Flow

1 Flow
1.1 Introduction
Industrial flow measurements include measuring of flow rate of solids, liquids and gases. There
are two basic ways of measuring flow ; one on volumetric basis and the other on weight basis.
Solid materials are measured in terms of either weight per unit time or mass per unit time.
Very rarely solid quantity is measured in terms of volume. Liquids are measured either in
volume rate or in weight rate. Gases are normally measured in volume rate. In this chapter,
the flow measurements of liquids and gases will be discussed in detail rather than that of
solids.
Fluids are classified into two types, namely incompressible and compressible. Fluids in
liquid phase are incompressible whereas fluids in gaseous phase are compressible. Liquid oc-
cupies the same volume at different pressures where as gases occupy different volumes at
different pressures. This point has to be taken care of while calibrating the flow meters. The
measurements taken at actual conditions should be converted either to Standard temperature
(0°C) and pressure (760 mm Hg) base (STP base) or to Normal temperature (20°C) and pres-
sure (760 mm Hg) base (NTP base).
1.2 Units of Flow

The units used to describe the flow measured can be of several types depending on how the
specific process needs the information.
Solids. Normally expressed in weight rate like Tonnes/hour, Kg/minute etc.
Liquids. Expressed both in weight rate and in volume rate.
Examples : Tonnes/hour, Kg/minute, litres/hour, litres/minute, m3/hour etc.
Gases. Expressed in volume rate at NTP or STP like Std m3/hour, Nm3/hour etc.
Steam. Expressed in weight rate like Tonnes/hour, Kg/minutes etc. Steam density at
different temperatures and pressures vary. Hence the measurement is converted into weight
rate of water which is used to produce steam at the point of measurement.
1.3 Measurement of Flow

Flow meter is a device that measures the rate of flow or quantity of a moving fluid in an open
or closed conduit. Flow measuring devices are generally classified into four groups.
1
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2 INDUSTRIAL INSTRUMENTATION
They are :
1. Mechanical type flow meters. Fixed restriction variable head type flow meters
using different sensors like orifice plate, venturi tube, flow nozzle, pitot tube, dall tube, quan-
tity meters like positive displacement meters, mass flow meters etc. fall under mechanical
type flow meters.
2. Inferential type flow meters. Variable area flow meters (Rotameters), turbine
flow meter, target flow meters etc.
3. Electrical type flow meters. Electromagnetic flow meter, Ultrasonic flow meter,
Laser doppler Anemometers etc. fall under electrical type flow meters.
4. Other flow meters. Purge flow regulators, Flow meters for Solids flow measure-
ment, Cross-correlation flow meter, Vortex shedding flow meters, flow switches etc.
The working principle construction, calibration etc. of the above flow meters will be
discussed in the following sections.
1.4 Mechanical Flowmeters

Fixed restriction variable head type flow meters using different sensors like orifice plate, venturi
tube, flow nozzle, pitot tube, dall tube, quantity meters like positive displacement meters,
mass flow meters are the popular types of mechanical flow meters.
1.4.1 Theory of Fixed Restriction Variable Head Type Flowmeters
In the variable head type flow meters, a restriction of known dimensions is generally
introduced into pipeline, consequently there occurs a head loss or pressure drop at the restric-
tion with increase in the flow velocity. Measurement of this pressure drop is an indication of
the flow rate.
V2 A2
A1
V1
Z1 Z2
P1 P2
Datum line
Fig. 1.1 Schematic representation of a one dimensional flow system with a restriction
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Head—type flow measurement derives from Bernoulli’s theorem which states that in a
flowing stream, the sum of the pressure head, the velocity head and the elevation head at one
point is equal to their sum at another point in the direction of flow plus the loss due to friction
between the two points. Velocity head is defined as the vertical distance through which a
liquid would fall to attain a given velocity. Pressure head is the vertical distance which a
column of the flowing liquid would rise in an open-ended tube as a result of the static pressure.
In general, a one—dimensional flow system is assumed. The schematic representation
of such a system with a restriction in the pipeline is shown in Fig. 1.1.
1.4.1.1 Flow of Incompressible Fluids in Pipes
Section-1 is the position of upstream tap and Section-2 that for downstream. The terms
T, A, ρ, V, P and Z represent Temperature, Area, Density, Stream velocity, Pressure and Central
line elevation respectively. If this elevation is quite small such that Z2 – Z1 is negligible, the
Bernoulli’s equation for an incompressible (ρ1 = ρ2) frictionless and adaptive flow is written as
P1 V12 P2 V2 2
+ = + ...(1.1)
ρ 2g ρ 2g
where g = acceleration due to gravity, giving
V2 2 ρ
P1 – P2 = [1 – (V1/V2)2] ...(1.2)
2g
The continuity equation for this type of flow is
Q = A2V2 = A1V1 ...(1.3)
where Q = volume flow rate in m3/sec.
Combining equations (1.2) and (1.3) and manipulating, one gets
A2 LM OP
2 g (P1 − P2 )
= A 2 M va 2 gh
[1 − (A /A ) ] MN PQ
Q = A2V2 = 2 ρ ...(1.4)
2 1
1
where Mva = = Velocity approach factor
F A IJ
1– G 2
2
HA K 1
P1 – P2
h= = Differential head.
ρ
This is equation for the ideal volume flow rate.
For actual flow conditions with frictional losses present, a correction to this formula is
necessary. Besides, the minimum area of flow channel occurs not at the restriction but at some
point slightly downstream, known as the ‘Venacontracta’. This in turn depends on the flow
rate. While the tapping positions are fixed, the position of maximum velocity changes with
changing flow rate.
The basic equations are :
V = K1 h ...(1.5)
Q = K1A h ...(1.6)
W = K1A hP ...(1.7)
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where V = Velocity of Fluid

Q = Volume flow rate
W = Mass flow rate.
A = Cross-sectional area of the pipe.
h = differential head between points of measurement.
ρ = density of the flowing fluid
K1 = Constant which includes ratio of cross-sectional area of pipe to cross-sectional
area of nozzle or other restrictions.
1.4.1.2 β Ratio
Most variable head meters depend on a restriction in the flow path to produce a change
in velocity. For the usual circular pipe, the Beta ratio is the ratio between the diameter of the
restriction and the inside diameter of the pipe.
β = d/D ...(1.8)
where d = diameter of the restriction
D = inside diameter of the pipe.
1.4.1.3 Reynolds Number
In practice, flow velocity at any cross section approaches zero in the boundary layer
adjacent to the pipe wall and varies across the diameter. This flow velocity profile has a signifi-
cant effect on the relationship between flow velocity and pressure difference developed in the
head meters.
Sir Osborne Reynolds proposed single, dimensionless ratio known as Reynolds number,
as a criterion to describe this phenomenon. This number, Re, is expressed as
ρVD
Re = ...(1.9)
µ
where V = velocity
D = Diameter of the pipeline
ρ = density and
µ = absolute viscosity.
Reynolds number expresses the ratio of inertial forces to viscous forces. At a very low
Reynolds number, viscous forces predominate and inertial forces have little effect. At high
Reynolds number, inertial forces predominate and viscous effects become negligible.
1.4.1.4 Discharge Coefficient (Cd)
Discharge coefficient, C is defined as the ratio between actual volumetric flow rate and
ideal volumetric flow rate.
qactual
Cd = ...(1.10)
qideal
where qactual = Actual volumetric flow rate
qideal = Ideal volumetric flow rate. (Theoretical)
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1.4.1.5 Flow Coefficient (K)

K = Cd/ 1 − β 4 ...(1.11)
where K = Flow coefficient
Cd = discharge coefficient
β = ratio of diameters = d/D
where 1/ 1 − β 4 is known as velocity approach factor (that is velocity at section-A1) Mva.
∴ K = Cd . Mva
Fig. 1.2 Orifice and Pressure-Differential Measurement
Measuring fluid flow with an orifice and differential pressure manometer as shown in
Fig. 1.2, requires that the effect of the fluid over the manometer liquid be taken into account.
Furthermore, the pressure differential at the orifice is usually expressed in liquid-column
height. Then
P1 – P2 = (ρm – ρf)h ...(1.12)
where h = differential at restriction, liquid column height
ρm = weight density of manometer fluid
ρf = weight density of fluid over the manometer fluid.
Finally if the flow rate is to be converted at the control room temperature at which the
fluid density is ρs, then from equations (1.4), (1.11) and (1.12).
2gh (ρ m − ρ f ) ρ ρ (ρ m − ρ f )
Q = KA2 . = KA2 2 gh ...(1.13)
ρ ρs ρs
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1.4.1.6 Flow of Compressible Fluids in Pipes

If the fluid is compressible, a flow rate can be obtained if the gas is considered ideal and
the flow is considered adiabatic.
The relation between pressure and velocity for flow of a compressible fluid through an
orifice can be found from the law of conservation of energy as employed in thermodynamics.
Assuming no heat flow to or from the fluid and no external work done on or by the fluid and
neglecting the very small datum level difference (Z1 – Z2), we have
V2 2 V2
P2v2 + + JE2 = P1v1 + 1 + JE1 ...(1.14)
2g 2g
where E = internal molecular energy of fluid
J = work equivalent of heat
v = Specific volume of fluid
Employing the definition of enthalpy H gives
V22 – V12 = 2gJ (H1 – H2) ...(1.15)
For an ideal gas and if specific heats are constant,
KR
H1 – H2 = T [1 – (P2/P1)(K–1)/K] ...(1.16)
J (K − 1) 1
where K = ratio of specific heats = Cp/Cv
R = gas constant for a given gas
T = absolute temperature.
From the equation of continuity (conservation of mass).
A 2 V2 A 1 V1
W= = ...(1.17)
v2 v1
where W is the mass flow rate.
Combining the foregoing equations and manipulating, we get the relation for flow of
ideal gases.
2 gK P1 (P2 /P1 ) 2 / K − (P2 /P1 ) (K +1) / K

W = A1β2 . . ...(1.18)
K − 1 v1 1 − β 4 (P2 /P1 ) 2 / K
Manometer, however, measures (P1 – P2) and not P2/P1, therefore, it is necessary to
convert the equation (1.18) such that W is a function of (P1 – P2). Write P2/P1 = 1 – x such that
x = 1 – (P2/P1). In general, for gas flow P2/P1 is very close to unity such that x is very close to
zero.
Hence, (P2/P1)2/K ≅ 1 – (2/K) x = 1 – (2/K) + (2/K) (P2/P1)
(P2/P1)(K+1/K) ≅ 1 – (K + 1/K) + (K + 1/K) (P2/P1) ...(1.19)
using equation (1.19), equation (1.18) is modified to
2 g (P1 − P2 )
w = CA1β2 ...(1.20)
v1 [1 − β 4 (P2 /P1 )]2 / k
where C is the discharge coefficient.
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For quick calculation an additional parameter known as the rational expansion factor Y
is defined as
Compressible flow rate (mass)
Y=
Incompressible flow rate (mass)
By determining the mass flow rate for incompressible fluids and multiplying with Y,
flow rate for compressible fluids can be found out and Y can be easily shown as
1 − β4 K (P2 /P1 ) 2 / K 1 − (P2 /P1 ) ( K – 1)/ K

Y= . . ...(1.21)
1 − β 4 (P2 /P1 ) 2 / K K −1 1 − (P2 /P1 )
Instead of calculating Y from the equation (1.21) empirical relations are suggested which
give good results for limited (P2/P1) values, such as 0.8 ≤ 1.0.
Y = 1 – [0.41 + 0.35β4] (P1 – P2/KP1) ...(1.22)
When the gas contains moisture, as further correction is required to account correctly
for the density of the vapour.
Pv {(S v /S) − 1}
M=1+ ...(1.23)
P
where Pv = Vapour pressure (abs)
Sv = Vapour specific gravity referred to air at the same pressure and temperature
S = Specific gravity of the gas
P = Pressure of the gas.
The specific volume of the gas may be found from
yRT
V= ...(1.24)
P
where y = compressibility factor
R = gas constant
The flow equation for gases is
vb 2 gM 1 (ρ m − ρ f ) h
Q = KA2Y ...(1.25)
Mb v1
where vb = Specific volume of gas at base condition
v1 = specific volume of gas at upstream conditions
M1 = Moisture factor at upstream conditions
Mb = Moisture factor at base conditions.
1.4.2 Orifice Flow Meter
An Orifice flow meter is the most common head type flow measuring device. An orifice
plate is inserted in the pipeline and the differential pressure across it is measured.
1.4.2.1 Principle of Operation
The orifice plate inserted in the pipeline causes an increase in flow velocity and a corre-
sponding decrease in pressure. The flow pattern shows an effective decrease in cross section
beyond the orifice plate, with a maximum velocity and minimum pressure at the venacontracta.
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The flow pattern and the sharp leading edge of the orifice plate (Fig. 1.3) which pro-
duces it are of major importance. The sharp edge results in an almost pure line contact be-
tween the plate and the effective flow, with the negligible fluid-to-metal friction drag at the
boundary.
Fig. 1.3 Flow pattern with orifice plate
1.4.2.2 Types of Orifice Plates

The simplest form of orifice plate consists of a thin metal sheet, having in it a square
edged or a sharp edged or round edged circular hole.
There are three types of orifice plates namely
1. Concentric
2. Eccentric and
3. Segmental type.
Fig. 1.4 shows two different views of the three types of Orifice plates.
(a) Concentric (b) Eccentric (c) Segmental
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(a) Concentric (b) Eccentric (c) Segmental
Fig. 1.4 Sketch of orifices of different types
The concentric type is used for clean fluids. In metering dirty fluids, slurries and fluids
containing solids, eccentric or segmental type is used in such a way that its lower edge coin-
cides with the inside bottom of the pipe. This allows the solids to flow through without any
obstruction. The orifice plate is inserted into the main pipeline between adjacent flanges, the
outside diameters of the plate being turned to fit within the flange bolts. The flanges are either
screwed or welded to the pipes.
1.4.2.3 Machining Methods of Orifices
Machining of the orifice plate depends on its specific use. Three types shown in Fig. 1.5
explains the machining methods.
α d D
F
t
Type-1 Type-2 Type-3
Fig. 1.5 Machining Methods of Orifices
Types 1 and 2 are very commonly used and F is known as the plater. These two are
easier to manufacture and are easily reproducible while type 3 is not. Thickness t as chosen to
withstand the buckling forces. Type 1 has also reduced pressure losses. Type 3, known as the
quadrant edged orifice, is used for more viscous fluids where corrections for low Reynolds
number and viscosity are necessary.
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1.4.2.4 Materials Chosen For Orifices

The material chosen for orifice plate is of any rigid material of non-rusting and non-
corrodible. It is vital that the material should not corrode in the fluid being metered. Other-
wise the edge of the orifice will get damaged to a sufficient extend to interfere with the charac-
ter of the flow and the accuracy of the measurement. We should choose a material whose
coefficient of Thermal expansion is known. The common materials used are Stainless steel,
Monel, Phosphor bronze, Glass, Ceramics, Plastics, Brass, Copper, Aluminium and Tantalum.
1.4.2.5 Position of Taps in Orifice
The area of the fluid stream continues to contract after the stream has left the orifice
and it has a minimum diameter at the venacontracta. The pressure of the fluid therefore
continue to fall after leaving the orifice.
There is a slight fall in pressure in the approach section and the static pressure is at a
minimum about one pipe diameter before the orifice plate. The pressure of the fluid then rises
near the face of the orifice. There is then a sudden fall of pressure as the fluid passes through
the orifice, but the minimum pressure is not attained until the venacontracta is reached.
Beyond the venacontracta, there is a rapid recovery in the static pressure.
Owing to friction and dissipation of energy in turbulence, the maximum downstream
pressure is always lesser than the upstream pressure. The pressure loss so caused depends
upon the differential pressure and increases as the orifice ratio decreases for a given rate of
flow.
The differential pressure obtained with an orifice plate will also depend upon the position
of the pressure taps. The points to be observed while locating the taps are :
(a) they are in the same position relative to the plane of the orifice for all pipe sizes.
(b) the tap is located at a position for which the slope of the pressure profile is at least,
so that slight errors in tap position will have less effort on the value of the observed pressure.
(c) the tap location in the installation is identical with that used in evaluation of the
coefficients on which the calculation is based.
Fig. 1.6 shows the location of Pressure taps with Orifice plate.
+ – + + –
–
Diagram of standard orifice Diagram of standard orifice Diagram of orifice plate with
plate with annular chambers plate with single taps pressure taps similar to
standard type
Fig. 1.6 Location of Pressure taps with Orifice plate
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There are five common locations for the differential pressure taps :
(i) Flange taps
(ii) Venacontracta taps
(iii) Radius taps
(iv) Full flow or pipe taps and
(v) Corner taps.
(i) Flange taps. They are predominantly used for pipe sizes 50 mm and larger and the
centerlines are 25 mm from the orifice plate surface. They cannot be used for pipe size of less
than 35 mm diameter. Since the venacontracta may be closer than 25 mm from the orifice
plate.
(ii) Venacontracta taps. These taps use an upstream tap located one pipe diameter
upstream of the orifice plate, and a downstream tap located at the point of minimum pressure.
Venacontracta taps normally limited to pipe size 150 mm or large depending upon the flange
rating and dimensions.
(iii) Radius taps. d1 = D and d2 = 1/2 D. These are similar to venacontracta taps except
that downstream tap is located at one half pipe diameter. These are generally considered
superior to the venacontracta tap because they simplify the pressure tap location dimensions
and do not vary with changes in orifice β ratio.
(iv) Pipe taps. Pipe taps are located 2.5 pipe diameters upstream (d1 = 2.5D) and 8
diameters downstream (d2 = 8D) from the orifice plate. Because of the distance from the ori-
fice, exact location is not critical, but the effects of pipe roughness, dimensional inconsistencies
and so on are more severe.
(v) Corner taps. These taps are similar in many respects to flange taps, except that
the pressure is measured at the ‘Corner’ between the orifice plate and the pipe wall. These are
used for diameters of less than 50 mm.
1.4.3 Venturi Tubes
Venturi tubes are differential pressure producers, based on Bernoulli’s Theorem. General per-
formance and calculations are similar to those for orifice plates. In these devices, there is a
continuous contact between the fluid flow and the surface of the primary device.
1.4.3.1 Classic Venturi Construction : [Long Form Venturi]
The classic Herchel Venturi tube is given in Fig. 1.7.
It consists of a cylindrical inlet section equal to the pipe diameter ; a converging conical
section in which the cross sectional area decreases causing the velocity to increase with a
corresponding increase in the velocity head and a decrease in the pressure head ; a cylindrical
throat section where the velocity is constant so that the decreased pressure head can be meas-
ured ; and a diverging recovery cone where the velocity decreases and almost all of the original
pressure head is recovered. The unrecovered pressure head is commonly called as head loss.
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Convergent
Cylindrical entrance Throat
inlet
Divergent outlet
Annular chambers
Classic Herschel venturi with annular pressure chambers
Fig. 1.7 Classic Long form Venturi
The classic venturi is always manufactured with a cast iron body and a bronze or stain-
less steel throat section. At the midpoint of the throat, 6 to 8 pressure taps connect the throat
to an annular chamber so the throat pressure is averaged. The cross sectional area of the
chamber is 1.5 times the cross sectional area of the taps. Since there is no movement of fluid in
the annular chamber, the pressure sensed is strictly static pressure. Usually 4 taps from the
external surface of the venturi into the annular chamber are made. These are offset from the
internal pressure taps. It is through these taps that throat pressure is measured.
Limitations
This flow meter is limited to use on clean, non-corrosive liquids and gases, because it is
impossible to clean out or flush out the pressure taps if they clog up with dirt or debris.
1.4.3.2 Short Form Venturi Tubes
In an effort to reduce costs and laying length, manufactures developed a second genera-
tion, or short-form venturi tubes shown in Fig. 1.8.
High pressure tap

Low pressure tap
Throat
Inlet Outlet
Inlet cone cone
Short-form venturi tube
Fig. 1.8 Short form Venturi

There were two major differences in this design. The internal annular chamber was
replaced by a single pressure tap or in some cases an external pressure averaging chamber,
and the recovery cone angle was increased from 7 degrees to 21 degrees. The short form venturi
tubes can be manufactured from cast iron or welded from a variety of materials compatible
with the application.
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The pressure taps are located one-quarter to one-half pipe diameter upstream of the
inlet cone and at the middle of the throat section. A piezometer ring is sometimes used for
differential pressure measurement. This consists of several holes in the plane of the tap loca-
tions. Each set of holes is connected together in an annular ring to give an average pressure.
Venturis with piezometer connections are unsuitable for use with purge systems used
for slurries and dirty fluids since the purging fluid tends to short circuit to the nearest tap
holes. Piezometer connections are normally used only on very large tubes or where the most
accurate average pressure is desired to compensate for variations in the hydraulic profile of
the flowing fluid. Therefore, when it is necessary to meter dirty fluids and use piezometer
taps, sealed sensors which mount flush with the pipe and throat inside wall should be used.
Single pressure tap venturis can be purged in the normal manner when used with dirty
fluids. Because the venturi tube has no sudden changes in contour, no sharp corners, and no
projections, it is often used to measure slurries and dirty fluids which tend to build up on or
clog of the primary devices.
1.4.3.3 Types of Venturi Tubes
Venturis are built in several forms. These include
1. a standard long-form or classic venturi tube (Fig. 1.7)
2. a modified short form where the outlet cone is shortened (Fig. 1.8)
3. an eccentric form [Fig. 1.9 (a)] to handle mixed phases or to minimize buildup of
heavy materials and
4. a rectangular form [Fig. 1.9 (b)] used in duct work.
(a) Eccentric type and (b) Rectangular venturi type
Fig. 1.9
1.4.3.4 Installation of Venturi Tubes

