Flow rate is determined inferentially by measuring the liquid's velocity or change in kinetic energy. A positive displacement flowmeter divides the liquid into specific increments and moves it on. The performance of flowmeters is also influenced by a dimensionless unit called the Reynolds number.
Flow rate is determined inferentially by measuring the liquid's velocity or change in kinetic energy. A positive displacement flowmeter divides the liquid into specific increments and moves it on. The performance of flowmeters is also influenced by a dimensionless unit called the Reynolds number.
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Flow rate is determined inferentially by measuring the liquid's velocity or change in kinetic energy. A positive displacement flowmeter divides the liquid into specific increments and moves it on. The performance of flowmeters is also influenced by a dimensionless unit called the Reynolds number.
Copyright:
Attribution Non-Commercial (BY-NC)
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Download as DOCX, PDF, TXT or read online from Scribd
An overview of types and capabilities, plus guidelines on selection, installation, and maintenance %RODUC%O easuring the flow of liquids is a critical need in many industrial plants. In some operations, the ability to conduct accurate flow measurements is so important that it can make the difference between making a profit or taking a loss. In other cases, inaccurate flow measurements or failure to take measurements can cause serious (or even disastrous) results. With most liquid flow measurement instruments, the flow rate is determined inferentially by measuring the liquid's velocity or the change in kinetic energy. Velocity depends on the pressure differential that is forcing the liquid through a pipe or conduit. Because the pipe's cross-sectional area is known and remains constant, the average velocity is an indication of the flow rate. The basic relationship for determining the liquid's flow rate in such cases is: Q = V x A where Q = liquid flow through the pipe V = average velocity of the flow A = cross-sectional area of the pipe Other factors that affect liquid flow rate include the liquid's viscosity and density, and the friction of the liquid in contact with the pipe. Direct measurements of liquid flows can be made with positive-displacement flowmeters. These units divide the liquid into specific increments and move it on. The total flow is an accumulation of the measured increments, which can be counted by mechanical or electronic techniques. Reynolds Numbers The performance of flowmeters is also influenced by a dimensionless unit called the Reynolds Number. It is defined as the ratio of the liquid's inertial forces to its drag forces.
Figure 1: Laminar and turbulent flow are two types normally encountered in liquid flow Measurement operations. Most applications involve turbulent flow, with R values above 3000. Viscous liquids usually exhibit laminar flow, with R values below 2000. %he transition zone between the two levels may be either laminar or turbulent. %he equation is: R = 3160 x Q x Gt D x where: R = Reynolds number Q = liquid's flow rate, gpm Gt = liquid's specific gravity D = inside pipe diameter, in. = liquid's viscosity, cp The flow rate and the specific gravity are inertia forces, and the pipe diameter and viscosity are drag forces. The pipe diameter and the specific gravity remain constant for most liquid applications. At very low velocities or high viscosities, R is low, and the liquid flows in smooth layers with the highest velocity at the center of the pipe and low velocities at the pipe wall where the viscous forces restrain it. This type of flow is called laminar flow. R values are below approximately 2000. A characteristic of laminar flow is the parabolic shape of its velocity profile, Fig. 1. However, most applications involve turbulent flow, with R values above 3000. Turbulent flow occurs at high velocities or low viscosities. The flow breaks up into turbulent eddies that flow through the pipe with the same average velocity. Fluid velocity is less significant, and the velocity profile is much more uniform in shape. A transition zone exists between turbulent and laminar flows. Depending on the piping configuration and other installation conditions, the flow may be either turbulent or laminar in this zone.
