
Turbine Flow Meters

It consists of a multi-bladed
rotor mounted at right angles
to the flow and suspended in
the fluid stream on a free-
running bearing.
The diameter of the rotor is
very slightly less than the
inside diameter of the
metering chamber, and its
speed of rotation is
proportional to the volumetric
flow rate.

15/10/2014 46
Turbine Flow Meters
The rotational speed is
a direct function of
flow rate and can be
sensed by magnetic
pick-up, photoelectric
cell, or gears.
Electrical pulses can
be counted and
totalized.
15/10/2014 47
Turbine Flow Meters
Paddle Wheel
15/10/2014
48
Paddle Wheel Meters
Advantages
Very good repeatability
Reduced susceptibility to fouling and deposits
Less sensitive to viscosity changes
Available in large sizes, good value for high flow rates
Low maintenance
Registers near zero flow rate

15/10/2014
49
High pressure drop that increases drastically with viscosity
Relatively high cost
Indirect measurement

Disadvantages
Inferential Meters
Electromagnetic
EM Meter

Vortex Shedding Meter
Vortex Generation Meter

Ultrasonic Flow Meters

New Flow Meters

Magnetic Flowmeter
New Flow Meters (Contd)

Swirl Meter
New Flow Meters (Contd)

Coriolis Mass Flowmeter

In the Coriolis meter the fluid is passed through a tube. The tubes are available in
different design like tubes of U-shape or horseshoe-shaped. The tubes can either be
curved or straight. When two tubes are used the flow is divided when entering the
meter and then recombined. The flow when enters the tube encounters oscillating
excitation force that causes the tubes to vibrate at a fixed frequency. The vibration is
induced in the direction that is perpendicular to flow of fluid. This creates the rotation
frame of reference. Consider the tube during oscillation moving up and downward,
when the tube is moving upward the fluid flowing in it tends to resist this and forces it
downward. When the tube moves in the opposite direction, so does the fluid and a
twist in introduced in the tube. All this might not be visible by directly observing. The
twist at inlet of fluid and outlet of fluid results in phase difference or time lag and that
is dependent on the fluid mass passing through the tube.
Case Study: Flow measurement of gas with changing composition
Case Study: Flow measurement of gas with changing composition
Case Study: Effect of pressure on gas flow sensor
Case Study: Effect of pressure on gas flow sensor
Case Study: Pressure drop in measuring gas flow
Case Study: Pressure drop in measuring gas flow
Case Study: Measuring high variable flow rate
Case Study: Measuring high variable flow rate
Case Study: Flashing flow
Case Study: Flashing flow
Discussion & Questions?
Dr. Shahid Naveed 15. Oktober 2014 / Dr. Ing Naveed Ramzan
64

Industrial Instrumentation: Dr. - Ing. Naveed Ramzan

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PEC UET Lahore Dr. Shahid Naveed 15. Oktober 2014 / Dr.

Ing Naveed Ramzan 1

For a fixed x-position, A is fixed. Then

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