A venturi tube may be installed in any position to suit the requirements of the applica-
tion and piping. The only limitation is that with liquids the venturi is always full. In most
cases, the valved pressure taps will follow the same installation guidelines as for orifice plates.
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It is recommended that the use of straightening vanes upstream of the venturi to reduce
the inlet pipe length. The vane installation should have a minimum of 2 diameters upstream
and 2 diameters downstream before entering the venturi. There is no limitation on piping
configuration downstream of the venturi except that a value should be no closer than 2
diameters.
1.4.4 Flow Nozzle
1.4.4.1 Flange Type Flow Nozzle
The Flow nozzle is a smooth, convergent section that discharges the flow parallel to the
axis of the downstream pipe. The downstream end of a nozzle approximates a short tube and
has the diameter of the venacontracta of an orifice of equal capacity. Thus the diameter ratio
for a nozzle is smaller or its flow coefficient is larger. Pressure recovery is better than that of
an orifice. Fig. 1.10 shows a flow nozzle of flange type.
Nipple
threaded
at one end
2½ k min.
D d
k
Weld
Drill pipe after

No burrs welding pipe
Flange type of flow nozzle Details of pressure tap
Fig. 1.10 Flow nozzle
1.4.4.2 Different Designs of Flow Nozzle

There are different standard designs differing in details of the approach section and the
length of the throat. Fig. 1.11 shows two accepted designs of flow nozzles.
Flow nozzles are usually made of gun metals, stainless steel, bronze or monel metal.
They are frequently chromium plated. Sometimes slettite coating is provided to have abrasion
resistance.
The pressure tappings may take the form of annular rings with slots opening into the
main at each side of the flange of the nozzle or of single holes drilled through the flange of the
main close to the nozzle flange.
It is not suitable for metering viscous liquids. It may be installed in an existing main
without great difficulty.
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(a) ASME long–radius flow nozzle
(b) Simplex type tg flow nozzole
Fig. 1.11 (a) The ASME long-radius

(b) The Simplex type tg
1.4.4.3 Advantages
1. Permanent pressure loss lower than that for an orifice plate.
2. It is suitable for fluids containing solids that settle.
3. It is widely accepted for high pressure and temperature steam flow.
1.4.4.4 Disadvantages
1. Cost is higher than orifice plate.
2. It is limited to moderate pipe sizes.
3. It requires more maintenance. (It is necessary to remove a section of pipe to inspect
or install it).
1.4.5 Dall Tube
1.4.5.1 Construction And Working
It is a modified version of venturi tube. It produces large differential pressure with low
pressure less than the conventional venturi tube. The photographic view and schematic sketch
of the dall tube are shown in Fig. 1.12.
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ne
t co
tle
Ou
Throat connection
ne Upstream connection
co
et
Inl
e
ng
Fla
Fig. 1.12 Dall Tube
It consists of a flanged spool piece body with a short, straight inlet section terminating
in an abrupt decrease in diameter or inlet shoulder. This is followed by a conical restriction
and a diverting outlet separated by a narrow annular gap. The high pressure tap is a hole
drilled through the body tangent to the inlet shoulder. The low pressure tap is drilled through
the body so as to connect with an annular slot in the throat. The inlet shoulder immediately
proceeding the restriction has little effect on permanent pressure loss. The outlet cone causes
a decrease in flow velocity that provides an increase in pressure recovery.
It is not suitable for measuring the flow of fluids containing solids which could settle out
in the throat slot. The Dall tube is used for water, sewage, air and steam flow measurement.
The Dall tubes are normally cast in gun metal. But for 450 mm and larger sizes, high grade
cast iron is used. When it is required to protect the tube from corrosion, it may be lithcote
lined.
1.4.5.2 Advantages
1. Low head loss
2. Short lying length
3. It is available in numerous materials of construction.
1. Pressure difference is sensitive to up-stream disturbances.
2. More straight pipe required in the approach pipe length.
3. It is not considered for measuring flow of hot feed water.
1.4.6 Installation of Head Flowmeters
The head flow meter consists of a primary element such as an orifice, venturi, or pitot
tube used with a differential pressure meter to measure the differential head caused by the
flowing fluid at the primary element. The differential pressure meter may be any of the various
meters such as the enlarged leg-mercury manometer, the bell gauge, the hollow gauge, the
diaphragm gauge, the tilting U-type gauge or electronic differential pressure flow transmitters.
The differential-pressure meter and the primary element require careful connection
and installation. It must be remembered that the meter is used for the purpose of measuring
differential pressure. Any extraneous or false head introduced by the connecting piping causes
a serious error.
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1.4.6.1 Pressure Pipe Layout

Pressure piping is the pipe which connects the pipe tapping of the head producers to the
meter or the differential pressure transducers. The important points to be carefully noted in
laying the pressure piping in order to avoid the false readings are :
1. Condensation of water vapour in the case of air or gas, and
2. Air or vapour locks in the case of liquids and steam.
The following rules should be strictly followed in laying the pressure pipe, so as to avoid
the above difficulties.
Meter below the pipe
If the meter or the differential transducer is to be located below the level of the main or
pipe line in which the orifices is installed, the pressure pipe should be laid as follows.
(a) Liquids and Steam
Pressure pipes should fall continuously from orifice to meter at a slope of not less than
1/10 as shown in Fig. 1.13.
If the horizontal distance is too high to allow this slope by direct connection between the
orifice and the meter, then pressure pipes may be first taken below the meter and then risen to
the meter.
Steam or
liquid Orifice
Blow down
Pressure (impulse) cocks
pipe
Air vessels
Root
valves Slope not less
than 1:10
Slope not less

than 1:10
Equalising
valve
Meter of
motor transducer
Fig. 1.13 Pressure connections to meter below orifice for liquids and steam
(b) Air and Gases

The pressure pipe must first be raised above 0.5 m vertically up from the orifice as
illustrated in Fig. 1.14 and then continuously fall at the slope of not less than 1 : 10 to the
meter.
C-8\N-IND\BOOK1-2
r
mete
ar
ne
ifice
Or
Distant or ifice
Blow-off
Fig. 1.14. Pressure connections to meter below orifice for Air and Gases.
Meter above the pipe

(a) Liquids and Steam
It may be noted that the special requirement for steam metering is the necessity of
interposing cooling chambers for the purpose of condensing the steam and providing an ad-
equate volume of water for supplying the meter displacement for all variations of load. With
cooling chambers, the piping remains full of water and the steam does not act on the meter.
In this case, the pipe is first laid vertically downwards to a distance of about 0.5 m in
order to minimise the possibility of entrance of air or gas from the main, and the pipe is raised
continuously at a slope of not less than 1 : 10 to the meter. The meter is fitted with air vessels
as shown in Fig. 1.15
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FLOW 19
Blow-off cocks
Air vessels
+ –
Fig. 1.15 Pressure connections to meter above orifice for liquids and steam
(b) Air and Gases

The impulse pipe is continuously raised at a slope of not less than 1 : 10 from orifice to
meter as shown in Fig. 1.16. The pressure pipes should be fitted with sumps at the lowest
points, and the sumps should be drained at suitable intervals, which is already shown in the
Fig. 1.14.
Dista
nt or if
ice
Orif
ice
nea
r me
ter
Fig. 1.16 Pressure connections to meter above orifice for air and gases
C-8\N-IND\BOOK1-2
1.4.6.2 Installation of condensation Pots

Condensation pots should be used when flow rate of steam is to be measured by means
of differential pressure transmitters. The condensation pots secure smooth column of conden-
sate in both the impulse lines connecting the differential pressure transmitters.
Four types of condensation pots are manufactured to suit the various pressure ranges.
(i) Made of cast iron for pressure upto 16 kg/cm2
(ii) Made of carbon steel for pressure upto 64 kg/cm2
(iii) Made of stainless steel for pressure above 64 kg/cm2 and below 100 kg/cm2.
(iv) Made of molybdenum steel for pressure upto 200 kg/cm2.
In the case of vertical steam mains, it is essential that both the condensation pots placed
at the level of the upper orifice connection. Its installation is illustrated in Fig. 1.17.
Condensation
pots
Removable
plug or
air cock
Approx. 40 mm bore
& 600 mm length
Dirt trap
Orifice
assembly
To meter
To meter
Lagging
Fig. 1.17 Installation of Condensation pots
A leg of large bore is used to convey the pressure from the lower connection to the
appropriate condensation pot. The bore should not be less than 14 mm throughout. If possible,
for obtaining better results, this pipe may be run in contact with the main within the main
lagging.
1.4.6.3 Installation of Sealing Pots
Sealing pot is intended for protecting primary instruments like, pressure gauges, pres-
sure or differential pressure transmitters etc. from the influences of chemically aggressive
medium under measurement.
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FLOW 21
They are also used in the metering of oils or tarry liquids, which are of low viscosity in
the mains due to high temperature ; but owing to atmospheric cooling in pressure pipes these
become viscous and as such make meter sluggish in response.
The sealing pots transmit the orifice pressures to a second and less viscous liquid, the
separating surfaces occurring in parallel bore of the sealing vessels and serving as friction less
pistons. These are usually connected very close to the mains. The sealing liquid must be non-
corrosive and immiscible with the fluid to be metered. It should preferably be of moderately
low viscosity such as transformer oil, spindle oil, kerosene, paraffin oil, glycerine etc.
Fig. 1.18 shows how installation of sealing pot is being made.
+ –
±
Equalising cock
Filling To meter
cock
To meter
Test cock
Sealing
liquid
lighter
than the
Sealing fluid measured
heavier than medium
measured fluid
Fig. 1.18 Installation of Sealing pots
1.4.6.4 Factors to be Considered in Piping Arrangement

The factors for selecting proper piping arrangement are listed below considering only
the important ones :
1. The piping arrangement must be absolutely free of leaks.
2. The connecting lines must be clean and free from obstructions. Use as few fittings
as possible.
3. The connecting lines must pitch a 50 mm to prevent gas packets and drainage.
4. The connecting lines should not be more than 15 m long, preferably less.
5. The connecting lines must be maintained at a temperature between 0 and 50°C.
6. The differential—pressure meter should be installed below the level of the primary
element if possible.
C-8\N-IND\BOOK1-2
7. Drain legs should be installed at the meter when dirt and sediment exist in the
connecting lines.
8. Condenser chambers used for steam lines must be in level.
9. Sealing chambers used for corrosive fluids must be in level and should be vented.
The proper connections for several examples are given in Fig. 1.19
Gas
Steam
Corrosive liquid Corrosive gas

Fig. 1.19 Installation of Orifice Head meters
Fig. 1.19 shows the arrangements for different mediums for accurate measurement. If
the pipe is tapped at the bottom, any solid matter flowing in the line might choke the tap. If the
pipe is tapped at the top, any dissolved gas might escape through the tap and reach the ma-
nometer upsetting the true reading. Generally, recommended taps are at the side of the pipe.
The pipes are arranged so that in case of an eventuality the meter can be removed without
much difficulty. Large chambers containing sealing liquids are mounted in the pipe lines so
that the liquid does not come in contact with the manometric fluid. These chambers are known
as sealing pots, and sealing liquids are chosen such that they do not mix with the process fluid
or the manometric fluid and are unaffected by them. The sealing liquids commonly chosen are
ethylene glycol, glycerin, dibultyl phthalate, chloro naphthalene and chlorinated oils. Gener-
ally the sealing fluid should be heavier than the flowing fluid. The sealing chambers are gen-
erally half filled through filling plugs with visual checks such as gauge glasses.
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FLOW 23
1.4.7 Pitot Tube

An obstruction type primary element used mainly for fluid velocity measurement is the
Pitot tube.
1.4.7.1 Principle
Consider Fig. 1.20 which shows flow around a solid body. When a solid body is held
centrally and stationary in a pipeline with a fluid streaming down, due to the presence of the
body, the fluid while approaching the object starts losing its velocity till directly in front of the
body, where the velocity is zero. This point is known as the stagnation point. As the kinetic
head is lost by the fluid, it gains a static head. By measuring the difference of pressure be-
tween that at normal flow line and that at the stagnation point, the velocity is found out. This
principle is used in pitot tube sensors.
V1, P1 Stagnation point (V 2 = 0)

Pressure P2
Fig. 1.20 Flow around a solid body
The simplest pitot tube consists of a tube with an impact opening of 3.125 mm to 6.35
mm diameter pointing towards the approaching fluid. This measures the stagnation pressure.
An ordinary upstream tap can be used for measuring the line pressure.
Impact pressure port
Static pressure port
Air flow
Fig. 1.21 A common industrial type pitot tube
C-8\N-IND\BOOK1-2
A common industrial type of pitot tube consists of a cylindrical probe inserted into the
air stream, as shown in Fig. 1.21. Fluid flow velocity at the upstream face of the probe is
reduced substantially to zero. Velocity head is converted to impact pressure, which is sensed
through a small hole in the upstream face of the probe. A corresponding small hole in the side
of the probe senses static pressure. A pressure instrument measures the differential pressure,
which is proportional to the square of the stream velocity in the vicinity of the impact pressure
sensing hole. The velocity equation for the pitot tube is given by
v = Cp 2 gh ...(1.26)
where Cp is the pitot tube constant.
Fig. 1.22 shows a typical pitot tube which also shows the taps for sensing static pres-
sure.
Impact pressure connection
Stainless steel tubing

Tubing adaptor
Static pressure holes

outer pipe only
Impact pressure
opening
Fig. 1.22 Typical pitot tube
The total pressure developed at the point where the flow is stagnated is assumed to
occur at the tip of a pitot tube or at a specific point on a bluff body immersed in the stream.
The pitot tube causes practically no pressure loss in the flow stream. It is normally
installed through a nipple in the side of the pipe. It is frequently installed through an isolation
valve, so that it can be moved back and forth across the stream to establish the profile of flow
velocity.
Certain characteristics of pitot tube flow measurement have limited its industrial appli-
cation. For true measurement of flow, it is essential to establish an average value of flow
velocity. To obtain this with a pitot tube, it is necessary to move the tube back and forth across
the stream to establish the velocity at all points and then to take an average.
C-8\N-IND\BOOK1-2
FLOW 25
For high-velocity flow streams, it is required to provide necessary stiffness and strength.
A tube inserted in a high-velocity stream has a tendency to vibrate and get broken. As a result,
pitot tubes are generally used only in low-to-medium flow gas applications where high accu-
racy is not required.
1.4.7.2 Averaging Pitot Tube (Annubar)
To obtain a better average value of flow, special two-chamber flow tubes with several
pressure openings distributed across the stream are available, as shown in Fig. 1.23. These
annular averaging elements are called annubars. They consist of a tube with high- and low-
pressure holes with fixed separations.
High pressure port Low pressure port
Average high pressure = P H PL = Average low pressure
Flow velocity
profile
High Low
pressure profile pressure profile
Average flow ∆P
profile
PH PL
Fig. 1.23 Averaging pitot tube (Annubar)
An annubar flow sensor produces a differential pressure (∆P) signal that is the alge-
braic difference between the average value of the high-pressure signal (Ph) and low-pressure
single (Pl) as shown in the above Fig. 1.23.
A high-pressure profile is produced by the impact of the flow velocity profile on the
upstream side of the sensing tube. Inside the high-pressure chamber, an average high-pres-
sure signal is obtained by correctly placing the sensing ports in the tube. The flow that passes
through the sensor creates a low-pressure profile. This pressure profile is sensed by down-
stream ports directly behind the high-pressure ports. Working on the same principle as the
high-pressure side, an average low pressure signal is produced in the low-pressure chamber.
1.4.7.3 Advantages
1. No pressure loss.
2. It is relatively simple.
3. It is readily adapted for flow measurements made in very large pipes or ducts.
C-8\N-IND\BOOK1-2
1. Poor accuracy.
2. Not suitable for dirty or sticky fluids and fluids containing solid particles.
3. Sensitive to upstream disturbances.
1.4.8 Differential Pressure Transmitters
The high performance differential pressure transmitter can be used to measure liquid,
gas or steam flow. It outputs a 4 to 20 mA DC signal corresponding to the measured differen-
tial pressure.
In the variable head producers, the relationship between the flow rate and the differen-
tial head produced is expressed as
Q∝ h ...(1.27)
As the above relationship is non-linear, it is necessary to make the current of the trans-
mitters as a linear one. For the purpose of linearising the current, the square root extractor,
which may be built-in or externally added, is used.
Fig. 1.24 shows the photographic view of high performance differential pressure
transmitter. Fig. 1.25 shows the differential pressure transmitter with built-in square root
extractor and Fig. 1.26 shows the differential pressure transmitter with external square root
extractor.
Fig. 1.24 High performance differential Pressure transmitter.
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FLOW 27
4-20 mA (linear to flow)

DPT with builtin
Load independent
h square
(250 to 600 Ω)
root extractor
Power supply
Fig. 1.25 Differential Pressure transmitter with built-in square root extractor.
4-20 mA (linear to head)

4-20 mA
DPT with builtin Square
Load independent
h square root
(250 to 600 Ω)
root extractor extractor
Power supply
Fig. 1.26 Differential Pressure transmitter with external square root extractor.
Fig. 1.27 shows the relationship between the power supply voltage and External load
resistance.
Differential pressure transmitters normally require a DC voltage supply of 12 V to 42 V
and connected to various other circuits using two wires only. They are called two wire
transmitters. Sometimes the output signal is passed through a standard resistor, also called a
conditioning resistor, of 250 Ω to convert the 4-20 mA current signal into 1-5V DC voltage
signal. The load independency of such a standard transmitter may vary from 600 Ω to 1500 Ω.
Improved version of such transmitters are called as “Smart transmitters” with computer
compatibility. It has flexibility to meet existing analog and emerging digital requirements. It
offers the familiarity of an analog transmitter with built-in BRAIN or HART (Highway
Addressable Remote Transducer) capability digital smart communication. Remote calibration,
span changing, zero adjustment are also possible.
C-8\N-IND\BOOK1-2
600
E-10.5
R=
0.0236 Digital
communication
External
range
load
resistance
250
R (Ω)
10.5 16.4 24.7 42

Power supply voltage E (VDC)
Fig. 1.27 Relationship between power supply voltage and external load resistance
Though the input signal conditioning circuits are different for different inputs, the main
amplifier, output circuit and communication facilities are same. Hence a transmitter can be
used for universal inputs. When combined with the HART communicator, it permits program-
ming input signals, spans, and parameters through two-way communication.
1.4.9 Quantity Meters
Quantity meters are used for the measurement of low flow rates in industries. These
meters operate by passing the fluid to be measured through the meter in separate and distinct
increments of alternately filling and emptying containers of known capacity. The number of
times the container is filled and emptied gives the quantity of flow.
1.4.9.1 Positive Displacement Meters
Positive displacement type flow meters are generally used for accurate measurement of
steady flow. These flow meters are working under the following principle.
Positive displacement meters split the flow of liquids into separate known volumes based
on the physical dimensions of the meter, and count them or totalize them. They are mechani-
cal meters in that one or more moving parts, located in the flow stream, physically separate
the fluid into increments. Energy to drive these parts is extracted from the flow stream and
shows up as pressure loss between the inlet and the outlet of the meter. The general accuracy
of these meters is dependent upon minimizing clearances between the moving and stationary
parts and maximizing the length of the flowing path. For this reason, accuracy tends to in-
crease as size increases.
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FLOW 29
Positive displacement meters may be divided into following categories :

(i) Nutating disc type.
(ii) Reciprocating piston type.
(iii) Oval gear type and
(iv) Helix type.
1.4.9.1.1 Nutating Disk Type
This meter, also known as disk meter, is used extensively for residential water service.
The moving assembly, which separates the fluid into increments consists of an assembly of a
radially slotted disk with an integral ball bearing and an axial pin. Fig. 1.28 shows the nutating
disk type meter.
Disc
Ball
Inlet Outlet
Fig. 1.28 Nutating disk meter
This part fits into and divides the metering chamber into four volumes, two above the
disk on the inlet side and two below the disk on the outlet side. As the liquid attempts to flow
through the meter, the pressure drop from inlet to outlet causes the disk to wobble or nutate,
and for each cycle to display a volume equal to the volume of the metering chamber minus the
volume of the disk assembly. The end of the axial pin, which moves in a circular motion, drives
a cam that is connected to a gear train and the totalizing register.
Inaccuracy : ± 1 to 2%.
Temperature range : – 150 to 120°C.
Max working pressure : 10 kg/cm2.
1.4.9.1.2 Reciprocating Piston Meter
In the reciprocating piston meter shown schematically in Fig. 1.29, the reciprocating
piston passes the liquid alternately through each end of the cylinder from the inlet to the
outlet and also the slide valve which controls the inlet and outlet ports and operates the coun-
ter. A number of piston operations on a center crank are generally incorporated in this type of
meter. For low flow, the differential pressure is small, for which large diameter pistons and
C-8\N-IND\BOOK1-2
small piston strokes are chosen with minimum of friction. Accuracy of this flow meter is within
0.5%.
Outlet
Piston
Slide valve
Inlet
Fig. 1.29 Operating Principle of the Piston meter
1.4.9.1.3 Oval—Gear Flow Meters