FLOWME%ER %!ES Numerous types of flowmeters are available for closed-piping systems. In general, the equipment can be classified as differential pressure, positive displacement, velocity, and mass meters. Differential pressure devices (also known as head meters) include orifices, venturi tubes, flow tubes, flow nozzles, pitot tubes, elbow-tap meters, target meters, and variable-area meters, Fig. 2. Positive displacement meters include piston, oval-gear, nutating-disk, and rotary-vane types. Velocity meters consist of turbine, vortex shedding, electromagnetic, and sonic designs. ass meters include Coriolis and thermal types. The measurement of liquid flows in open channels generally involves weirs and flumes. Space limitations prevent a detailed discussion of all the liquid flowmeters available today. However, summary characteristics of common devices are shown in Table 1. (Click here to see Table1) Brief descriptions follow. Differential !ressure Meters The use of differential pressure as an inferred measurement of a liquid's rate of flow is well known. Differential pressure flowmeters are, by far, the most common units in use today. Estimates are that over 50 percent of all liquid flow measurement applications use this type of unit. The basic operating principle of differential pressure flowmeters is based on the premise that the pressure drop across the meter is proportional to the square of the flow rate. The flow rate is obtained by measuring the pressure differential and extracting the square root. Differential pressure flowmeters, like most flowmeters, have a primary and secondary element. The primary element causes a change in kinetic energy, which creates the differential pressure in the pipe. The unit must be properly matched to the pipe size, flow conditions, and the liquid's properties. And, the measurement accuracy of the element must be good over a reasonable range. The secondary element measures the differential pressure and provides the signal or read-out that is converted to the actual flow value. Orifices are the most popular liquid flowmeters in use today. An orifice is simply a flat piece of metal with a specific-sized hole bored in it. ost orifices are of the concentric type, but eccentric, conical (quadrant), and segmental designs are also available. In practice, the orifice plate is installed in the pipe between two flanges. Acting as the primary device, the orifice constricts the flow of liquid to produce a differential pressure across the plate. Pressure taps on either side of the plate are used to detect the difference. ajor advantages of orifices are that they have no moving parts and their cost does not increase significantly with pipe size. Conical and quadrant orifices are relatively new. The units were developed primarily to measure liquids with low Reynolds numbers. Essentially constant flow coefficients can be maintained at R values below 5000. Conical orifice plates have an upstream bevel, the depth and angle of which must be calculated and machined for each application. The segmental wedge is a variation of the segmental orifice. It is a restriction orifice primarily designed to measure the flow of liquids containing solids. The unit has the ability to measure flows at low Reynolds numbers and still maintain the desired square-root relationship. Its design is simple, and there is only one critical dimension the wedge gap. Pressure drop through the unit is only about half that of conventional orifices. Integral wedge assemblies combine the wedge element and pressure taps into a one-piece pipe coupling bolted to a conventional pressure transmitter. No special piping or fittings are needed to install the device in a pipeline. etering accuracy of all orifice flowmeters depends on the installation conditions, the orifice area ratio, and the physical properties of the liquid being measured. Venturi tubes have the advantage of being able to handle large flow volumes at low pressure drops. A venturi tube is essentially a section of pipe with a tapered entrance and a straight throat. As liquid passes through the throat, its velocity increases, causing a pressure differential between the inlet and outlet regions. The flowmeters have no moving parts. They can be installed in large diameter pipes using flanged, welded or threaded-end fittings. Four or more pressure taps are usually installed with the unit to average the measured pressure. Venturi tubes can be used with most liquids, including those having a high solids content. Flow tubes are somewhat similar to venturi tubes except that they do not have the entrance cone. They have a tapered throat, but the exit is elongated and smooth. The distance between the front face and the tip is approximately one-half the pipe diameter. Pressure taps are located about one-half pipe diameter downstream and one pipe diameter upstream. Flow ozzles, at high velocities, can handle approximately 60 percent greater liquid flow than orifice plates having the same pressure drop. Liquids with suspended solids can also be metered. However, use of the units is not recommended for highly viscous liquids or those containing large amounts of sticky solids. !itot tubes sense two pressures simultaneously, impact and static. The impact unit consists of a tube with one end bent at right angles toward the flow direction. The static tube's end is closed, but a small slot is located in the side of the unit. The tubes can be mounted separately in a pipe or combined in a single casing. Pitot tubes are generally installed by welding a coupling on a pipe and inserting the probe through the coupling. Use of most pitot tubes is limited to single point measurements. The units are susceptible to plugging by foreign material