A special variety of the rotating tube flow meter is the oval – geared metering elements.
These oval-geared meters are generally used on very viscous liquid, which is difficult to meas-
ure using other flow meters. In this design, as shown in Fig. 1.30, a precise volume of liquid is
captured by the gap formed between housing and the gear.
Fig. 1.30 Oval-gear flow meter
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FLOW 31
To explain the operation in detail, let us consider the Fig. 1.31.
Trapped
liquid
A
A A
B B
B
Trapped
Position A Position B liquid Position C
Fig. 1.31 Working principle of Oval-gear flow meter
In position A, uniform forces are applied equally on the top and bottom of oval gear B, so
that the gear does not rotate. Rotor A has entrapped a known volume of liquid between the
rotor and the meter body, and there is a balanced force on the bottom of the gear. However,
there is a force on the bottom of gear A, causing it to rotate clockwise (CW). This causes gear B
to rotate in a counter clock wise (CCW) direction to position B.
In position B, fluid enters the space between gear B and the meter body, as the fluid
that was entrapped between gear A and the body simultaneously leave the area of entrap-
ment. The higher upstream pressure oppose the lower downstream pressure at the ends of
gear A and gear B, which makes gear A and gear B continue to rotate in CW and CCW direc-
tions respectively, to position C.
In position C, a known amount of fluid has been entrapped between gear B and the
meter body. This operation is then repeated, with each revolution of the gears representing
the passage of four times the amount of fluid that fills the space between the gear and the
meter body. Therefore, the fluid flow is directly proportional to the rotational velocity of the
gears.
If slippage between the oval-gears and the housing is small, and the flow rate and vis-
cosity are high, these flow meters can provide high accuracies. (0.1%).
These flow meters are available in the sizes suitable for 6 mm to 400 mm diameters
pipelines. Their materials of construction include brass, carbon steel, and 316 stainless steel.
Operating pressures are available up to 100 kg/cm2 and temperatures up to 300°C.
1.4.9.1.4 Helix Type Flow Meters
The Helix flow meter is a positive displacement device utilizing two uniquely nested,
radically pitched helical rotors as the measuring elements. Close machining tolerances ensure
minimum slippage and thus high accuracy. Fig. 1.32 illustrates the photographic view of a
helix type flow meter.
C-8\N-IND\BOOK1-2
Fig. 1.32 Viscous Helix flow meter
1.4.10 Inferential Flow Meters

In the inferential type of flow metering techniques, the out quantity flow rate is inferred
from a characteristic effect of a related phenomenon. Turbine flow meters, variable area flow
meters and target flow meters are some of the types of inferential flow meters.
1.4.10.1 Turbine Flow Meters
Principle
The turbine flow meter is mainly used for the purpose of measurement of liquid and gas
at very low flow rates. A simple turbine flow meter shown in Fig. 1.33, provides a frequency
Magnetic pickup coil Pulses to

amplifier
Magnetic blade tip
Flow
Rotor
Fig. 1.33 A simple Turbine Flow meter
C-8\N-IND\BOOK1-2
FLOW 33
output signal that varies linearly with volumetric flow rate over specified flow ranges. The
entire fluid to be measured enters the flow meter, then passes through a rotor. The fluid
passing through the rotor causes it to turn with an angular velocity that is proportional to the
fluid linear velocity. Therefore, the volumetric flow rate is linear within the given limits of
flow rate.
Let us consider a typical Turbine flow meter shown in Fig. 1.34, which consists of a
multibladed rotor (turbine wheel) which is mounted at right angles to the axis of the flowing
fluid. The rotor is supported by ball or sleeve bearings on a shaft which is retained in the flow
meter housing by a shaft-support. The rotor is rotating freely about its axis.
Pick-up coil
Alnico magnet
Fig. 1.34 Turbine Flow meter
Working
The flowing fluid impinges on the blades of turbine (rotor), imparting a force to the
blade surface which causes the rotation of the rotor. At a steady rotational speed, the speed of
the rotor is directly proportional to the fluid velocity, and hence to volumetric flow rate. The
speed of rotation is monitored in most of the meters by a magnetic pick-up coil, which is fitted
to the outside of the meter housing. The magnetic pick-up coil consists of a permanent magnet
with coil windings which is mounted in close proximity to the rotor but external to the fluid
channel. As each rotor blade passes the magnetic pick-up coil, it generates a voltage pulse
which is a measure of the flow rate, and the total number of pulses give a measure of the total
flow. By digital techniques, the electrical voltage pulses can be totalled, differenced and ma-
nipulated so that a zero error characteristic of digital handling is provided from the electrical
pulse generator to the fluid readout.
C-8\N-IND\BOOK1-2
The number of pulses generated is given as

Tp f
np = ...(1.28)
Q
where np = pulses per volume unit
Tp = time constant in minutes
Q = Volumetric flow rate
f = frequency in Hz.
The turbine meters are available in sizes ranging from 6.35 mm to 650 mm and liquid
flow ranges from 100 cubic centimeter to over 50 cubic meters.
Advantages
1. Better Accuracy [± 0.25% to ± 0.5%].
2. It provides excellent repeatability [± 0.25% to ± 0.02%] and rangeability (10 : 1 and
20 : 1).
3. It has fairly low pressure drop.
4. It is easy to install and maintain.
5. It has good temperature and pressure ratings.
6. It can be compensated for viscosity variation.
Disadvantages
1. High cost.
2. It has limited use for slurry applications.
3. It is not suitable for non-lubricating fluids.
4. They cannot maintain its original calibration over a very long period and therefore
periodical recalibration is necessary.
5. They are sensitive to changes in the viscosity of the liquid passing through the meters.
6. They are sensitive to flow disturbances.
7. Due to high bearing friction is possible in small meters, they are not preferred well
for low flowrates.
Applications
The turbine meters are widely used for military applications. They are particularly use-
ful in blending systems for the petroleum industry. They are effective in aerospace and air
borne applications for energy-fuel and cryogenic flow measurements.
1.4.10.2 Variable Area Flow Meters
Basic Principle
In the orifice meter, there is a fixed aperture and flow is indicated by a drop in differen-
tial pressure. In area meter, there is a variable orifice and the pressure drop is relatively
constant. Thus, in the area meter, flow is indicated as a function of the area of the annular
C-8\N-IND\BOOK1-2
FLOW 35
opening through which the fluid must pass. This area is generally readout as the position of a
float or obstruction in the orifice.
The effective annular area in area meter is nearly proportional to height of the float,
plummet or piston, in the body and relationship between the height of float and flow rate is
approximately linear one with linear flow curve as well as scale graduations.
Types of Variable Area Flow Meters
Area meters are of two general types :
1. Rotameters and
2. Piston type meter.
Rotameters. In this meter, a weighted float or plummet contained in an upright ta-
pered tube, is lifted to the position of equilibrium between the downward force of the plummet
and the upward force of the fluid in addition to the buoyancy effect of the fluid flowing past the
float through the annular orifice. The flow rate can be read by observing the position of the
float.
Piston Type Meter. In this meter, a piston is accurately fitted inside a sleeve and is
lifted by fluid pressure until sufficient post area in the sleeve is uncovered to permit the pas-
sage of the flow. The flow is indicated by the position of the piston.
Fig. 1.35 shows the types of Variable area flow meter (a) Rotameter and (b) Piston Type
meter.
(a) (b)
Fig. 1.35 Types of Variable area flow meter (a) Rotameter (b) Piston Type meter
C-8\N-IND\BOOK1-2
Performance Characteristics
1. Linearity. The flow rate (volume) through a variable area meter is essentially pro-
portional to the area and, as a result, most of these meters have essentially equal-scale incre-
ments. A typical indicating rotameters scale is non linear by about 5%.
2. Differential. An important characteristic of the variable area meter is that the pres-
sure loss across the float is a constant. The overall differential across the meter will increase at
higher flow rates because of friction losses through the fittings.
3. Accuracy. The most common accuracy is ±2% of full scale reading. This increases
considerably with individual calibration and scale length. Repeatability is excellent.
4. Capacity. Variable area flow meters are the most commonly used means for measur-
ing low-flow rates. Full scale capacities range from 0.5 cm3/min of water and 30 std cm3/min of
air in the smallest units to over 1200 litres/min of water and 1700 m3/h of air in 8 cm height
meters.
5. Minimum Piping Requirement. An area meter usually can be installed without
regard to the fittings or lengths of straight pipe proceedings or following the meter.
6. Corrosive or Difficult to handle liquid. These can often be handled successfully
in an area meter. They include such materials as oil, tar, refrigerants, sulphuric acid, black
liquor, beverages, aqua regia and molten sulphur. In general, if the nature of the fluid does not
permit the use of a conventional differential pressure type meter because the fluid is dirty,
viscous or corrosive, certain area meters have an advantage over other types of meters.
7. Pressure Drop. By placing very light floats in over sized meters, flow rates can be
handled with a combination of very low pressure loss (often 2.5 cm of water column or less) and
10 : 1 flow range.
Basic Equations
The following flow equations are developed based primarily on liquids. However, the
resultant working equations can be used equally well on gas service.
The variable area meter shown in Fig. 1.36 consists of a tapered metering tube and a
float which is free to move up and down within the tube. The metering tube is mounted verti-
cally with the small end at the bottom. The fluid to be measured enters at the bottom of the
tube, passes upward around the float, and out at the top.
When there is no flow through the meter, the float rests at the bottom of the metering
tube where the maximum diameter of the float is approximately the same as the bore of the
tube. When fluid enters the metering tube, the buoyant effect of the fluid lightens the float,
but it has a greater density than the liquid and the buoyant effect is not sufficient to raise it.
There is a small annular opening between the float and the tube. The pressure drop across the
float increases and raises the float to increase the area between the float and tube until the
upward hydraulic forces acting on it are balanced by its weight less buoyant force. The meter-
ing float is ‘floating’ in the fluid stream. The float moves up and down in the tube in proportion
to the fluid flow rate and the annular area between the float and the tube. It reaches a stable
position in the tube when the forces are in equilibrium.
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FLOW 37
Glass tube
Guide wire
Float
I Sharp edge creates

uniform turbulence
Spherical at both high and
low Reynolds numbers
Viscosity-insensitive
Float shapes
Fig. 1.36 Fundamental operation of a variable area flow meter
With upward movement of the float towards the larger end of the tapered tube, the
annular opening between the tube and the float increases. As the area increases, the pressure
differential across the float decreases. The float assumes a position, in dynamic equilibrium,
when the pressure differential across the float plus the buoyancy effect balances the weight of
the float. Any further increase in flow rate causes the float to rise higher in the tube ; a de-
crease in flow causes the float to drop at a lower position. Every float position corresponds to
one particular flow rate and no other for a fluid of a given density and viscosity. It is merely
necessary to provide a reading or calibration scale on the tube and flow rate can be determined
by direct observation of the position of the float in the metering tube. Definitions of the terms
in the following analysis are written reference to Fig. 1.36. According to Bernoulli’s theorem :
V2 – V1 = 2 g ( h1 − h2 ) ...(1.29)
where V1 = velocity of fluid at section-1
V2 = velocity of fluid at section-2
g = acceleration due to gravity
h1 = hydraulic head at section-1
h2 = hydraulic head at section-2
The hydraulic head drop is expressed in terms of pressure drop as
h1 − h2
= P1 – P2 ...(1.30)
ρ
where P1 = Pressure at section-1
P2 = Pressure at section-2
ρ = specific weight of fluid
The continuity of flow equation may be written as
Q = A2V2ρ ...(1.31)
C-8\N-IND\BOOK1-3
where Q = Flow
A2 = Area at section-2
To allow for factors not included in this analysis, however, a factor Cd, called the coefficient
of discharge, is introduced. Then Equation (1.31) becomes
Q = CdA2V2ρ ...(1.32)
Neglecting V1 in Equation (1.29) and combining Equation (1.29) and (1.32), the expression
becomes
Q = CdA2 2 gγ (P1 − P2 ) ...(1.32A)
Dropping V1 from Equation (1.29) is justified on the basis that the area A1 >> A2, causing
V1 << V2.
To express the flow in volumetric units, since q = Q/γ, Equation (1.33) becomes
2 g (P1 − P2 )
q = CdA2 ...(1.32B)
ρ
where q = flow in volumetric unit.
From the force equation at equilibrium condition,
P1[πDf2/4] + Vf ρ = P2 [πDf2/4] + Vf ρf ...(1.33)
where Df and ρf are the diameter and density of float
from the equation (1.33), P1 – P2 = Vf (ρf – ρ) [4/πDf2] ...(1.33A)
by substituting P1 – P2, flow q can be calculated as
D p2 − D f 2 π gV f (ρ f − ρ) LM3 π
(D p 2 – D f 2
OP
q = Cd
Df 2ρ N A2 =
4 Q ...(1.37)
Rotameter-Elements
The term “Rotameter” was derived from the fact that floats originally were produced
with slots to give them rotation for the purpose of centering and stabilizing the float.
The essential elements of any rotameter are listed as follows. In addition to suitable
inlet and outlet connections, they comprise (1) a metering tube and (2) a float.
1. Metering Tubes. In modern practice, they are formed on a mandrel and annealed to
prevent internal stresses so that strong, uniform tubes result. This method also permit the
forming of tubes with greater reproducibility and interchangeability and forming special shapes,
such as non conical tubes with curved elements designed to spread out the graduations at the
lower end of the range. It is possible to modify the conical form slightly in order to give the
exact linear relationship between aperture and float position which is not quite achieved with
a purely conical tube.
The most important special shape is a modified conical section having internal beading
or lands which serve to guide the float. Fig. 1.37 shows some types of glass rotameter tubes
with ribs or beads for float guides.
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FLOW 39
Float
Top of
tube
Bottom of
tube
Beads or ribs Flats Flutes

Fig. 1.37 Several types of glass rotameter tubes with ribs or beads for float guides
2. Floats. Floats can be made from several materials to obtain corrosion resistance or
capacity modification. Ratings are generally in terms of meter capacity, using a stainless steel
float. It has been found that the float shape determines to a large extend of how much a
rotameter will be influenced by changes in the viscosity of the measured fluid. Floats having
sharp edges have been found to be relatively insensitive to viscosity changes over a consider-
able viscosity range. Some typical float shapes are shown in Fig. 1.38.
Fig. 1.38 Partial representation of typical rotameter float shapes
Advantages
1. Low cost.
2. Low pressure drop.
3. Rangeability is better.
4. It is suitable for small flow rates.
5. It is easily equipped with alarms and switches or any transmitting devices.
6. It also measures the flow rate of corrosive fluids.
7. There is an availability of viscosity-immune floats.
8. It can be used in some light slurry services.
Disadvantages
1. It is difficult to handle the glass tube type.
2. It must be mounted vertically.
3. It is not suitable for pulsating services.
C-8\N-IND\BOOK1-3
4. Generally it is limited to small pipe services.

5. It is limited to low temperatures.
6. Accuracy is = ± 1/2 to 10%.
7. It requires in-line mounting.
1.4.10.3 Target Flow Meters
Principle of Working. Material buildup in front of orifice plates can cause both meas-
urement errors and plugging when the process stream is a liquid slurry or a gas carrying wet
solids. The annular orifice, which is illustrated in Fig. 1.39 was introduced to solve this prob-
lem by providing an annular opening for the solids to pass through. Target flow meters are
similar in design except that the pressure taps have also been eliminated and the detection of
differential pressure been replaced by force measurement. Both of these designs are suited for
dirty or low turbulence flow metering applications, if high precision is not required.
Spiders Pressure taps Supporting

spider
D d
Spiders t
Flow Pressure Annular
measuring orifice space
holes
Fig. 1.39 Annular orifice plate installation
Construction. The target meter combines in a single unit an annular orifice and a
force-balance transducer. Output is either an electric or pneumatic signal proportional to the
square of the flow. Target meters are available in sizes from 1/2 to 8 inch pipe diameter. The
annular orifice is formed by a circular disk supported in the center of a tubular section having
the same diameter. Flow through the open ring between disk and tube develops a force on the
disk proportional to velocity head (the square of the flow). The disk is mounted on a rod pass-
ing out through a flexible seal. The force on the disk is measured from the rod outside the seal,
using a standard force-balance transducer integrally mounted on the flow tube.
Applications. The target meter is applied in a number of fields for measurement of
liquids, vapours and gases. It allows unimpeded flow of condensates and extraneous material
along the bottom of a pipe and at the same time allows unimpeded flow of gas or vapour along
the top of the pipe.
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FLOW 41
Operating temperature range : 300° C.

Operating pressures : 15 kg/cm2.
Targets with diameters of 0.6, 0.7 and 0.8 times tube diameter are available. Overall
accuracy of calibrated target meters is better than that of orifice-type systems.
1.4.11. Mass Flow Meters
The knowledge of mass flow rates is necessary in combustion fuel control, in reactor
recipe formulations and in many other applications, from mining and dredging to food, pulp
and paper, pharmaceuticals and the chemical industry.
1.4.11.1 Angular-Momentum-Type Mass Flow Meters
The principle of angular momentum can be described by referring to Newton’s second
law of the angular motion and the definition of angular momentum, using the following nota-
tion :
H = angular momentum
I = moment of inertia
ω = angular velocity
α = angular acceleration
T = torque
r = radius of gyration
m = mass
t = time
Newton’s second law of angular motion states that
T = Iα ...(1.35)
and defines that H = Iω ...(1.36)
But, Since by definition I = mr2 ...(1.37)
Now equation (1.35) becomes T = mr2α ...(1.38)
and equation (1.36) becomes H = mr2ω ...(1.39)
Since α = ω/t ...(1.40)
equation (1.38) becomes T = m/t r2ω ...(1.41)
Solving for mass flow rate, m/t, we get
m/t = T/r2ω ...(1.42)
Also, dividing both sides of equation (1.39) by t
H/t = m/t r2ω ...(1.43)
Since torque is in terms of force, the right-hand side of equation (1.42) must be multi-
plied by g (9.8 m/sec2) to obtain a dimensionally correct equation. Therefore, since r2 is a con-
stant for any given system, the flow of fluid can be determined if an angular momentum is
introduced into the fluid stream and measurements are made of the torque produced by this
angular momentum and of the fluid’s angular velocity.
C-8\N-IND\BOOK1-3
1.4.11.2 Constant-Torque-Hysteresis Clutch

Another angular-momentum type mass flow meter eliminates the necessity of making a
torque measurement after imparting a constant torque to the fluid stream. The relationship
between mass flow and torque is
m T
= 2 ...(1.44)
t r ω
Therefore, if T is held at a constant value, and since r2 is a physical constant of any
given system,
m k
= ...(1.45)
t ω
This relationship is used in designing a mass flow meter as follows : A synchronous
motor is placed in the center of the flow meter assembly. This motor is magnetically coupled to
an impeller which is located within the flowing process stream. The magnetic coupling be-
tween the motor and the impeller is provided by means of a hysteresis clutch which transmits
a constant torque from the motor to the impeller. Thus, a measurement of the rotational speed
of the impeller is inversely proportional to the mass flow rate.
1.4.11.3 Impeller-Turbine Mass Flow Meters
Fig. 1.40 shows an impeller turbine mass flow meter.
Turbine Signal
generator
Impeller
Fluid
path
Restraining
spring
Housing
Fig. 1.40 Impeller turbine mass flow meter
The impeller, turbine-type mass flow meter uses two rotating elements in the fluid
stream, an impeller and a turbine. Both elements contain channels through which the fluid
flows. The impeller is driven at a constant speed by a synchronous motor through a magnetic
coupling and imparts an angular velocity to the fluid as it flows through the meter. The turbine
located downstream of the impeller removes all angular momentum from the fluid and thus
receives a torque proportional to the angular momentum. This turbine is restrained by a spring
C-8\N-IND\BOOK1-3
FLOW 43
which deflects through an angle which is proportional to the torque exerted upon it by the
fluid, thus giving a measure of mass flow.
1.4.11.4 Twin-Turbine Mass Flow Meter
Another angular-momentum-type device is the twin turbine mass flow meter. In this
instrument two turbines are mounted on a common shaft.
Fig. 1.41 shows a twin-turbine mass flow meter in which two turbines are connected
with a calibration torsion member. A reluctance type pick up is mounted over each turbine and
a strong magnet is located in each turbine within the twin-turbine assembly.
Pickup 1 Pickup 2
Turbine 1 Turbine 2
Fig. 1.41 Twin-turbine mass flow meter
Each turbine is designed with a different blade angle ; therefore there is a tendency for
the turbines to turn at different angular velocities. However, since the motion of the turbines
is restricted by the coupling torsion member, the entire assembly rotates in unison at some
average velocity, and an angular phase shift is developed between the two turbines. This angle
is a direct function of the angular momentum of the fluid. As was previously shown, angular
momentum is a function of mass flow. In the twin-turbine assembly, the turbines are not
restrained by a spring, but the torsion member which holds them together twisted. Therefore,
the angle developed between the two turbines is a direct function of the twist or torque exerted
by the system.
This angle is measured by a unique method. As each turbine magnet passes its own
pickup coil, the coil generates a pulse. The pulse from the upstream turbine is used to open an
electronic gate, while the pulse from the down-stream turbine closes this gate. An oscillator is
placed in the electronic circuit and the oscillations are counted while gate is opened. The number
of oscillations is thus a function of the angle between the two turbines. Knowledge of the angle
gives the value of torque which, in turn, is proportional to the mass flow rate.
C-8\N-IND\BOOK1-3
1.4.11.5 Gyroscopic Mass Flow Meter

Another angular momentum mass flow meter shown in Fig. 1.42 operates on the princi-
ple of gyroscope. It consists of a pipe shaped in the form of a circle or a square. A motor intro-
duces an oscillating vibration at a constant angular velocity ‘ω’ about the A axis. When the
fluid passes through the loop, a precession-type moment is produced about the B axis and is
measured by the deflection of the sensing element. This deflection can be shown to be directly
proportional to mass flow.
T Flow
Flexible
L coupling
C
ω
A
Fig. 1.42 Gyroscopic Mass Flow meter
The gyroscopic mass flow meter can handle slurries in the medium pressure and tem-
perature ranges but its industrial use is very limited due to its high cost and inability to
handle high flow rates.
1.4.11.6 Coriolis Mass Flow Meter
1.4.11.6.1 Measuring Principle
The measuring principle is based on the controlled generation of Coriolis forces. These
forces are always present when both translational and rotational movements are superim-
posed.
→ → →
Fc = 2 ∆m ( v . ω) ...(1.46)
→
where Fc = Coriolis force
∆m = moved mass
→
ω = angular velocity and
→
v = radial velocity in the rotating or oscillating system.
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FLOW 45
The amplitude of the Coriolis force depends on the moving mass ∆m, its velocity v in the
system and thus on the mass flow. Instead of a constant angular velocity ω, Coriolis sensor
uses oscillation. In another [called promoss F d m] sensors, two parallel measuring tubes con-
taining flowing fluid oscillator in anti phase, acting like a tuning fork. The Coriolis forces
produced at the measuring tubes cause a phase shift in the tube oscillations. This principle is
illustrated in Fig. 1.43.
At zero flow, in other words when the fluid is at a standstill, the two tubes oscillate in
phase (1). Mass flow causes deceleration of the oscillation at the inlet of the tubes (2) and
acceleration at the outlet (3).
The phase difference (A-B) increases with increasing mass flow. Electrodynamic sen-
sors register the tube oscillations at the inlet and outlet.
System balance is ensured by the anti phase oscillation.
A
B
1 2 3
Fig. 1.43 Coriolis principle
The classic Coriolis-type mass flow meter Fig. 1.44 consists of a centrifugal-pump impeller
wheel and a vaned sensing wheel which acts as a turbine wheel to extract the angular momen-
tum imparted to the fluid by the impeller.
Fig. 1.44 Classical Coriolis mass flow meter
1.4.11.6.2 Working
The sensing (or turbine) wheel is contained in the same housing as the impeller and is
attached to the latter by a strain gauge ; the combination is driven at a constant known speed.
The power applied to the impeller is merely that required to overcome the frictional drag of the
system.
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The torque measured is that required to impart to the fluid stream a Coriolis accelera-
tion, and is given by the expression
γ = w (R22 – R12) (m/t) ...(1.47)
where R2, R1 = outer and inner radii.
1.4.11.6.3 Features
1. Balanced dual-type system for universal use in a wide range of process conditions.
2. High vibration immunity.
3. Compact design, occupying very little space.
4. Measurement is independent of fluid properties.
5. Hygienic design in accordance with the latest requirement.
6. Guaranteed product quality.
7. Robust field housing (aluminium or stainless steel).
8. High accuracy.
Liquids : ± 0.15%
Gases : ± 0.50%.
1.4.11.6.4 Advantages
1. It is obstruction less.
2. It is insensitive to viscosity, pressure and temperature.
3. It can handle clean liquids, mixed fluids, multiphase fluids, foams, slurries and liq-
uids with entrained gases.
4. This can be used for fluctuating flows.
1.4.11.7 Thermal Mass Flow Meters
1.4.11.7.1 Types of Thermal Mass Flow Meters
Thermal flow meters can be divided into two categories :
1. Flow meters that measure the rise in temperature of the fluid after a known amount
of heat has been added to it. They can be called heat transfer flow meters.
2. Flow meters that measure the effect of the flowing fluid on a hot body. These instru-
ments are sometimes called hot wire probes or heated-thermopile flow meters.
Both types of flow meters can be used to measure flow rates in terms of mass, a very
desirable measurement, especially on gas service.
1.4.11.7.2 Heat Transfer Flow Meters
The equation of the heat transfer flow meter is based on :
Q = W CP (T2 – T1) ...(1.48)
where Q = Heat transferred (Cal/hr)
W = Mass flow rate of fluid (kg m/hr)
CP = Specific heat of fluid (Cal/kg m °C)
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FLOW 47
T1 = Temperature of the fluid before heat is transformed to it (°C)

T2 = Temperature of the fluid after heat has been transferred to it (°C)
Solving for W, we get
Q
W= ...(1.49)
CP (T2 − T1 )
A simple flow meter based upon this equation is shown schematically in Fig. 1.45.
Heat is added to the fluid stream with an electric immersion heater. The power to the
heater equals the heat transferred to the fluid (Q) and is measured by a Watt meter. T1 and T2
are thermocouples or resistance thermometers. By measuring Q, T1 and T2, the flow rate (W)
can be calculated as specific heat of the fluid (Cp) is known. T1 and T2 do not have to be sepa-
rately detected ; they can be connected together so that the temperature difference (T2 – T1) is
measured directly.
Temperature
difference
indicator
Mass flow
rate
Constant
power
source
Resistance Resistance Resistance
Thermometer Heater Thermometer
Fig. 1.45 Heat transfer flow meter
1.4.11.7.3 Thermal Flow Meter with External Elements and Heater

A flow meter using heat transfer principle described above has many limitations. The
temperature sensors and the heater must protrude into the fluid stream. Thus these compo-
nents (particularly the heater) are easily damaged by corrosion and erosion. Furthermore, the
integrity of the piping is sacrificed by the protrusions into the fluid stream, increasing the
danger of leakage.
To overcome these problems, the heater and the upstream and downstream tempera-
ture sensors can be mounted outside of the piping, which is shown in Fig. 1.46.
C-8\N-IND\BOOK1-3
Flow
Film
Upstream
temperature
sensor
measures Tf Heater
supplies Downstream
Q temperature
sensor
measures Tw
Fig. 1.46 Thermal flow meter with external elements and heater
In this type of construction the heat transfer mechanism becomes more complicated and
the relationship between mass flow and temperature difference becomes non-linear and to
overcome this non-linear relationship, heated tube type is introduced.
1.4.11.7.4 Heated Tube-Type Mass Flow Meter
Fig. 1.47 illustrates the non-linear shift in ∆T in a heated-tube-type flow meter, where
the asymmetricity of the temperature distribution increases with flow.
Heat sink Meter Heat sink
Thermocouples
TC-1 TC-2
Tube
Transformer
Zero
flow
Temperature of tube
Small
flow
TC-1 TC-2
L/2 0 L/2
Length of tube
Fig. 1.47 Heated tube-type mass flow meter
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FLOW 49
In this type of flow meter, when a fluid flows in a pipe, a thin layer (film) exists between
the main body of the fluid and the pipe wall. When heat is passing through the pipe wall to the
fluid, this layer resists the flow of heat. If the heater is sufficiently insulated and if the piping
material is a good conductor, the heat transfer from the heater to the fluid can be expressed as
Q = hA (Tw – Tf) ...(1.50)
where h = film heat transfer coefficient
A = Area of pipe through which heat is passing
Tw = Temperature of wall
Tf = Temperature of fluid.
The film heat transfer coefficient ‘h’ can be defined in terms of fluid properties and tube
dimensions.
These types of flow meters are best suited for the measurement of homogeneous gases
and are not recommended for applications where the process fluid composition or moisture
content is variable. In order for these flow meters to be useful in a system, both the thermal
conductivity and the specific heat of the process fluid must be constant.
1.4.11.7.5 By Pass-Type Designs
In order to make the heat-transfer-type flow meter suitable for the measurement of
larger flow rates, the by pass designs have been introduced which is shown in Fig. 1.48.
The thermal flow meter tubes in these bypass units are small capillary tubes, usually
under 3 mm diameter. Their small size is advantageous in minimizing the electric power re-
quirement and also in increasing their speed of response, but it necessitates the use of up-
stream filters to protect against plugging.
Meter Meter
Laminar flow
element
Bypass Bypass
line orifice
Main
orifice
Lower flowrates Higher flowrates
Fig. 1.48 Bypass-type thermal mass flow meters
1.4.11.7.6 Hot Wire probes

In this design two thermocouples (A and B) are connected in series forming a thermo-
pile. A schematic of this type of flow meter is shown in Fig. 1.49.
This thermopile is heated by passing an alternating current through it. A third thermo-
couple (C) is placed in the direct current output circuit of the thermopile. Alternating current
does not pass through this thermocouple, and it is therefore not electrically heated.
C-8\N-IND\BOOK1-3
Flow tube
A
C
110 V
60 ~
Indicator, recorder
or controller
Fig. 1.49 Hot wire flow-sensing probe
This assembly is inserted into the process fluid (usually gas) stream. The gas cools the
heated thermopile by convection. Since the AC input power to the thermopile is held constant,
the thermopile will attain an equilibrium temperature and produce an emf, that is a function
of the gas temperature, velocity, density, specific heat and thermal conductivity. The third,
unheated thermocouple (C) generates an emf that is proportional to the gas temperature. This
cancels the effect of the ambient gas temperature on the output signal of the heated thermo-
pile. A and B are the heated thermocouples ; C is the unheated one.
The output signal (voltage) of this instrument is given by the equation :
C
e= ...(1.51)
2 (π KC P ρ dv) 1/ 2 + K
where e = Voltage generated
C = instrument constant
K = Thermal conductivity of fluid
CP = Specific heat of fluid
d = diameter of heated thermocouple wire
v = velocity of fluid
ρ = density of the fluid.
Since K is very small, and since the term (KCP ρ)1/2 remains constant over a wide range
of temperatures, this type of instrument can be used to measure the mass flow rate of gases.
1.4.11.8 Volume Flowmeter Plus Density Measurement :
(Radiation-Type Mass Flowmeters) :
One of the earliest methods of mass flow determination was to install two separate
sensors—one to measure the volumetric flow, the other to detect the density of the flowing
stream—and then use the two transmitter signals as inputs into a mass flow computing module.
While feasible, the products of different suppliers and corrections for such process variables as
temperature, pressure, viscosity, particle sizes and velocity profile changes. The introduction
of the density/mass flow systems has made it easier to use this technique.
The key working component in these combination designs is the multiple input trans-
mitter, as illustrated in Fig. 1.50, which in addition to a radiation–type density input also
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FLOW 51
accepts a flow measurement signal from any volumetric flow meter. Based on these two in-
puts, the microprocessor–based transmitter generates an output signal, which relates to mass
flow.
Indicator
Radiation transmitter
type density
sensor
Mass flow
output
Volumetric
flow meter
Fig. 1.50 Combination mass flow system
A further improvement occurred in the design of these density/mass flow systems when
the density and volumetric flow sensors were combined into a single package (Fig. 1.51).
Field
coil
Process
fluid Pipe
Electrode
Electrode
Gamma
source Detector
Magnetic
field Field coil
Fig. 1.51 Mass Flow meter combining a magnetic flow meter and a radiation—type densitometer
in a single unit
These units are usually comprised of a magnetic flow meter and a gamma-radiation-
based densitometer, all in a single unit with a microcomputer. This mass flow unit does not
require compensation for changes in process variables and is installed as a single, obstructionless
mass-flow sensor. Its features and materials of construction are similar to those of a magnetic
flow meter, except that it is bulkier and more expensive, due to incorporation of the radiation-
type densitometer. Because the flow sensor is a magnetic flow meter, the unit is also limited to
being used on process fluids having at least 3.0 µS/cm conductivity.
C-8\N-IND\BOOK1-3
1.5 Electrical Type Flow Meter
1.5.1 Electromagnetic Flow Meter

1.5.1.1 Principle
Electromagnetic flow meters use Faraday’s law of electromagnetic induction for making
a flow measurement. Faraday’s law states that, whenever a conductor of length ‘l’ moves with
a velocity ‘v’ perpendicular to a magnetic field ‘B’, an emf ‘e’ is induced in a mutually perpen-
dicular direction which is given by
e = Blv ...(1.52)
where B = Magnetic flux density (Wb/m2)
l = length of conductor (m)
v = Velocity of the conductor (m/s)
The volume flow rate Q is given by
Q = (πd2/4) v ...(1.53)
where d = diameter of the pipe
v = average velocity of flow (conductor velocity in this case)
From equation (1.52)
v = e/Bl ...(1.54)
Q = πd2e/4Bl
Q = Ke
where K is a meter constant.
Thus the volume flow rate is proportional to the induced emf.
In the electromagnetic meter, the constant magnetic field is generated around the pipe
by magnet and the flowing liquid acts as a conductor. The flowing liquid can be regarded as a
continuous series of discs passing through the magnetic field, the bore of the pipe being di-
rectly proportional to length of the conductor. Thus the emf generated is directly proportional
to the velocity of flow. The complete compensation for variation in the field-strength due to
voltage fluctuation can be had by using a null-balance form of measuring instrument ener-
gised from the same source as the magnet.
The flow tube of the electromagnetic type meter containing the detecting electrodes
supplied as a separate unit with flanged ends which can be bolted into the main pipe into
which liquid flow is to be measured. The flow tube has got the same bore as that of the pipe line
into which meter is to be installed and is insulated from the liquid being metered. The flow
tube bore is protected by an insulated lining of glass or neoprene which also serves to prevent
the short-circuiting of emf through the electrodes. The flow tube should have high electrical
resistivity so that the magnetic flux does not by-pass the metered liquid and also to minimise
the eddy currents.
The electrode potential is detected by two metal electrodes essentially of the point type
made of stainless steel, or platinum where high resistance to corrosion is necessary. These are
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FLOW 53
located diametrically opposite to each other with their surfaces flush with the inside surface of
the lining, so that they do not disturb the flow pattern.
Thus the electro magnet is of the core type and consists of two saddle shaped copper
coils. This flow tube is rigidly located in the air gap and the laminated iron core, for focussing
the magnetic field in a direction at right angles to the flowing liquid, being positioned beneath
the coils. At alternating electric supply is used to energize electro magnet as a.c. supply avoids
polarisation of the electrodes.
Thus the emf across the electrodes will be directly proportional to the velocity of flows of
the metered liquid and it will not be influenced by variations in the specific resistance of the
liquid if there is no current flow through it. For this purpose null balance potentiometer is
used. A simplified circuit is shown in Fig. 1.52.
A.C. supply
Indicator
Electro magnet
Amplifier
Flow tube
Electrode
Transformer
Slide wire Reversable
servo-motor
Mechanical
Electro magnet link
Current transformer
Zero adjustment
Fig. 1.52 Electromagnetic flow meter
For obtaining perfect balance it is essential that the input and feedback signals must be
equal in phase as well as in magnitude. A very small difference in phase can also cause lot of
error as the input signal can be resolved into two components, one in phase with the feedback
and one 90 degrees out of phase. The circuit must be designed to be insensitive to any 90
degrees out of phase signals, which appear due to the self capacity of the transmission line
connected with a high source resistance. Further as the source resistance of an electromag-
netic meter is both large and variable, the 90 degrees out of phase component is not stable and,
therefore, automatic provision to suppress it is desirable. The movement of the slide wire
contact arm is used to drive the indicating/recording instrument.
1.5.1.2 AC and DC Excitation Schemes
In AC type magnetic flow meters a.c. line voltage is applied to the magnetic coils. The
signal generated is a low level AC signal in the high µV to low mV range. A more recent
development is the pulsed DC type magnetic flow meter. In this design, the coils are periodi-
cally energized. There are many forms of excitation in use, but generally they can be catego-
rized into two families : those which use on-off excitation and those which use plus-minus
excitation. In either case, the principle is to take a measurement of the induced voltage when
C-8\N-IND\BOOK1-3
the coils are not energized and to take a second measurement when the coils are energized and
the magnetic field has stabilized. Fig. 1.53 shows some of the types of excitation offered.
Voltage drive Current drive

Half wave Full wave Tri-state Full wave Tri-state
2T
t
Tr
Ts
Fig. 1.53 Types of pulsed DC Coil excitation
In all of the pulsed DC approaches, the concept is to take a measurement when the coils
are excited and store (hold) the information and then take a second measurement of the in-
duced voltage when the coils are not excited. The voltage induced when the coils are energized
is a combination of both noise and signal. The induced voltage when the coils are not energized
is noise only. Subtracting the noise measurement from the signal plus noise yields signal only
which is illustrated in Fig. 1.54.
Flow
signal
S1
Noise
S2
t1 t2 t1
Magnet Magnet
ON OFF
Time
t1 Magnet "ON" signal sampling time During interval t1 :
t2 Magnet "OFF" signal sampling time Signal voltage = S1 + S2
S1 Flow signal During interval t2 :
S2 Noise voltage Signal voltage = S2
Subtracting :
(S1 + S2) – S2 = S1
(Flow signal only)
Fig. 1.54 Plot of the output signal
C-8\N-IND\BOOK1-3
FLOW 55
The pulsed DC-type systems establish zero during each on-off cycle. This occurs several
times every second. Because zero is known, the end result is that pulsed DC systems are
potential percent-of-rate systems.
The AC type systems must be periodically re-zeroed by stopping flow and maintaining a
full pipe in order to zero out any voltage present at that time. The noise voltage can change
with time, resulting in a potential offset. Therefore AC-type systems normally are percent-of-
full scale systems.
1.5.1.3 Dual-Frequency Excitation
Changing the method of excitation from line frequency (AC) to low frequency (DC) pro-
vided dramatic improvements in both the accuracy and the zero stability of electromagnetic
flow meters. A limitation of low frequency (DC) designs is their relatively low speed of re-
sponse (0.2—2 sec) and their sensitivity to measurement noise caused by slurries or low con-
ductivity fluids.
The idea behind dual-frequency excitation is to apply both and thereby benefit from
both of their advantages : The zero stability of low-frequency excitation and the good noise
rejection and high speed of response of high-frequency excitation. This is achieved by exciting
the magnetic field coils by a current with such a compound waveform as illustrated in Fig.
1.55. One component is a low-frequency waveform, much below 50 Hz, which guarantees good
zero stability. The output generated by the low-frequency signal is integrated via a long time
constant to provide a smooth and stable flow signal.
Low frequency
Electrodes sampling Integrating circuit
+ Output
Magnetic Differentiating
flowmeter circuit
Magnet High
coil frequency
Low frequency sampling
Dual frequency
excitation
High frequency
Fig. 1.55 Dual-frequency excitation Design
The high-frequency component is superimposed on the low-frequency signal to provide

immunity to noise caused by low conductivity, viscosity, slurries or electrochemical reactions.
The output generated by a high-frequency component is sampled at a high frequency and is
processed in a differentiating circuit having the same time constant as the integrating circuit.
By adding the two signals, the result is an output that is free of ‘Slurry’ noise and has good zero
stability plus good speed of response.
C-8\N-IND\BOOK1-3
1.5.1.4 Construction of Electromagnetic Flow Meter

Fig. 1.56 is a cutaway view showing
how the principle of electromagnetic induc- Balancing voltage
interconnection Signal interconnection
tion is employed in a practical flow meter. terminal block terminal block
The basic elements of the flow meter are a
Calibration
section of non conducting pipe section such components
as glass-reinforced polyester or a nonmag- Insulating
netic pipe section lined with an appropriate pipe liner
electrical conductor such as Teflon, Kynar,
Fiberglass, Vitreous enamel, rubber, neo-
prene or polyurethane., among others. On
alternate sides of the pipe section are mag-
net coils which produce the magnetic field
perpendicular to the flow of liquid through
the pipe. Mounted in the pipe, but insulated
from it and in contact with the liquid, is a
pair of electrodes which are located at right
angles both to the magnetic field and the Magnet coils
axis of the pipe. Meter electrode
As the liquid passes through the pipe Meter pipe Laminated
section, it also passes through the magnetic section iron core
field setup by the magnet coils inducing a
Fig. 1.56 Cutaway view of Electromagnetic flow meter
voltage in the liquid ; the amplitude of the
voltage is directly proportional to the liquid velocity. This voltage is conducted by the elec-
trodes to a separate converter which in effect is a precision voltmeter capable of accurately
measuring the voltage generated and converting that voltage to the desired control signals.
These may be equivalent electronic analog signals, typically (4-20) mA DC, or a frequency or
scaled pulse output.
1.5.1.5 Limitations of electromagnetic Flow Meters
(i) The substance being measured must be conductive. Therefore, it can’t be employed
for metering the flow rate of gases and steam, petroleum products and similar liquids having
very low conductivity.
(ii) To render the meter insensitive to variations in the resistance of liquid, the effective
resistance of the liquid between the electrodes should not exceed 1% of the impedance of the
external circuit.
(iii) It is a very expensive device.
(iv) As the meter always measures the volume rate, the volume of any suspended matter
in the liquid will be included.
(v) To avoid any trouble which would be caused by entrained air, when the flow tube is
installed in a horizontal pipe-line, the electrodes should be on the horizontal diameter.
C-8\N-IND\BOOK1-3
FLOW 57
(vi) As a zero check on the installation can be performed only by stopping the flow,
isolating valves are required and a bypass may also be necessary through which the flow may
be directed during a zero check.
(vii) The pipe must run full, in case regulating valves are installed upstream of the meter.
1.5.1.6 Advantages of Electromagnetic Flow Meter
(i) The obstruction to the flow is almost nil and therefore this type of meters can be
used for measuring heavy suspensions, including mud, sewage and wood pulp.
(ii) There is no pressure head loss in this type of flow meter other than that of the
length of straight pipe which the meter occupies.
(iii) They are not very much affected by upstream flow disturbances.
(iv) They are practically unaffected by variation in density, viscosity, pressure and tem-
perature.
(v) Electric power requirements can be low (15 or 20 W), particularly with pulsed DC-
types.
(vi) These meters can be used as bidirectional meters.
(vii) The meters are suitable for most acids, bases, water and aqueous solutions because
the lining materials selected are not only good electrical insulators but also are corrosion-
resistant.
(viii) The meters are widely used for slurry services not only because they are obstruction
less but also because some of the liners such as polyurethane, neoprene and rubber have good
abrasion or erosion resistance.
(ix) They are capable of handling extremely low flows.
1.5.1.7 Disadvantages of EM Flow Meter
(i) These meters can be used only for fluids which have reasonable electrical conductivity.
(ii) Accuracy is only in the range of ± 1% over a flow rate range of 5%.
(iii) The size and cost of the field coils and circuitry do not increase in proportion to their
size of pipe bore. Consequently small size meters are bulky and expensive.
1.5.1.8 Applications of EM Flow Meters
This electromagnetic flow meter being non intrusive type, can be used in general for any
fluid which is having a reasonable electrical conductivity above 10 microsiemens/cm. Fluids
like sand water slurry, coal powder, slurry, sewage, wood pulp, chemicals, water other than
distilled water in large pipe lines, hot fluids, high viscous fluids specially in food processing
industries, cryogenic fluids can be metered by the electromagnetic flow meter.
1.5.2 Ultrasonic Flow Meters
1.5.2.1 Introduction
Pressure variations travel through a fluid at the velocity of sound relative to the fluid. If
fluid is in motion with certain velocity, then the absolute velocity of pressure disturbance
propagation is the algebraic sum of the two. The term ‘ultrasonic’ refers to the pressure differ-
ences (usually are short bursts of sine waves) whose frequency is above the range audible to
human hearing which is 20 to 20000 Hz.
C-8\N-IND\BOOK1-4
1.5.2.2. Principle
The ultrasonic flow meter operates on the principle that the velocity of sound in a fluid
in motion is the resultant of the velocity of sound in the fluid at rest plus or minus the velocity
of the fluid itself.
1.5.2.3 Types of Ultrasonic Flow Meters
(i) Transit time flow meters
(ii) Doppler Flow meter.
1.5.2.3.1 Transit Time Flow Meters
As the name implies, these devices measure flow by measuring the time taken for an
ultrasonic energy pulse to traverse a pipe section, both with and against the flow of the liquid
within the pipe. Fig. 1.57 shows a representative transit time flow meter.
Transducer B
Flanged Flanged
end end
V L θ
Transducer A
Fig. 1.57 Transit-time flow meter
The time (tAB) for the ultrasonic energy to go from transducer A to transducer B is given
by the expression :
tAB = L/(C + V. cos θ) ...(1.56)
The time (tBA) to go from B to A is given by
tBA = L/(C – V.cos θ) ...(1.57)
where C is the speed of sound in the fluid
L is the acoustic path length in the fluid
and θ is the angle of the path with respect to the pipe axis.
By combining and simplifying, it can be shown that for V << C :
∆t = tBA – tAB = 2.L.V. cos θ/C2 ...(1.58)
It can be shown that :
V = L.∆t/2 cos θ tA2 = K ∆t/tA2 ...(1.59)
where tA is the average transit time between the transducers.
Since the cross sectional area of the pipe section or ‘spool pipe’ is known, the product of
area and velocity will yield the volumetric flow rate.
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FLOW 59
1.5.2.3.2 Frequency Difference-Type

In this type, the reciprocals of transit times are used. This leads to a frequency differ-
ence (∆f) which is proportional to the flow velocity V. The difference in frequencies is related to
the velocity as follows :
V = ∆f.L/2. cos θ ...(1.60)
The multipulse time shift reflection method uses one or more pulses and times them to
determine the change in range per second to an ensemble of scatters. The change in range per
unit time yields the velocity of scatters.
1.5.2.4. Flow Meter Construction
The ultrasonic flow meter usually consists of an electronic housing, transducers and a
pipe section. A spool piece with integral transducer is one of the most common types of con-
struction and it is shown in Fig. 1.57. The manufacturer mounts the transducers to a flanged
pipe section (spool piece). Usually the unit is calibrated by the manufacturer to meet the user’s
specifications. The spool piece thus becomes an integral part of the hydraulic system so it is
not easily retrofitted into an existing system.
Mounting Mounting
hardware hardware
Alignment
hardware
Existing pipe
Fig. 1.58 External Transducers
Clamp-on transducers are capable of being mounted outside an existing pipe as shown
in Fig. 1.58. This type of system can be calibrated by the manufacturer only if detailed infor-
mation on pipe diameter, pipe wall thickness, process fluid, percent of solids concentration,
process temperature, variations in process temperature etc. are also provided by the custom-
ers. This type of flow meter is easily retrofitted onto an existing system, since no pipe section
needs be installed.
1.5.2.5 Performance
As with most flow meters, the spool piece or pipe section must always be full to assure
proper operation and volumetric flow indication. Most manufacturers will specify the mini-
mum distance from valves, pumps, etc. that will ensure accurate flow meter performance.
Typically 10 to 20 diameters upstream and 5 diameters downstream are required. The flow
C-8\N-IND\BOOK1-4
meter relies upon an ultrasonic signal traversing across the pipe ; therefore, the liquid must be
relatively free of solids and air bubbles. Bubbles in the flow stream generally cause more
attenuation than solids and so the flow meter can tolerate a large percentage of solids than
bubbles.
Depending on the process fluid, proper transducer materials and protection must be
chosen to prevent transducer damage due to chemical action. Process temperature limitations
must also be considered for proper flow meter application.
Accuracy for a simple path flow meter is around 1 to 2% of rate depending upon design,
velocity, pipe size and process. Repeatability is typically about 0.5% depending upon velocity
range and calibration.
To improve performance and accuracy for larger pipe sizes, some suppliers offer flow
meters with two, four or more pairs of transducers arranged to interrogate multiple acoustic
paths. The cost of such units is higher than that of a single path flow meter.
1.5.2.6 Doppler Flow Meters
This type of flow meter is based on Doppler principle. The transmitter of a Doppler flow
meter projects an ultrasonic beam at a frequency of about 0.5 MHz into the flowing stream and
deflects the reflected frequency. The difference between transmitted and reflected velocities is
called the ‘beat frequency’ and is related to the velocity of the reflecting surfaces (solid parti-
cles and gas bubbles) in the process stream.
1.5.2.6.1 Principle of Operation
As shown in Fig. 1.59, an ultrasonic wave is projected at an angle through the pipe wall
into the liquid by a transmitting crystal in a transducer mounted outside the pipe. Part of the
energy is reflected by bubbles or particles in the liquid and is returned through the pipe wall to
a receiving crystal. If the reflectors are travelling at the fluid velocity, the frequency of the
reflected wave is shifted according to the Doppler principle, in proportion to the flow velocity.
θ
CT
Fig. 1.59 Doppler Flow meter Principle of operation
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FLOW 61
Combining Snell’s law and Doppler equation, the flow velocity can be determined as
follows if V << C.
V = ∆f.Ct/(2.fo . cos θ) = ∆f.K ...(1.61)
where ∆f = Difference between transmitted and received frequency.
fo = frequency of transmission
θ = angle of the transmitter and receiver crystal with respect to the pipe axis
Ct = Velocity of sound in the transducer.
As shown in equation (1.61), velocity is a linear function of ∆f. Since the inside diameter
(ID) of the pipe is known, volumetric flow rate can be measured as a function of V and square
of ID
Volumetric flow rate (Q) ∝ V.(ID)2 ...(1.62)
1.5.2.6.2 Construction
In the single transducer design, both the transmitter and receiver crystals are con-
tained in a single transducer assembly which is to be mounted on the pipeline. Alignment of
the crystal is thus controlled by the manufacturer. This approach is shown in Fig. 1.59.
In dual transducer design, the transmitter crystal and the receiver crystal are mounted
separately on opposite sides of the outside of the pipe. Alignment is maintained by a mounting
assembly that maintains the relative positions of the transducers as shown in Fig. 1.60.
Mounting and
alignment
hardware
Fig. 1.60 Two-transducer approach
When the process stream contains large amount of solids and the velocity of the solid
particles near the wall is likely to be less than the average in a single transducer installation
(causing large errors), it is recommended that the two-transducers approach is used. With this
approach the reflected ultrasonic radiation is received from portions of the flow stream.
1.5.2.6.3 Application and Performance
A Doppler unit will indicate velocity in a partially full pipe as long as the transducer is
mounted below the liquid in the pipe.
The minimum pipe distance required from valves, pumps etc. is typically 10 to 20
diameters upstream and 5 diameters downstream for clean fluids. This requirement can increase
with process solids concentration or solids composition.
C-8\N-IND\BOOK1-4
A Doppler flow meter relies upon reflectors in the flow stream to reflect ultrasonic energy.
There is a lower limit for the concentration and size of solids or bubbles in the liquid that will
give reliable, accurate operation. The flow must be fast enough to keep the solids or bubbles in
suspension.
The Doppler flow meters will operate independently of pipe material provided the pipe
is sonically conductive. Such pipes as concrete, clay and very porus cast iron absorb the ultrasonic
energy and are not suited for Doppler-type flow metering.
The maximum operating temperatures is about 100°C. The inaccuracy or error of the
Doppler type flow meter is about 3% of span. The error does vary with flow velocity, pipe size
and flow meter calibration. Repeatability is about 1% of full span.
1.5.3 Laser Doppler Anemometer Systems
Anemometers are used to measure air and gas flows in a variety of applications.
1.5.3.1 Principle of Operation
When sound or light is beamed into the atmosphere, the inhomogeneities in the air will
reflect these beams. The resulting Doppler shift in the returning frequencies can be inter-
preted as an indication of wind velocity.
1.5.3.2 Working
When laser-based Doppler anemometers are used, the intensity of the light scattered by
the particles in the air is a function of their refractive index and the size of the reflecting
particles.
The Laser Doppler anemometer (LDA) is based on the Doppler effect. The Doppler shift
of frequency occurs as light is dispersed on the surface of moving particles. The shift in the
frequency of the light source (laser beam) is proportional to the velocity of the particles. The
frequency shift is very small (from 1 KHz upto a tenth of a MHz) in comparison with the light
frequency and thus it can be directly measured. Therefore, the arrangement using the inter-
ference of the original and refracted lights is used. This is called as ‘differential mode’ of LDA.
Fig. 1.61 illustrates the LDA Principle.
The frequency ‘f ’ of electrical signals produced by a particle moving with velocity ‘V’ is
given by
2 V sin θ / 2 LM OP
2 sin θ / 2
f =
λ
=
N λ QV
f = KV
where λ = Laser wavelength and θ = angle of the beam.
Beams from the laser source intersect each other in the measurement zone, where a set
of interference plates are formed. When particles pass through these, they generate optical
signals with flash frequencies which equal the Doppler frequency. This signal is scanned by
the photo multiplier and is analysed. The signal has several cycles, variable amplitude, and
high frequency and background noise.
1.5.3.3 Applications
The use of this non contact measurement method is suitable for nearly all hydro
dynamical and aero dynamical velocity measurement applications.
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FLOW 63
→
Photomultiplier V
Measuring
zone φ 125 µm
Stop
→
V
Laser Lenses
assembly
Refracting
Lens
prism
Fig. 1.61 Operation of the laser Doppler anemometer
1.6 Other Types of Flow Meters

Purge flow regulators for low flow rate measurements, Cross-correlation flow meters
for solids flow measurements, Belt type feeders for solids flow measurements, Vortex flow
meters for moderate flow measurements and different designs of flow switches are discussed
in this section.
1.6.1 Purge Flow Regulators
Purge flows are low flow rates of either gases or liquids. They usually serve to protect
pressure taps from contacting hot or corrosive process fluids or from plugging. They can also
protect electrical devices from becoming ignition sources by maintaining a positive inert gas
pressure inside their housings or to protect the cleanliness of the optics of analyzers through
purging.
The low flow rates of the purge media can be detected by a variety of devices including
capillary, miniature orifice, metering pump, positive displacement, thermal and variable—
area type sensors.
1.6.1.2 Rotameter Type Purge Meter
Rotameter-type purge meter is the least expensive and most widely used purge meter.
These meters take many forms, all of which are inexpensive, and are intended for low flow
measurement. Most purge meters are selected to handle inert gases or liquids at low flow rates
where these fluids are used as a purge ; therefore, accuracy is not critical. Purge meters are
available with optional needle control valves. Fig. 1.62 shows a typical purge-type rotameter
with integral needle control valve.
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End fitting
Tube adaptor spring
Ball check valve
Tube adaptor
Protection shield
Metering tube
Float
Tube adaptor
End fitting
Needle
valve
Meter body
Fig. 1.62 Purge rotameter with integral needle control valve
The metering needle valves are usually multiple-turn units provided with long stems.
The opening around their needle-shaped plugs can approach capillary dimensions. The flow
rate through these devices is a function of not only the opening of the valve and the pressure
differential across it, but also of both the density and the viscosity of the purge media.
When the purge flow meter is combined with a differential pressure regulator, it be-
comes a self-contained flow controller which is illustrated in Fig. 1.63.
By adjusting springs #1 and #2 for a constant pressure difference of about 1.5 to 2 m of
water, this constant pressure drop (Pi – P0) is maintained across the flow control valve (V) and
the purge flow is thereby fixed. Fig. 1.63 describes a configuration in which the outlet pressure
(P0) is constant and the inlet pressure Pi is variable. Units are also available for bubbler and
purge applications where the inlet pressure Pi is constant and the outlet P0 is variable. In that
case the constant pressure drop across the valve (V) is maintained to equal (Pi – P0).
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FLOW 65
Flow P0
outlet pressure
Tube
Spring 1
Diaphragm Float
Pi
Regulator
valve Flow control
valve (V)
Spring 2
Flow P inlet pressure
Fig. 1.63 Purge flow regulator consisting of a glass tube rotameter, and inlet needle valve, and
a differential pressure regulator
Purge flow controllers on gas service are usually provided with an accuracy of 5% full
scale over a range of 10 : 1.
1.6.2 Cross Correlation Flow Meter
The oldest and simplest methods of flow measurement are the various tagging
techniquies. Here a portion of the flow stream is tagged at some upstream point and the flow
rate is determined as a measurement of transmit time. Variation of this technique include
particle tracking, pulse tracking, dye or chemical tracing, including the radioactive types.
1.6.2.2 Working Principle
Flow metering based on correlation techniques is similar in concept to the tagging or
tracing techniques because it also detects transit time. As illustrated in Fig. 1.64, any measur-
able process variable which is noisy can be used to build a correlating flow meter. The only
requirement is that the noisy pattern must persist long enough to be seen by both detectors ‘A’
and ‘B’ as the flowing stream travels down the pipe. Flow velocity is obtained by dividing the
distance between the identical pair of detectors by the transit time.
The following process variables display persistent-enough noise patterns or fluctuations
so that cross-correlation flow meters can be built by using an identical pair of these sensors :
Density, Pressure, Temperature, Ultrasonics, Gamma radiation, Capacitive density and
Conductivity. Several of the above process variables such as temperature, gamma radiation
and capacitive density have been investigated as potential sensors for correlation flow meters.
C-8\N-IND\BOOK1-4
One instrument has been developed utilizing the principle of ultrasonics cross-correlation to
measure heavy water flow. Others are available for paper pulp application using photometric
sensors and for solids flow measurements utilizing capacitance detectors.
Position “B” Transport pipe

Position “A” I
lay
e de
Tim
Flow
n(t) 5 to 10 × dia.
(internal)
outlet run
m(t)
“A”
Upstream 20.4"
m(t) transducer (52 mm)
signal
Time t
Transit
time
T 10 to 20 × dia.
(internal)
inlet run
Downstream
transducer
n(t) “B” signal
Time t
Fig. 1.64 Cross-correlation flow metering Fig. 1.65 Installation requirements of cross-
correlation type solids flow meter
Fig. 1.65 shows installation requirements of cross-correlation type solids flow meter.
When fully developed, correlation flow metering can extend the ability to measure the flow not
only into the most hostile process environments, but also into areas of multiphase flow.
1.6.2.3 Advantages
The advantages of tagging techniques include the ability to measure the velocity of only
one component in a multi component flow stream without requiring calibration.
The applications of the cross-correlation flow meter include pumped paper pulp, pneu-
matically conveyed coal dust, cement, grain, plastic granules, chalk and chemical food stuffs.
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FLOW 67
1.6.3 Solids Flow Measurement

Continuous determination of flow rate of dry materials such as coal, cement, powdered
chemicals, paper and fruits is necessary in many industrial processes. Meters for measuring
flow of dry materials are essentially of the weighing type, in that they determine the weight of
material passing a given point.
Belt feeders are compact factory—assembled devices utilizing belts to transport the
material across a weight-sensing mechanism. In the case of meters, an uncontrolled solids
flow passes across a constant speed belt and the belt load signal is thus a function of gravimetric
flow rate.
The feeder in its most basic form consists of a meter to which a controller and volumet-
ric solids flow regulator is added. The flow regulator is normally a simple gate, but may be in
the form of a rotary gate, screw or other volumetric control device capable of being fitted with
a suitable actuator.
1.6.3.2 Belt Type Gravimetric Feeder
Fig. 1.66 illustrates a simpler feeder. It incorporates a constant speed belt coupled with
a gate to modulate the solids flow rate such that belt load is balanced by an adjustable poise
weight. The feeder, which is still used in some industrial applications today, is unique in its
simplicity but includes number of disadvantages relative to more modern designs as follows :
Inlet chute
Control gate
Rate setting Pivot Constant speed

poise weight conveyor belt
Fig. 1.66 Early belt-type mechanical gravimetric feeder
1. The entire feeder is weighed rather than only a portion of the belt ; consequently, the
low ratio of live load to tare coupled with mechanical friction in the linkage pivots results in
relatively low sensitivity in the belt load detection system.
2. The position of the gate control element is proportional to the belt load error. In the
same manner that a float-operated level control valve cannot maintain the level at set point if
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valve supply pressure vary, this feeder cannot maintain set gravimetric rate if the bulk den-
sity of the solids varies.
It should be noted that the basic principle involving the weighing of the entire feeder
has been applied in modern designs. Successful operation of these versions has been achieved
by adding belt load error detecting instrumentation and by actuating the control gate from an
external power source. A controller with reset function eliminates the set point error.
1.6.3.3 Belt Type Electromechanical Gravimetric Feeder
Fig. 1.67 describes the basic construction of the electromechanical gravimetric feeder.
Here the belt load is balanced by a mechanical beam and poise weight system which energizes
one or other of two clutches via a pair of mercury switches energized by a magnet attached to
the beam. These clutches actuate and establish the direction of travel of the gate-positioning
Gate actuator Magnet-mercury switch

and clutch unit Belt load
belt load error detector
(Lowers gate) setpoint
(Raises gate) indicator
Rate setting
poise weight
Belt travel
totalizer
Belt drive Flexure supported
weigh decks
Fig. 1.67 Belt-type electromechanical gravimetric feeder
mechanism. The gate modulates as required to maintain the desired belt load as established
by the position of the poise weight on the balance beam. It can be seen that this feeder will
maintain belt load regardless of changes in material density, subject to the volumetric control
limits of the gate. Belt load set point is indicated by a mechanical counter geared to the beam
poise weight drive. A second counter geared to the belt drive totalizes the length of the belt
travelled. By varying drive gears, these counters can be provided to read directly. Total weight
fed can thus be calculated by multiplying the readings of the two counters. Remote belt load
set point and readout functions are available as well as a belt travel contact switch may be
used to operate a remote counter or to shut down the feeder via a predetermining counter after
the desired total weight of material has been fed. Adjustable micro switches actuated by gate
position may be utilized to activate alarms indicating either a stoppage of the material supply
to the feeder or over travel of the control gate resulting from abnormal low material density.
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FLOW 69
1.6.3.4 Belt Type Gravimetric Feeder with Pneumatic system

Fig. 1.68 illustrates the gravimetric meter which is available with either pneumatic or
electronic weight detection and transmission system. In the case of the pneumatic version
shown, the preliminary calibration procedure involves adjustment of the tare weight with the
Air supply
Output to
remote indicator
recorder or controller
Pneumatic
relay
Balancing
piston
Flapper
and
nozzle
Tare weight
Belt drive
Ball and disc

continuous
Flexure supported integrator
weigh decks
Fig. 1.68 Belt-type gravimetric meter with pneumatic system
beam in center position, and location of the nozzle relative to the flapper. This establishes a
condition such that balance is achieved when balancing piston pressure is 0.2 kg/cm2. When
material crosses the belt, beam movement throttles the nozzle. Nozzle back pressure is im-
posed on the pneumatic relay, which in turn increases its output pressure until the balancing
piston rebalances the beam. The balancing pressure is thus proportional to belt load and since
the belt speed is constant, balancing pressure is proportional to measured weight-rate. Also
shown is an optional ball and disc integrator. The disc is driven by the front belt roll of the
feeder and the ball is positioned by a pneumatic positioner. This ball and disc type integrates
continuously. It is especially recommended for user with gravimetric meters in applications
involving the measurement of rapidly varying instantaneous flow rates. The integrator is sup-
plied with a digital totalizer and can be furnished with a pulse transmitting switch to operate
a remote counter.
The feed rate of all belt-type gravimetric feeders is a function of the belt speed and the
belt load. Belt speed is normally expressed in terms of meter per minute, while belt load is
defined as kg per metre of belt.
Feed rate = Belt speed × Belt load
In the case of the constant speed belt feeders, rate is directly proportional to belt load.
Rate set point is thus in terms of belt load, and the belt load signal generated by the device can
be read out as rate.
C-8\N-IND\BOOK1-4
Another method of rate adjustment utilizes belt speed variation with belt load as con-
trolled constant. Still another involves variation of both belt speed and belt load wherein the
rate signal is the multiplicand of the belt speed and belt load measurement signals generated
by the feeder.
1.6.4 Vortex Shedding Flow Meter
1.6.4.1 Vortex Shedding Phenomenon
When an obstruction (a non-streamlined object) is placed in the path of a flowing stream,
the fluid is unable to remain attached to the object on its downstream sides and will alter-
nately separate (shed) from one side and then the other. The slow-moving fluid in the bound-
ary layer on the body becomes detached on the downstream side and rolls into eddies and
vortices,. Fig. 1.69. It is also noted that the distance between the shed vortices is constant,
regardless of flow velocity. This principle is called as Karman’s principle.
d
V
ID
l
The distance between the Karman vortices (I) is only a function of the width of the obstruction (d)
and therefore the number of vortices per unit of time gives flow velocity (V).
Fig. 1.69 Karman vortices
Stated in terms of a flag fluttering in the wind, it is noted that the intervals between
vortices (l) is constant and is only a function of the diameter of the flag pole (d). Therefore, the
faster the wind, the faster the vortices are formed and the faster the flag flutters as a conse-
quent, but without changing its wavelengths.
In building a flow meter based on Karman’s principle, the manufacturer usually selects
an obstruction width (d) that is one-quarter of the pipe diameter (ID). As long as the obstruc-
tion is not coated, as long as the pipe Reynold’s number high enough to produce vortices and as
long as the detector is sensitive enough to detect these vortices, what results is a flow meter
that is sensitive to flow velocity and is insensitive to the nature of the flowing media (liquid,
gas, steam), density etc.
As per Strouhal’s statement, if one knows the vortex shedder width (d) and has a detec-
tor that is sensitive enough to count the vortices and determine the vortex frequency (f), one
can measure the flowing velocity of any substances as :
Flow velocity = Kfd ...(1.63)
where K is a constant.
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FLOW 71
1.6.4.2 Vortex Flow Meter Detection

As a vortex is shed from one side of the bluff body, the fluid velocity on that side in-
creases and the pressure decreases. On the opposite side, the velocity decreases and the pres-
sure increases, thus causing a net pressure change across the bluff body. The entire effect is
then reversed as the next vortex is shed from the opposite side. Consequently, the velocity and
pressure distribution adjacent to the bluff body change at the same frequency as the vortex
shedding frequency.
Various detectors can be used to measure one of the following :
1. The oscillating flow across the face of the bluff body.
2. The oscillating pressure difference across the sides of the bluff body.
3. A flow through a passage drilled through the bluff body.
4. The oscillating flow or pressure at the rear of the body.
5. The presence of free vortices in the downstream to the bluff body.
A flow-sensitive detector can be either a heated thermistor element or a spherical mag-
netic shuttle. Detectors that are sensitive to pressure use either metal diaphragms or vanes.
Pressure exerted on diaphragms can be converted into variable capacitance or variable strain
or can be converted into an electrical signal through any of the sensor. Depending on the
characteristics of the sensing system, the flow meter will be suitable for liquid or gas or both.
The earliest detector designs were highly sensitive to plugging and required frequent
maintenance. Fig. 1.70.
Thermistor
sensor
Flow
Magnetic Nickel
pickup shuttle ball
Fig. 1.70 Early vortex flow meter detectors
Those early detectors were replaced by units that could not plug and were solid state in
design. Fig. 1.71.
C-8\N-IND\BOOK1-4
Other design modifications aim at compensating for background noise by using two
detectors, of which one is exposed to vortex forces and the other is not, and using their differ-
ence as the measurement signal.
Oscillator
preamplifier
Vortex
Ve generating strut
Fixed vortex
locit generating strut Receiver
y
Ch Thermistor
an
ge sensors
w
Flo
Strain gauge Cantilevered strut Ultrasonic transmitter

Flow velocity
across front Pressure at rear of bluff body Free vortices
face
Fig. 1.71 Solid state vortex flow meter detectors
1.6.4.3 Features of Vortex Shedding Flow Meter

1. The vortex shedding meter provides a linear digital output signal without the use of
separate transmitters or converters, simplifying equipment installation.
2. Meter accuracy is good over a potentially wide flow range, although this range is
dependent upon operating conditions.
3. The shedding frequency is a function of the dimensions of the bluff body and it
ensures good long term stability of calibration and repeatability of better than
± 0.15% of rate.
4. There is no drift because this is a frequency system.
5. The meter does not have any moving or wearing components, providing improved
reliability and reduced maintenance.
6. The calibration of the meter is virtually independent of the operating conditions
(viscosity, density, pressure, temperature and so on) whether the meter is being
used on gas or liquid.
7. The vortex shedding meter also offers a low installed cost, particularly in pipe sizes
below 6 inch diameter.
8. The limitations include meter size range. Meters below 12 mm diameter are not
practical.
1.6.4.4 Selection of Vortex Shedding Flow Meter
As the first step in the selection process the operating conditions should be compared
with the meter specification. The meter wetted materials (including bonding agents) and sen-
sors should then be checked for compatibility with the process fluid both with regard to chemi-
cal attack and safety. Applications where there are large concentrations of solids, two-phase
flow, or pulsating flow should be avoided or approached with extreme caution. The meters can
have a rangeability of about 20 : 1 with a pressure loss of approximately 0.2 kg/cm2.
C-8\N-IND\BOOK1-4
FLOW 73
The meter’s good accuracy and digital linear output signal make its application over
wide flow ranges a practical proposition. The rangeability declines proportionally with in-
creases in viscosity and decreases in density, or reductions in the maximum flow velocity of
the process. Vortex shedding meters are therefore unsuitable for use of high-viscosity liquids.
1.6.5 Flow Switches
Flow switches are used to determine whether the flow rate is above or below a certain
value. This value (set point) can be fixed or adjustable. When the set point is reached, the
response can be the actuation of an electric or pneumatic circuit. When the flow switch is
actuated, it will stay in that condition until the flow rate moves back from the set point by
some amount. This difference between the ‘set point’ and the ‘reactivation point’ is called the
switch ‘differential’. The differential can be fixed or adjustable. If the differential is small, the
switch is likely to cycles it control circuit as the flow actuates around its set point.
In certain applications, a manual reset feature is desirable. This will guarantee that
once the switch is actuated, it will not be allowed to return to its preactuation state until
manually reset by the operator. This feature is designed to require the operator to review and
eliminate the cause of the abnormal flow condition before resetting the switch variations.
1.6.5.1 Design Variations
1.6.5.1.1 Folding Paddle Switch
The least expensive and therefore the most widely
used are the various paddle type devices. One such device
is illustrated in Fig. 1.72. At ‘no flow’ the paddle hangs
loosely in the pipe in which it is installed. As flow is initi-
ated, the paddle begins to swing upward in the direction
of the flow stream. This deflection of the paddle is trans-
lated into mechanical motion by a variety of techniques
including a pivoting cam, a flexure type, or a bellows as-
sembly. The mechanical motion causes the switch to open
or close. If a mercury switch is used, the mechanical mo-
tion drives a magnetic sleeve into the field of a permanent
magnet which trips the switch. A hermetically sealed
switch will be directly actuated by the permanent magnet
as it moves up or down according to the paddle movement.
If a micro switch is used, the translated motion will cause
direct switch actuation. The range and actuation point of
paddle switches can be changed and adjusted by changing
Fig. 1.72 Folding paddle switch
the length of the paddle. For any given pipe size, the ac-
tuation flow rate decreases as the paddle length increases.
Paddle-type flow switches are sensitive to pipeline turbulence, pipeline variation and
installation. For these reasons, it is advisable to provide them with the equivalent of a 10 pipe
diameter straight upstream run, to use dampers if pipe vibration or pulsating flow is expected,
and to readjust their settings if they are to be mounted in vertical upward flow lines. The
conventional paddle-type designs are incapable of distinguishing low flow velocities from no-
flow conditions. Therefore, if low flows are to be detected, the folding circular paddle should be
C-8\N-IND\BOOK1-4
used, which permits the full diameter paddle to fold back upon itself, to minimize pressure
drop.
1.6.5.1.2 Swinging Vane Design
In smaller sized pipelines where it is desired to provide local flow indication, in addition
to the flow switch action, the variable area type flow switches can be considered. If the vertical
upward flow configuration of the rotameter design is not convenient from a piping layout point
of view, the circular, swinging vane design, shown in Fig. 1.73 can be considered.
Fig. 1.73 Swinging vane flow switch
1.6.5.1.3. Capacitance-Type Flow Switch

If the purpose of the flow switch is to protect pumps from running dry, the wafer-type
capacitance insert unit is a good choice which is shown in Fig. 1.74.
PVC facing
150 I.B. flange

PVC ring
Mild steel ring
PVC ring
PVC ring
Fig. 1.74 Capacitance type flow/no-flow switch
1.6.5.1.4 Thermal Flow Switch

Flow switch reliability is increased by the elimination of moving parts, so that pipe
vibration or fluid flow pulses will not cause erroneous switch actuation. One of the most popu-
lar solid-state designs is the thermal flow switch which is shown in Fig. 1.75.
All heat actuated flow switches sense the movement or stoppage of the process stream
by detecting the cooling effect (temperature change) on one or more probes. They are available
C-8\N-IND\BOOK1-4
FLOW 75
both in the flow through and in the probe configuration. One design consists of a heater probe
and two sensor probes, connected in a wheatstone bridge. When the flow stops, an imbalance
in the bridge circuit occurs.
Resistance
dir Flow temp, sensor
ec
tio
n
Pipeline
Active
sensor
Warm convection
current carries
heat from the
heater to the
active sensor Heater
Reference
sensor
Fig. 1.75 Thermal flow switch
The main advantage of this design is its ability to detect very low flow velocities. Its
main limitation is that it cannot respond instantaneously to flow changes. Depending on switch
adjustments and on type of process fluid, the speed of response will vary from 2 seconds to 2
minutes.
1.6.5.1.5 Bypass Flow Switch
Piston Magnetic Magnetic

switch field
Spring
Flow
Permanent Differential pressure

magnet producing vane
externally adjustable
Fig. 1.76 Bypass flow switch
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A bypass-type switch shown in Fig. 1.76 has an externally adjustable vane that creates
a differential pressure in the flow stream. This differential pressure forces a proportional flow
through the tubing that bypasses the vane. A piston retained by a spring is in the bypass
tubing and will move laterally as flow increases or decreases ; the piston’s movement activates
a switch. Bypass flow switches can be used for fairly low flow rates and their ability to be
externally adjusted is a desirable feature.
1.6.6 Anemometers
The use of hot wire resistance transducer is to measure the flow rate of fluids by means
of measuring velocity of non conducting liquids. In open channels and closed pipes it can be
conveniently measured by suitably locating the hot wire filament.
1.6.6.1 Hot Wire Filament
Hot wire filament is usually made by wire of platinum or tungsten material. It is suit-
ably mounted in the flow channel by means of a support as shown in Fig. 1.77. The diameter of
the wire may vary from 5 µm to 300 µm and the length is about half the diameter of the pipe.
A smaller diameter gives a larger resistance per unit length and less inertia but is also less
capable of sustaining large fluid pressure. The capability of its withstanding large pressure
shocks is decided after actual testing. The hot wire element is centrally located inside the pipe
such that the axis of the wire is normal to the direction of fluid flow.
Hot wire filament
In Out
Flow pipe
Fig. 1.77 Hot wire filament
1.6.6.2 Principle
In hot wire anemometers, the filament is heated initially by means of passing an elec-
tric current. This heated resistive filament mounted on a tube is exposed to air flow or wind,
which is cooled because of fanning effect. Depending on the velocity of air flow, the amount of
cooling varies. The resistance of the probe when it is hot is different from that when it is
cooled. This difference in resistance or this variation in resistance is converted into a voltage
variation and thereby the flow velocity is converted into a voltage variation.
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FLOW 77
1.6.6.3 Types of Hot Wire Anemometers

Hot wire anemometers are commonly available in two forms :
(i) Constant current type and
(ii) Constant temperature type.
Both utilize the same physical principle but in different ways.
1.6.6.3.1 Constant Current Type
In the constant—current mode of
operation, the current through the hot
wire is kept constant at a suitable value.
The measuring circuit of this type is Eb
R1 R2
shown in Fig. 1.78(a).
In this type, the hot wire resistive
filament which is mounted centrally in
G
the flow pipe, carrying a fixed current is
exposed to the flow velocity. The hot wire
Ri
filament attains an equilibrium tempera-
Rw R3
ture when the i2R heat generated in it is
just balanced by the heat loss from its
surface. The proper circuit design is
needed so that i2R heat is essentially con-
stant. Thus the hot wire filament tem- Fig. 1.78 (a) Measuring circuit of a constant current type
perature must adjust itself to change the
heat loss until the equilibrium is reached and this equilibrium wire temperature is a measure
of velocity. The wire temperature can be measured in forms of its electrical resistance.
Ri > 2 K Ω
R1, R2, R3 and Rw ≅ 1 to 2 Ω
Energy balance equation for equilibrium conditions is written as
i2Rw = hA(Tw – Tf)
where i = Hot wire current
Rw = Wire resistance
Tw = Wire temperature
Tf = Temperature of flowing fluid
h = Film coefficient of heat transfer
A = Heat transfer area.
The measuring circuit of the constant-current anemometer can be used for the meas-
urement of steady velocities as well as rapidly fluctuating components such as turbulent com-
ponents superimposed on an average velocity.
1.6.6.3.2 Constant-Temperature Type
The current through the hot wire filament is adjusted to keep the wire temperature
constant in this type. A galvanometer is used to detect the balance conditions. The bridge is
C-8\N-IND\BOOK1-5
connected to a battery voltage source in series with an adjustable resistor of a very large value
(2KΩ). The voltage drop across the hot wire filament is measured by a high resistance
millivoltmeter whenever the bridge is brought to balance condition.
DC
amplifier
R1 R2
Rs
Rw R3
Fig. 1.78 (b) Measuring circuit of a constant temperature type
The measuring circuit is shown in Fig. 1.78 (b) . When there is no flow, the bridge is in
balance condition. For a change in flow, resistance of
the hot wire (Rw) changes and the bridge is unbal-
2
anced. The unbalanced voltage is amplified and is used I
as a supply to the bridge. The bridge current required
for balancing gives the change in the flow velocity.
This current is measured by measuring the voltage
across the standard resistance Rs.
When the resistance of hot wire filament Rw is
maintained constant by adjusting Rs, the current
through the ammeter in series with Rw is obtained for
V
varying the voltage V. The variation of the current I2
as a function of the voltage V is shown in Fig. 1.79. Fig. 1.79 Variation of I2 with respect to V
It is called as calibration curve.
1.6.6.4 Comparison Between Constant-Current Type And Constant-
Temperature Type
In constant current type, the current has to be kept at a large value and if sudden drop
in velocity of fluid/gas occurs, the convection loss is very much reduced and thereby resulting
in burning out of the hot wire filament.
In constant-temperature type, the disadvantages are the instability and drift problems
in the amplifier design and high noise figure obscuring measurements of very small velocity
fluctuations.
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FLOW 79
1.6.7 Mechanical Anemometer

These anemometers have been used to measure air and gas flows in a variety of applica-
tions. They are also used to measure the velocity of wet and dry gases.
Designs of Mechanical Anemometers :
1. Vane anemometer
2. Three-cup anemometer
3. Impeller anemometer.
1.6.7.1 Vane Anemometer
Fig. 1.80 shows the vane-design. In this type, the vanes rotate in response to airflow
with the angular velocity of the vanes being proportional to the wind speed. When a portable
unit is required or when the local readout is satisfactory, vane motion is passed to the indica-
tor through a gear and spring assembly. If the reading is to be remote, a magnetically coupled
or capacitively coupled pickup can be used to generate a transmission signal.
0
90 10
80
20
70
30
60
50 40
Fig. 1.80 Vane design anemometer
1.6.7.2 Three-Cup Anemometer

Fig. 1.81 shows a three-cup anemometer. This type of anemometer is not sensitive to
the direction of the fluid. In this design the shaft drives a direct current tachometer generator
with an output voltage that is proportional to the wind speed. This signal may be used to drive
a remote mounted indicator recorder.
C-8\N-IND\BOOK1-5
Fig. 1.81 Three cup-anemometer.
1.6.7.3 Impeller Anemometer

The impeller design is shown in Fig. 1.82. This anemometer also has a shaft-driven
tachometer. Since the tail on the impeller design always keep the impellers pointed into the
wind, this instrument can be used to detect both wind speed and wind direction. The speed of
response for anemometer is given in meters of wind and is known as distance constant.
Fig. 1.82 Impeller-anemometer.
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FLOW 81
1.7 Flow Meter Calibration
1.7.1 Introduction
Flow rate calibration depends on standards of volume and time or mass and time. Pri-
mary calibration is generally based on the establishment of steady flow through the flow
meter to be calibrated and subsequent measurement of the volume or mass of the flowing fluid
that passes through in an accurate time interval. If steady flow exists, the volume or mass flow
rate may be inferred from such a procedure. As in any other calibration, significant deviations
of the conditions of use from those at calibration will invalidate the calibration. Possible sources
of error in flow meters include variations in fluid properties (density, viscosity and tempera-
ture), orientation of meter, pressure level, flow disturbance (such as elbows, tees, valves etc)
upstream to the meter.
1.7.2 Methods of Calibration of Flow Meter With Liquids
1.7.2.1 Dynamic Weighing (Gravimetric) Method
A commercial calibrator for precise primary calibration of flow meters using liquids is
shown in Fig. 1.83. These units use a convenient dynamic weighing scheme, and are available
in different models to cover the range from 0.5 to 70,000 kg/hr and have an overall accuracy of
± 0.1%. The sequence of the calibration procedure is explained below :
(a) Running operation before Test : Fig. 1.83(a)
Fluid contained in the reservoir is pumped through a closed hydraulic circuit. First, it
enters the filter and then the heat exchanger equipment, which controls temperature within
± 20°C. It then passes through the control valves, the meter under test, the back pressure
valve, the weigh tank, and then back into the reservoir.
Actuator
dump valve
Timer
Weigh
Back pressure beam
Control valve
Timer
Flow meter
being tested Actuator
Flow control
Heat exchanger
Filter
Pump
Reservoir
Fig. 1.83 (a)
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(b) Start of preliminary fill : Fig. 1.83(b)

When the control valves have been adjusted for desired flow, a tare weight is placed on
the weigh pan. Then the cycle start button is pushed, resetting the timer, closing the dump
valve which starts the filling of the weigh tank.
Actuator
dump valve
Timer
Back pressure
Weigh
Control valve beam
Flow meter
being tested
Timer
Actuator
Flow control
Tare weight
Heat exchanger
Filter
pump
Reservoir
Fig. 1.83 (b)
(c) End of the pre-fill, start of weighing cycle : Fig. 1.83(c)

Actuator
dump valve
Timer
Weigh
Back pressure beam
Control valve
Timer
Flow meter Actuator
being tested
Flow control
Heat exchanger
Filter Dump valve
pump
Reservoir
Fig. 1.83 (c)
As the weigh tank fills, the weigh pan rises, tripping the timer actuator, and the electronic
timer begins counting in milliseconds, starting the actual weighing cycle. The preliminary fill
balanced out by the tare weight before actual weighing begins, permits a net measurement of
C-8\N-IND\BOOK1-5
FLOW 83
the new fluid added after preliminary fill. The preliminary fill method permits the measurement
of only a portion of the cycle, eliminating the mechanical errors in the start and stop portions
and allowing dynamic errors to be self cancelling.
(d) Weighing cycle in Operation : Fig. 1.83(d)
The weighing cycle is continued as a precision weight is placed on the weigh pan, again
deflecting the beam. The uniquely designed cone shaped deflector at the inlet of the weigh
tank permits the even distribution of measured fluid.
Actuator
dump valve
Timer
Back pressure
Weigh
Control valve beam
Timer
Flow meter Actuator
being tested
Precision
Flow control test weight
Heat exchanger
Filter Dump valve
pump
Reservoir
Fig. 1.83 (d)
(e) End of Weighing Cycle : Fig. 1.83(e)

Actuator
dump valve
Timer
Weigh
Back pressure beam
Control valve
Timer
Flow meter Actuator
being tested
Flow control
Heat exchanger
Filter Dump valve
pump
Reservoir
Fig. 1.83 (e)
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As the tank fills, the weigh pan rises, until it again trips the timer actuator, stopping
the timer and the indicating the time within a thousandth of a second. By combining the
precision test weight with the timed interval, the actual flow rate in kg/hr is easily and accu-
rately determined. From these basic mass units, other flow units can be accurately calculated.
(f) Emptying for Recycling : Fig. 1.83(f)
After the beam movement trips the timer, the weigh tank automatically empties in less
than 25 seconds, even at maximum flow. The calibrator is now ready for the next flow setting.
This fast recycling cuts total calibrating time as much as 50%.
Actuator
dump valve
Timer
Weigh
Back pressure beam
Control valve
Flow meter Timer

being tested Actuator
Flow control
Heat exchanger
Filter
pump
Reservoir
Fig. 1.83 (f)
1.7.2.2 Pipe Prover Method

Another type of calibrator called pipe prover is particularly useful for fast response,
high resolution flow meters such as turbine, positive displacement, vortex shedding types,
where steady state can be achieved quickly. The integration of the flow rate to get total flow is
accomplished accurately by accumulating the meter pulse-rate output in counter. Although
they can be used with flow rate meters, in practice their use is largely confined to the calibra-
tion of quantity meters. A ‘dedicated prover’ is permanently built in large petroleum metering
stations.
One such pipe prover (bidirectional) which is currently most popular is shown in
Fig. 1.84.
A hollow sphere of synthetic rubber is inflated with water under pressure until its di-
ameter is about 2% larger than that of the epoxy-liner pipe from which the prover is con-
structed. When the sphere is forced into the pipe, it seals it and acts as a kind of piston which
is capable of going round the bends. A four way valve is used to control the flow of liquid after
it has passed through the meter which is to be calibrated, by causing the liquid to travel
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FLOW 85
through the prover either from left to right or from right to left. At either end of the prover
there is a chamber of enlarged diameter to receive the sphere at the end of each trip.
Spring Sphere
buffer Detector 2
Hinged
closure
Calibrated volume
Block-and-bleed
valve Signal
cable
4-way
diverter
valve Detector 1
Meter on
test
Signal cable Pulse counter
Flow
Fig. 1.84 Principle of the bidirectional pipe prover
Before starting the calibration run, the flow is allowed to by-pass the prover. At the
start of a test, the flow is directed through the prover in such a way that the sphere travels the
whole length of the prover. Soon after the start of its run, it passes a sphere detector, which
operates an electrical gating circuit and causes the electrical pulse from the meter on test to be
counted. Near the end of the run, a second sphere detector is operated which stops the count of
pulses. The pulse count from the meter is then compared with the known volume of the prover
between sphere detectors, which has been determined from a previous static calibration of the
prover. Additional accuracy is gained by totalising the pulse counts and the prover volumes
during two successive runs one in each direction. Directional effects in the sphere detectors
are thus largely cancelled out.
The accuracy of the bidirectional prover is as high as ± 0.1% of flow rate and between
± 0.05 and ± 0.02% on total volume.
1.7.2.3 Master Meters Method
The simplest and cheapest way of calibrating a flow meter is to put it in series with
another flow meter of higher accuracy and to compare their readings. This can give reasonably
accurate results over a short period, provided that care is taken to install the two meters
sufficiently far apart to ensure that the downstream meter is not affected by the presence of
the upstream meter. A serious disadvantage of the method is that the performance of the
master meter will gradually change with time ; consequently, recalibration of the master
meter will be needed at intervals.
C-8\N-IND\BOOK1-5
Also if the master meter should suffer any kind of sudden mechanical wear, its perform-
ance could change in a very short period without the operator being aware of the fact. As a
safeguard against this happening, it is possible to use two master meters in series as shown in
Fig. 1.85.
Master meter 1 Master meter 2 Meter on test
Flow
(a) Both are O.K.
Master meter 1 Master meter 2 Meter on test
(b) One master meter is malfunctioning
Fig. 1.85 Two master meters are in series
A long as the two meters continue to give the same reading the operator can be confi-
dent that all are well, but as soon as one master meter gives a significantly different reading
from the other, he knows that one meter is malfunctioning. The rig must then be shut down
while both meters are removed for recalibration.
To avoid having to shut down the rig in circumstances like this, three master meters
can be installed in series. In this case, the malfunctioning meter will immediately betray itself
by showing that it is out of step Master meter (in frequent use)
with the other two. The defec-
tive master meter can then be
taken out of the line and sent
away for recalibration, while
the operator continues to use Meter on test
his rig with the other two mas-
ter meters in operation. Flow
Block and-blead valves
A third alternative is to
use two master meters in par-
allel, with high-fidelity shut-off
valves, as shown in Fig. 1.86.
This system is suitable
only when meters of high
repeatability, such as large tur- Super-master meter (in occasional use)
bine meters, are to be cali-
brated, because the meter of Fig. 1.86 The use of two Master meters in alternate parallel
test provides the only way to
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FLOW 87
compare the performances of the two master meters. One master is used as the main calibra-
tion device, while the other master meter as a ‘super master meter,’ being used alternately
with the first master meter on infrequent occasions as a check that the master meter, remains
unchanged. As soon as a change in the performance of the master meter is observed it is
removed for recalibration. When it is fitted back after recalibration it is regarded as the super
master meter, while the other meter becomes the master meter. This situation remains until
another recalibration is called for, when the roles of the two meters are again reversed.
A well maintained master meter calibration system should provide accuracies of ± 0.2%
on flow rate and ± 0.1% or ± 0.5% on volume.
1.7.3 Methods of Calibrating Flow Meters With Gases
1.7.3.1 Soap Film Burettes
It is suitable only for low flow rates, since it is difficult to form a stable soap film across
a burette of more than about 50 mm diameter. The film is made to act as a frictionless ‘piston’
which travels freely with the flowing stream of gas, so that the velocity of the film is a good
indication of the velocity of the flowing gas. Fig. 1.87.
Detector
Flow
Meter on test
Detector
Timer
Rubber bulb
Soap solution
Fig. 1.87 Principle of the Soap-film burette
The soap film burette can be used to calibrate both flow rate and quantity meters. It will
measure flow rate with an accuracy of ± 0.5% and volume with an accuracy between ± 0.5%
and ± 0.2%.
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1.7.3.2 Bell Prover System

Bell prover system for calibrating gas flow meter is shown in Fig. 1.88.
The gas flowing through the flow meter during a timed interval is trapped in gasometer
bell and its volume is measured. Temperature and pressure measurements allow calculation
of mass and conversion of volume to any desired standard conditions. By filling the bell with
gas, rising it to the top, and adding appropriate weights, such a system may be used as a gas
supply to drive gas through a flow meter as the bell gradually drops at a measured rate. By
using a precision analytical balance to measure the mass accumulated in storage vessel over
time, accuracies, of ± 0.02% were obtained for flow rate upto 9 kg/sec.
Pulley
Cylinder
Gas
Counter
weights
Meter on test
Water bath Exhaust
Fig. 1.88 Simplified schematic arrangement of bell prover system for calibrating small gas quan-
tity meters
1.7.3.3 Sonic Venturi-Nozzles

The Sonic Venturi-nozzle is a very convenient device for calibrating a gas flow rate
meter at one volumetric flow rate. Fig. 1.89.
L = 7d
Flow
25d D 8°
R = 2d
Fig. 1.89 Standard sonic venturi-nozzle
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FLOW 89
It depends upon the fact that in the throat of a nozzle, the gas cannot travel faster than
the speed of sound. Provided the upstream pressure is sufficient to ensure that sonic velocity
is actually reached, the flow rate through the nozzle will therefore always have a fixed value
for a given gas at a specified temperature and pressure. The tapered section of the nozzle plays
no part in controlling the flow rate ; its function is merely to assist, in recovering some 90-95%
of the initial pressure, thus conserving energy.
If a number of sonic venturi nozzles of various sizes are used in succession a gas flow
meter can be calibrated over a range of flow rates with them. When the highest possible accu-
racies (about ± 0.5% on flow rate) are called for it is usual for venturi—nozzles to be calibrated
against a primary gas flow standard before they are used as calibration devices. If slightly
lower accuracies are acceptable their performance can be predicted fairly reliably from a knowl-
edge of their dimensions.
1.7.3.4 Gravimetric System for Gas-Meter Calibrator
The gravimetric calibration is a highly sophisticated and expensive device, but is regarded
as the best available primary system for calibrating secondary high-pressure gas flow standards.
It can also be used directly for the calibration of high-pressure gas meters. It is broadly similar
in principle to the gravimetric system with static weighing for liquids, but with one important
difference. In the liquid system the meter being calibrated is at upstream of the flow diverted,
but in the gas system it is at downstream and in a line venting to atmosphere. This enables the
meter to be read under steady-state conditions, thus overcoming the problem of diminishing
flow rate, which occurs while the weighing vessel is being filled.
Diverter unit
Critical Meter on test
venturi-nozzle Ball valves
Inlet
(at constant
P and T)
Flow control
valve Disconnecting
union
Weighing
vessel
Pressure
control valves
Weighbridge
Fig. 1.90 Simplified Arrangement of a Gravimetric system for compressed gases
As shown in Fig. 1.90, a critical venturi-nozzle is used to maintain a constant flow rate
through the test system. In the first part of the test, the flow at downstream of this nozzle is
diverted through the meter being calibrated, while its reading is noted. Then the flow is di-
verted into a light weight spherical pressure vessel for a measured time, and the measure-
ments of the weight of this sphere before and after diversion are used to calculate the mass
C-8\N-IND\BOOK1-5
flow rate during the diversion period. By varying the pressure upstream of the critical venturi-
nozzle, a fairly wide range of mass flow rates can be covered with this system, and by using
several alternative nozzles of different sizes, an almost unlimited range can be covered.
The accuracy of flow rate measurement in a system of this kind is between ± 0.5%
and ± 0.2%.
1.7.3.5 PVT System
The PVT (Pressure-Volume-Temperature) method illustrated in Fig. 1.91 is used mainly
as a primary standard, to calibrate reference meters and sonic venturi nozzles which can there-
after be used as secondary calibration devices.
In this system, a storage vessel of known volume is charged with gas at high pressure.
The pressure and temperature of the gas in the vessel are first measured, then the gas is
allowed to flow out through a regulating sonic nozzle in series with the meter on test, and
finally the pressure and temperature of the gas in the storage vessel are measured again at
the end of a measured period of time.
Temperature Pressure
measurement measurement
Heat exchanger Meter on test

Pressure control
valve
Heat exchanger
Calibrated storage Exhaust

tank
Regulating sonic
nozzle
Fig. 1.91 PVT System
From these measurements the mass flow rate through the system during the test period
can be calculated. Heat exchangers and an upstream pressure controller are used to control
the conditions during flow and thus the performance of the meter under test can be deter-
mined over a wide range. Accuracies of flow rate measurement between ± 0.5% and ± 0.2% can
be achieved.
1.8 Flow Meter Selection

The selection of a flow meter for an industrial application is influenced by complex
desired data. While purchasing a flow meter, it is better to get advice from an expert on the
C-8\N-IND\BOOK1-5
FLOW 91
selection based on the availability of flow meter and draw out a complete specification of the
flow metering application.
1.8.1 Factors to be Considered
There are many factors which are to be considered before drawing up specifications for
a flow meter. They are :
1. Measurement requirements
2. External conditions of the flow pipe
3. Internal conditions of the flow pipe
4. Properties of the flowing fluid
5. Installation and accessories and
6. Cost consideration.
Let us examine the above six factors in detail.
1.8.1.1 Measurement Requirements
The requirements of measurement can be addressed based on.
(i) The measured variable like point velocity, average velocity or volume rate.
(ii) The range of operation. For wide range of operation, electromagnetic, ultrasonic,
cross-correlation, turbine type etc. are suitable.
(iii) Cost computation. If it is for costing purpose, the meter should have low and
consistent uncertainty in measurement.
(iv) Pressure head loss and maximum pressure of flowing fluid. For high pres-
sure fluids the meter body and inner construction should be sturdy.
(v) Accuracy, Precision and facilities available for maintenance.
(vi) Speed of response. For fluctuating flow, response of the meter should be good
with small time constants.
(vii) Calibration facilities and Installation.
1.8.1.2 External Conditions of the Flow Pipe
Before selection of a flow meter, it is important to examine the environment and the
place where the meter is going to get installed. The following points need to be considered.
(i) Approachability. It is better to know that once the meter is installed whether it is
accessible for removal, recalibration etc.
(ii) It is important to note that the installation of the meter either in an air conditioned
space or in a place which is vulnerable for wide temperature variation.
(iii) Humidity condition, vibration, hostile environment and water facility are the im-
portant parameters to be considered.
1.8.1.3 Conditions Internal to the Flow Pipe
The conditions internal to the pipe affect the accuracy of measurement of flow meters.
Some of the factors that affect the accuracy are protrusions, pipe bore, size, roundness, tough-
ness, hydrodynamic noise pulsations etc.
C-8\N-IND\BOOK1-5
1.8.1.4 Properties of the Fluid

The properties of the fluid to be metered should be clearly understood by the person who
is to select the meter. Many flow problems are due to the impurities present in the fluid, the
effect of which cannot always be quantitatively established.
1. Viscosity. Viscosity of the flowing fluid is a critical factor. If the viscosity of the fluid
changes, the Reynolds number changes, which in turn affect the calibration curve of the flow
meter.
2. Fluid activity. The fluid to be metered may be radioactive or chemically reactive.
Radioactivity presents special problems. For metering the velocity of fluids having high levels
of radiation, flow meters offering long periods of reliable operation without maintenance are
required. If the fluid is corrosive, then Electromagnetic flow meter or Vortex flow meter can be
used.
3. Flammability. Fluids which are inflammable or react violently with other materials
need flow meters like turbine and vortex flow meter. They are suitable for operation in haz-
ardous areas.
4. Scaling Deposits. Special care should be taken for fluids having a property to deposit
scales since scaling can block pressure lines and ducts.
5. Other properties. The fluid properties like compressibility, abrasiveness,
transparency, electrical conductivity, magnetic properties and lubricity should be noted before
selection of flow meter is made.
1.8.1.5 Accessories
When a flow meter is chosen, the associated accessories should also be chosen which are
compatible with the meter. All the precautions and points considered for the meter should be
considered for the accessories also. Some of the accessories for a flow meter are :
1. Valves and manifolds for equalizing, draining, venting and isolation.
2. Sumps, gas vents, poles and drains.
3. Cooling chambers when measuring condensible vapours.
4. Straighteners for improving velocity profile.
5. Piezometer rings for averaging the flow velocity profile for orifice plates.
6. Separators to prevent contaminating fluids like water in oil from entering the flow
meter.
7. Gas detectors to provide a warning if the flow meter is not running full.
1.8.1.6 Economic Factors
Any decision on the purchase or selection of flow meter will certainly take the economic
factors into consideration. But that should not be given the top priority. When computing the
cost of flow meters, the cost of accessories, transmitters etc. if needed, the maintenance cost
for a period should also be taken into consideration.
C-8\N-IND\BOOK1-5
FLOW 93
1.8.2 List of Desirable Characteristics

A partial list of characteristics that are desirable in a flow meter selection is given below :
(i) A wide operating temperature range.
(ii) A wide dynamic range of measurement.
(iii) Insensitivity to flow profit, viscosity, and other physical properties of the fluid.
(iv) Non-corrodible and non-degradable materials of construction.
(v) Small irrecoverable head loss.
(vi) Suitability for liquids and gases.
(vii) Availability in all practical sizes.
(viii) Safety in all practical sizes.
(ix) Immunity to pulsating flow effects.
(x) Immunity to vibration.
(xi) Fast response to flow changes.
(xii) Accuracy.
(xiii) Calibration.
(xiv) Low cost to purchase and maintain.
Of course, no flow meter is available which meets all these requirements and it is un-
likely that one will ever be developed.
1.8.3 Highest Possible Accuracy
1. ORIFICE ± 2.0%
2. VENTURI ± 1.0%
3. NOZZLE ± 1.5%
4. PITOT ± 0.5%
5. EM ± 0.5%
6. UF ± 1.0%
7. CC ± 0.5%
8. VS ± 1.0%
9. ROTAMETER ± 2.0%
10. HOTWIRE ± 2.0%
11. GILFLOW ± 1.0%
12. NMR ± 0.5%
13. LDU ± 0.05%
14. PD ± 0.1%
15. TURBINE ± 2.0%
16. MASSFLOW ± 1.0%
C-8\N-IND\BOOK1-5
1.8.4 Guidelines for Flow Meter Selection

In Summary, Table 1.1 gives the guidelines for flow meter selection and Table 1.2 gives
the application details of various flow meters.
Guide to Flowmeter Selection
Table 1.1
Property Rotameter Orifice Turbine EM Flow Meter
Service Liquid Liquid Liquid Electrically

and Gases and Gases and Gases conducting
liquid and slurries
Liquid 0.01 cc/m 0.1 cm/m 0.001 cc/m 0.01 cc/m

Flow 16000 l/m Large 160000 l/m 2000000 l/m
Limits
Gases 0.3 cc/m 50 cc/m upto
at air 40,000 l/m onwards 10,000,000
Equivalent 50,00000 l/m
at STP
Scale or Linear Square Linear for Linear

Signal or root Reynolds
Charac. Log no. 100000
Range 5 : 1 to 12 : 1 4:1 10 : 1 to 15 : 1 10 : 1
Range 12 : 1 12 : 1 15 : 1 and 100 : 1

with span float to more
adjusted be changed
Accuracy + 2% FS + 1% FS + 0.25% of + 0.5%

if calibrated (uncalibrated) reading reading
Transmitter Visual or Analog Analog Analog

Types Analog Pneumatic Elec. Elect.
Pneumatic or Elec. Digital Digital
Maximum 1 – 10 m 3 – 60 m 10 – 40 m Negligible
overall of of of
Pr. Loss H2O H2O H2O
Viscosity Good Fairly Fairly No effect

Immunity good good
Immunity Immunity
C-8\N-IND\BOOK1-5
Table 1.2 Flow Meter Application Table
FLOW
S. No
Low Viscous
Low Water
Flow
Flow Meter
Types
Appli-
cations
Water
Solids in
Liquid
High Pres.
Gases
Low pres.
Gases
Large Air
Ducts
Low Gas
Flow
Hot
Liquids
Hot Gases
Gyogenic
Fluids
High
Viscous
Larger Meter
Pipes
C-8\N-IND\BOOK1-5
1 Venturi ✓ ✓ ✓ ✓ ✓ ✓
2 Orifice ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 Nozzle ✓ ✓ ✓ ✓ ✓
4 Target ✓ ✓ ✓
5 Rotameter ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
6 Spring Loaded ✓ ✓ ✓ ✓ ✓ ✓
Lower Rotameter
7 Turbine ✓ ✓ ✓
8 Bypass Rotameter ✓ ✓ ✓ ✓ ✓
9 EM ✓ ✓ ✓ ✓ ✓ ✓
10 UF ✓ ✓ ✓ ✓
11 VS ✓ ✓ ✓ ✓
12 Fluidic ✓ ✓
13 Swirl ✓
14 NMR ✓ ✓ ✓
15 Mass ✓ ✓ ✓ ✓ ✓
16 Hot wire ✓ ✓ ✓ ✓
17 Insertion ✓ ✓ ✓ ✓ ✓ ✓
18 CC ✓ ✓ ✓
19 PD ✓ ✓ ✓ ✓ ✓
95
1.9 Problems and Solutions

Problem 1. Water is pumped through a 75 mm diameter pipe with a flow velocity of 760
mm/sec. Find the volume flow rate and mass flow rate. Density of the water is 1000 kg/m3.
Solution.
(i) Volume flow rate Q = VA
πd 2
where Area A =
4
π × (75 × 10 −3 ) 2
= = 4.417 × 10–3 m2
4
Volume flow rate Q = 760 × 10–3 × 4.417 × 10–3 = 3.357 × 10–3 m3/sec.
(ii) Mass flow rate W = ρQ
ρ is given as 1000 kg/m3
Mass flow rate W = 1000 × 3.357 × 10–3 = 3.357 kg/sec.
Problem 2. Determine the volumetric flow of water in m3/hr flowing in a pipe having a
diameter of 40 mm through an orifice having a diameter of 20 mm. Manometer reading across
the tapping is 15 cm of Hg. Assume correction factor = 1 and density of water is 1000 kg/m3.
Solution. Diameter of pipe D = 40 mm
Diameter of orifice d = 20 mm
Manometer reading (differential pressure) = 15 cm of Hg.
Differential pressure is calculated in terms of water column as
h = (13.6 – 1) × (15 × 10) mm of water
[density of mercury is 13.6 times that of water, and the manometer limbs are filled with
water above mercury column.]
= 1890 mm of water.
β = d/D = 20 mm/40 mm = 1/2
Velocity approach factor
1 1
Mv.a = 4
= = 1.032
1 − ( d/D) 1 − (1/2) 4
Cd for d/D ratio is 0.5999 from the graph [BS : 1042 : 196]. Volumetric flow rate is
calculated as follows :
Q = CdMv.a A2 . 2 gh m3/sec
Q = 0.5999 × 1.032 × π/4 (20 × 10–3)2 . 2 × 9.81 × 1890 × 10 –3

= 1.184 × 10–3 m3/sec = 1.184 × 10–3 × 3600 = 4.262 m3/hr
Problem 3. Determine the nominal flow velocity V2 at the orifice having a diameter of
20 mm kept in a pipe of 40 mm diameter. Reynolds number Ra is 105. Assume density of water
= 1000 kg/m3 and kinematic viscosity is 10–2 stokes. (cm2/sec).
C-8\N-IND\BOOK1-6
FLOW 97
Solution. We know from equation 1.9

Re = ρV1D/µ
This can be rewritten as
V1 = Re µ/ρD = Re ν/D [since µ = ρν]
given : ν = Kinematic viscosity = 10–2 stokes. = 10–2 cm2/sec = 10–6 m2/sec
Re = 105
D = 40 × 10–3 m
V1 = Re ν/D = 105 × 10–6/(40 × 10–3)
= 2.5 m/sec
V1A1 = V2A2
V2 = Nominal velocity at the orifice
π/4 (40 × 10 −3 ) 2
= V1 × A1/A2 = 2.5 ×
π/4 (20 × 10 −3 ) 2
= 2.5 × (42/22) = 2.5 × (16/4) = 10.0 m/sec.
Problem 4. For the above problem (2), calculate the pressure difference at the tap-
pings. Assume corner tapping is the selected type. Assume Cd = 0.61
Solution. D = 40 mm
d = 20 mm
From equation 1.4
2 g (P1 − P2 )/ρ
V2 = Cd
1 − (A 2 /A 1 ) 2
1 1 1
Mv.a = = =
2
( 1 − (A 2 /A 1 ) ) 1 − ( d/D) 4
( 1 − ((20 × 10 −3 /40 × 10 −3 ) 4 )
1 1
= = = 1.0327.
1 − (1/2) 4 1 − 0.0625
V2 = 10 m/sec [It is calculated in the problem (3)]
10 = 0.61 × 1.0327 × (2 × 9.81 × (P1 − P2 )/1000
2 × 9.81 10
P1 − P2 =
1000 0.61 × 1.0327
0.01962 P1 − P2 = 15.87
0.14 P1 − P2 = 15.87
P1 − P2 = 113.35
P1 – P2 = 12849.8 kg/m2 = 1.28 kg/cm2.
C-8\N-IND\BOOK1-6
Problem 5. Determine the volume flow rate of water through a pipe of 150 mm diam-
eter when measured by (i) an orifice plate of size 75 mm dia and (ii) Venturi tube of throat size
75 mm dia. The differential pressure recorded is 250 pa. Assume the density of water is 1000
kg/m3.
Solution. Volume flow rate of water is calculated as follows.
1 πd 2
Q= × Cd . × 2 gh
1 − ( d/D) 4 4
where h = P1 – P2/ρ
(a) For orifice plate : Cd = 0.6
1 π (75 × 10 −3 ) 2
Q= × 0.6 × × (2 × 9.81 × 250)/1000
1 − (1/2) 4 4
= 1.032 × 0.6 × 4.417 × 10–3 × 2.214

= 0.006057 m3/sec. = 6.057 litres/sec.
(b) For venturi Tube : Cd = 0.99
Q = 1.032 × 0.99 × 4.417 × 10–3 × 2.214
= 9.99 × 10–3 m3/sec. = 9.99 litres/sec.
Problem 6. A venturi tube of throat diameter 10 cm is placed in a pipe of diameter 20
cm to measure the volumetric flow. The volumetric flow rate through venturi tube is 0.02 m3/
sec. Water has the viscosity of 10–3 Pas. Determine the Reynolds number and the upstream to
throat differential pressure developed.
Solution.
ρVd
(i) Reynolds number =
µ
Volumetric flow rate = 0.02 m3/sec.
0.02
Velocity = Volumetric flow/area =
π/4 (10 × 10 −2 ) 2
i.e., V = 2.546 m/sec.
1000 × 2.546 × (10 × 10 −2 )
Now Reynolds number Re = = 2.546 × 105.
10 −3
(ii) Volumetric flow rate :
Q = Mv.a Z . a2 2 g (P1 − P2 )/ρ ...(1)
where Cd = 0.98
Q = 0.02 m3/sec.
Assume Z = 1,
1 1
Mv.a = =
4
1 − (d/D) 1 − (10/20) 4
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FLOW 99
1
Mv.a. = = 1.032
1 − (1/2) 4
π (10 × 10 −2 )
a2 = = 7.85 × 10–3.
4
Substituting all the values in Equation (1),
(2 × 9.81 × ∆P)
0.02 = 1.032 × 0.98 × 7.85 × 10–3 ×
1000
(2 × 9.81 × ∆P)
0.02 = 7.939 × 10–3
1000
(2 × 9.81 × ∆P)
= 2.52
1000
0.14 ∆P = 2.52
∆P = 2.52/0.14 = 18
∆P = 324 kg/m2 = 0.0324 kg/cm2.
Problem 7. An incompressible fluid is flowing in a 300 mm pipe under a pressure head
of 2 kg/cm2. Calculate the fluid velocity and volumetric flow rate.
Solution. Fluid velocity.
V= 2 gh
V= 2 × 9.8 × (20) [1 kg/cm2 = 10 metres water head]

= 19.8 m/sec2.
Volumetric flow rate. Q = AV
πd 2
where Area A=
4
d = (300 × 10–3) m
π (300 × 10 −3 ) 2
A= = 0.07 m2.
4
Q = 19.8 m/sec × 0.07 m2 = 1.38 m3/sec.
Problem 8. An incompressible fluid is flowing through an orifice plate with a flow
coefficient of 0.6 causing a pressure drop of 400 mm of water column. Calculate the fluid
velocity.
Solution. The fluid velocity measured by an orifice is given by an equation
V = Cd 2 gh
where Cd = 0.6
g = 9.8 m/sec2.
h = (400 × 10–3) m
V = 0.6 2 × 9.8 × 400 × 10 −3 = 1.68 m/sec.
C-8\N-IND\BOOK1-6
Problem 9. A pitot tube with a coefficient of 0.98 is used to measure the velocity of
water in a pipe. The differential pressure head is 900 mm. What is the velocity ?
Solution. V = Cd 2 gh
where Cd = 0.98
g = 9.8 m/sec2
h = (900 × 10–3) m
V = 0.98 2 × 9.8 × 900 × 10 −3 = 4.11 m/sec.

Problem 10. Determine the flow velocity necessary to produce a dip of 20 kPa from a
pitot-static velocity measurement when used (a) in water (b) in air.
Solution. Assume density of water = 1000 kg/m3 and Density of Air = 1.29 kg/m3.
Flow velocity = V = 2 gh/ρ = 2∆P/ρ
∆P = 20 kPa.
(i) When flowing fluid is water.
V= 2 × 20 × 10 3 /1000 = 6.324 m/sec.

(ii) When air is flowing,
V= 2∆P/ρ = 2 × 20 × 10 3 /1.29 = 176 m/sec.

Problem 11. A pitot tube properly placed just in front of the submarine is connected to
a manometer. The pressure difference in the manometer was found as 25 kN/m2. Find the
speed of submarine if the density of sea water is 1026 kg/m3.
2∆P
Solution. Flow velocity = V = ρ
∆P = 25 kN/m2
ρ = 1026 kg/m3
2 × 25 × 10 3
V= = 6.98 m/sec = 25.128 km/hr.
1026
Problem 12. A pitot tube mounted on an aircraft is connected to a pressure gauge
which reads a pressure of 12.5 kN/m2. Determine the flying speed of the aircraft ? Density of
air at that height can be taken as 1.290 kg/m3.
2∆P
Solution. Flying speed =
ρ
2 × 12.5 × 10 3
= = 139.21 m/sec = 501.16 km/hr.
1.290
C-8\N-IND\BOOK1-6
FLOW 101
Problem 13. A rotameter uses a cylindrical float of 3.5 cm height, 3.5 cm dia and den-
sity of 3900 kg/m3. The maximum inside diameter of the metering tube is 5 cm. Determine the
maximum flow rate handling capacity of the rotameter if the fluid is water.
Solution. The volume of the float
π (3.5 × 10 −2 ) 3
Vf = = 3.36 × 10–5 m3
4
Assume Cd = 0.6 (For water)
Dia of the float Df = (3.5 × 10–2) m
Inside diameter of the Pipe
Dp = (5 × 10–2) m
Volume of the float Vf = 3.36 × 10–5 m3
D p2 − D f 2 π gV f (ρ f − ρ)
Volumetric flow Q = Cd .
Df 2ρ
= 0.6 ×
LM 0.05 − 0.035 OP
2 2
π × 9.8 × 3.36 × 10 −5 × (3.9 × 10 3 − 1 × 10 3 )
N 0.035 Q 2 × (1 × 10 3 )
= 0.6 × 0.03642 × 1.499 × 10 −3 = 0.6 × 0.03642 × 0.03872

= 8.4631 × 10–4 m3/sec.
Problem 14. Consider a rotameter float of volume of 520 mm3 with an included angle
taper of 5°, with an effective diameter of 15 mm and a vertical range of movement of 250 mm
and is made from aluminium of relative density 2.7. If the internal diameter of the measuring
tube at the bottom is 18 mm. Determine the range of flow if paraffin is used as a process fluid
which has a relative density of 0.8.
Solution. Given Vf = [520 × 10–9] m3 x
Df = 15 mm
π (15 × 10 −3 ) 2
Af =
4 5°
= 1.7671 × 10–6 m2
250 mm
Cd = 1
From the figure x = 18 + 2 × 250 × tan 5
= 61.7 mm.
Case 1. When float is at the bottom, the flow
through the rotameter is minimum [Dp = 18 mm] 18 mm
2 2
Dp − Df π gV f (ρ f − ρ)
Qmin =
Df 2ρ
=
LM (18 × 10 ) − (15 × 10 ) OP
−3 2 −3 2
π × 9.8 × 520 × 10 −9 × (2.7 − 0.8)
N 15 × 10 −3
Q 2 × 0.8
C-8\N-IND\BOOK1-6
= 6.6 × 10–3 × 1.903 × 10 −5 = 6.6 × 10–3 × 4.362 × 10–3

= 2.879 × 10–5 m3/sec.
Case 2. When float is at the top, the flow through the rotameter is maximum [Dp = 61.7
mm]
. × 10 −3 ) 2 − (15 × 10 −3 ) 2 π × 9.81 × 520 × 10 −9 × (1.9/0.8)

(617
Qmax =
15 × 10 −3 2
= 0.2387 × 4.362 × 10–3 = 104.1 × 10–5 m3/sec.
Problem 15. A coal conveyor system moves at a speed of 328 m/min. A weighing plat-
form is 16 m in length and a particular weighing shows a reading of 165 kg. Find the coal
delivery in kg/hr.
Solution. The flow rate can be calculated as
WR
Q=
L
where Q = Flow rate.
W = weight of material on section of length.
R = Conveyor speed m/min.
L = Length of weighing platform in m.
(165 kg) × (328 m/min)
Q=
16 m
= 3382.50 kg/min = 56.4 kg/hour.
Problem 16. Given a beat frequency (∆f) of 100 cps for an ultrasonic flowmeter, the
angle (θ) between the transmitters and receivers is 45° and the sound path (d) is 300 mm.
Calculate the fluid velocity in m/sec. [Assume the ultrasonic transmitter is of single trans-
ducer assembly type].
Solution. Fluid velocity is calculated by
∆f . d
V=
2 cos θ
where ∆f = 100 cps
d = 300 m
θ = 45°
100 × (300 × 10 −3 ) 30
V= = = 21.2 m/sec.
2 cos 45° 2 × 0.707
Problem 17. Determine the volume flow rate in litres/min in an oval gear type flow
meter. The volume trapped between the gears and the casting is 120 CC and the speed of the
rotation is 150 rpm.
Solution. We know that in an oval gear type flow meter, the volume flow rate is 4 times
the speed of rotation, of the volume trapped between the gear and the casting.
Volume flow rate Q = 4 × 150 × 120 = 72000 cm3/min = 72 litres/min.
C-8\N-IND\BOOK1-6
FLOW 103
Problem 18. Calculate the induced emf in an electromagnetic flow meter due to the
flow of a conductive fluid in a pipe with inner diameter of 2.75 cm. The flux density B = 6 mV.
sec/cm2 and volume flow rate Q = 2500 cm3/min.
Solution. Quantity Flow rate Q = 2500 cm3/min
πd 2 π
Area = = (2.75)2 = 5.94 cm2.
4 4
2500
Velocity = = 7.01 cm/sec.
60 × 5.94
Flux density B = 6 mV sec/cm2
6 × 10 −3 V sec
= = 60 V sec/m2 = 60 Weber/m2.
(10 −2 ) 2 m 2
Induced emf e = Blv = 60 × (2.75 × 10–2) × (7.01 × 10–2)
= 0.1156 V = 115.6 mV.
Problem 19. Determine the velocity of flow in an electromagnetic flow meter for the
following conditions. The flux density in the liquid has an average value of 0.08 Weber/m2. The
diameter of the pipe is 10 cm. The induced voltage of the electromagnetic flow meter is re-
corded as 0.2 mV.
Solution. e = B lv
e 0.2 × 10 −3
v= =
Bl 0.08 × (10 × 10 −2 )
= 0.025 m/sec = 2.50 cm/sec.
Problem 20. Consider an electromagnetic flow meter which is used to measure volu-
metric flow of a process fluid in a pipe of 60 mm dia. The velocity profile is symmetrical and can
be assumed uniform. The flux density in the liquid is 0.1 Wb/m2. The output from the flow
meter is given to an amplifier of gain 1000 and impedance between the electrodes is 275 KΩ.
The input impedance of the amplifier is 275 KΩ. Find the average velocity of the liquid when
the P-P voltage at the amplifier output is 0.3 V.
Solution. Diameter of the pipe = 60 mm.
Flux density = 0.1 Weber/m2.
Amplifier gain = 1000.
275 KΩ
Amplifier
gain em
275 KΩ
ei eo
1000
em
C-8\N-IND\BOOK1-6
P-P Amplifier output = 0.3 V. V

P
Peak value = 0.15 V.
Input to the Amplifier = 0.15 × 10–3 V.
(Peak value). 0.3 V 0.15 V
From the above circuit diagram. t

275
ei = em
275 + 275
[275 + 275] ei = 275 em
2ei = em P
em = 2 × 0.15 = 0.3 × 10–3 V.

We know that, em = Blv.
Velocity of flow v = em/Bl
0.3 × 10 −3
= = 0.05 m/sec = 5 cm/sec.
0.1 × 60 × 10 −3
1.10 Questions and Problems

1. List the different units of flow.
2. Define mass flow rate.
3. What is meant by variable area flow meter ?
4. Water is pumped through a 150 mm diameter pipe with a flow velocity of 3.5 m/sec. Find
the volume flow rate and the weight flow rate. The density of water is 1000 kg/m3.
5. An incompressible fluid is flowing through an orifice plate with a flow coefficient of 0.5,
causing a pressure drop of 500 mm. Calculate the fluid velocity.
6. Explain the flow measurement by orifice plate with the help of a sketch giving the in-
stallation details.
7. Does the venacontracta position change in fluid flow line with change in fluid flow rate ?
8. When is a Venturi tube preferable to orifice plate ?
9. A pitot tube with coefficient of 0.93 is used to measure the velocity of air in a pipe. The
measured differential pressure is 300 mm. What is the velocity of air in the pipe ?
10. Explain the advantages and disadvantages of the three main types of orifice plates.
11. Discuss the basic principle used in positive-displacement flow meters to measure fluid
flow.
12. An incompressible fluid is flowing in a 100 mm pipe under a pressure head of 1.5 kg/
cm2. Calculate the fluid velocity and volume flow rate.
13. Explain in detail the operation of rotary-vane, oval-gear and nutating disk PD flow
meters.
14. What is meant by inferential flow meters ?
C-8\N-IND\BOOK1-6
FLOW 105
15. What are the types of inferential flow meters ?

16. Explain about target flow meters.
17. What is the principle of turbine flow meter ?
18. Does the operation of the turbine flow meter depend on liquid characteristics ?
19. Will you recommend DC supply to the electromagnet of a magnetic flow meter
carrying mercury ?
20. Which flow meters are preferable for the measurement of flow of corrosive liquids ?
21. What is the concept of cross-correlation flow meter ?
22. How will you measure the flow rate of solids ?
23. An incompressible fluid is flowing in a 300 mm pipe under a pressure head of 2.5 kg/
cm2. Calculate the fluid velocity and volume flow rate.
24. How will you measure the mass flow rate ?
25. What are the types of mass flow meters ?
26. State the features of ‘coriolis’ mass flow meters.
27. What is ‘Vortex’ ?
28. What is a flow switch ?
29. What are the types of flow switches ?
30. What is the principle of hot-wire anemometers ?
31. Explain the two types of hot wire anemometers.
32. Explain the types of mechanical anemometers.
33. Explain the principle of thermal mass flow meters.
34. Explain the excitation schemes of an electro magnetic flow meter.
35. Explain the principle of operations of an electromagnetic flow meter. Discuss its merits.
36. In an ultrasonic flow meter, the beat frequency is 805 cps, the angle (θ) between the
transmitters and receivers is 45°, and the sound path is 125 mm. Calculate the fluid
velocity in m/sec.
37. Which type of flow meter can be used to calibrate other flow meters ?
38. State the types of calibration methods available for gas flow measurement.
39. Write short notes on flow regulators.
40. Briefly explain about the selection of a flow meter.
C-8\N-IND\BOOK1-6

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1 Flow

1.2 Units of Flow

1.3 Measurement of Flow

1.4 Mechanical Flowmeters

where V = Velocity of Fluid

1.4.1.5 Flow Coefficient (K)

Fig. 1.2 Orifice and Pressure-Differential Measurement

1.4.1.6 Flow of Compressible Fluids in Pipes

2 gK P1 (P2 /P1 ) 2 / K − (P2 /P1 ) (K +1) / K

1 − β4 K (P2 /P1 ) 2 / K 1 − (P2 /P1 ) ( K – 1)/ K

Fig. 1.3 Flow pattern with orifice plate

1.4.2.2 Types of Orifice Plates

(a) Concentric (b) Eccentric (c) Segmental

(a) Concentric (b) Eccentric (c) Segmental

Fig. 1.4 Sketch of orifices of different types

Fig. 1.5 Machining Methods of Orifices

1.4.2.4 Materials Chosen For Orifices

Fig. 1.6 Location of Pressure taps with Orifice plate

High pressure tap

Fig. 1.8 Short form Venturi

(a) Eccentric type and (b) Rectangular venturi type

1.4.3.4 Installation of Venturi Tubes

Drill pipe after

Flange type of flow nozzle Details of pressure tap

Fig. 1.10 Flow nozzle

1.4.4.2 Different Designs of Flow Nozzle

(a) ASME long–radius flow nozzle

(b) Simplex type tg flow nozzole

Fig. 1.11 (a) The ASME long-radius

1.4.6.1 Pressure Pipe Layout

Slope not less

(b) Air and Gases

Meter above the pipe

(b) Air and Gases

1.4.6.2 Installation of condensation Pots

Fig. 1.17 Installation of Condensation pots

Fig. 1.18 Installation of Sealing pots

1.4.6.4 Factors to be Considered in Piping Arrangement

Corrosive liquid Corrosive gas

1.4.7 Pitot Tube

V1, P1 Stagnation point (V 2 = 0)

Impact pressure port

Static pressure port

Fig. 1.21 A common industrial type pitot tube

Impact pressure connection

Stainless steel tubing

Static pressure holes

Fig. 1.22 Typical pitot tube

High pressure port Low pressure port

Average high pressure = P H PL = Average low pressure

Fig. 1.23 Averaging pitot tube (Annubar)

Fig. 1.24 High performance differential Pressure transmitter.

4-20 mA (linear to flow)

4-20 mA (linear to head)

10.5 16.4 24.7 42

Positive displacement meters may be divided into following categories :

Fig. 1.28 Nutating disk meter

Fig. 1.29 Operating Principle of the Piston meter

1.4.9.1.3 Oval—Gear Flow Meters

Fig. 1.30 Oval-gear flow meter