in the liquid. Advantages of pitot tubes are low cost, absence of moving parts, easy installation, and minimum pressure drop. Elbow meters operate on the principle that when liquid travels in a circular path, centrifugal force is exerted along the outer edges. Thus, when liquid flows through a pipe elbow, the force on the elbow's interior surface is proportional to the density of the liquid times the square of its velocity. In addition, the force is inversely proportional to the elbow's radius. Any 90 deg. pipe elbow can serve as a liquid flowmeter. All that is required is the placement of two small holes in the elbow's midpoint (45 deg. point) for piezometer taps. Pressure-sensing lines can be attached to the taps by using any convenient method. %arget meters sense and measure forces caused by liquid impacting on a target or drag-disk suspended in the liquid stream. A direct indication of the liquid flow rate is achieved by measuring the force exerted on the target. In its simplest form, the meter consists only of a hinged, swinging plate that moves outward, along with the liquid stream. In such cases, the device serves as a flow indicator. A more sophisticated version uses a precision, low-level force transducer sensing element. The force of the target caused by the liquid flow is sensed by a strain gage. The output signal from the gage is indicative of the flow rate. Target meters are useful for measuring flows of dirty or corrosive liquids. Variable-area meters, often called rotameters, consist essentially of a tapered tube and a float, Fig. 3. Although classified as differential pressure units, they are, in reality, constant differential pressure devices. Flanged-end fittings provide an easy means for installing them in pipes. When there is no liquid flow, the float rests freely at the bottom of the tube. As liquid enters the bottom of the tube, the float begins to rise. The position of the float varies directly with the flow rate. Its exact position is at the point where the differential pressure between the upper and lower surfaces balance the weight of the float. Because the flow rate can be read directly on a scale mounted next to the tube, no secondary flow-reading devices are necessary. However, if desired, automatic sensing devices can be used to sense the float's level and transmit a flow signal. Rotameter tubes are manufactured from glass, metal, or plastic. Tube diameters vary from 1/4 to greater than 6 in. !ositive-Displacement Meters Operation of these units consists of separating liquids into accurately measured increments and moving them on. Each segment is counted by a connecting register. Because every increment represents a discrete volume, positive-displacement units are popular for automatic batching and accounting applications. Positive-displacement meters are good candidates for measuring the flows of viscous liquids or for use where a simple mechanical meter system is needed.
Reciprocating piston meters are of the single and multiple-piston types. The specific choice depends on the range of flow rates required in the particular application. Piston meters can be used to handle a wide variety of liquids. A magnetically driven, oscillating piston meter is shown in Fig. 4. Liquid never comes in contact with gears or other parts that might clog or corrode. Oval-gear meters have two rotating, oval-shaped gears with synchronized, close fitting teeth. A fixed quantity of liquid passes through the meter for each revolution. Shaft rotation can be monitored to obtain specific flow rates. utating-disk meters have a moveable disk mounted on a concentric sphere located in a spherical side-walled chamber. The pressure of the liquid passing through the measuring chamber causes the disk to rock in a circulating path without rotating about its own axis. It is the only moving part in the measuring chamber. A pin extending perpendicularly from the disk is connected to a mechanical counter that monitors the disk's rocking motions. Each cycle is proportional to a specific quantity of flow. As is true with all positive-displacement meters, viscosity variations below a given threshold will affect measuring accuracies. any sizes and capacities are available. The units can be made from a wide selection of construction materials. Rotary-vane meters are available in several designs, but they all operate on the same principle. The basic unit consists of an equally divided, rotating impeller (containing two or more compartments) mounted inside the meter's housing. The impeller is in continuous contact with the casing. A fixed volume of liquid is swept to the meter's outlet from each compartment as the impeller rotates. The revolutions of the impeller are counted and registered in volumetric units. Helix flowmeters consist of two radically pitched helical rotors geared together, with a small clearance between the rotors and the casing. The two rotors displace liquid axially from one end of the chamber to the other. 'elocity Meters These instruments operate linearly with respect to the volume flow rate. Because there is no square-root relationship (as with differential pressure devices), their rangeability is greater. Velocity meters have minimum sensitivity to viscosity changes when used at Reynolds numbers above 10,000. ost velocity-type meter housings are equipped with flanges or fittings to permit them to be connected directly into pipelines.
%urbine meters have found widespread use for accurate liquid measurement applications. The unit consists of a multiple-bladed rotor mounted with a pipe, perpendicular to the liquid flow. The rotor spins as the liquid passes through the blades. The rotational speed is a direct function of flow rate and can be sensed by magnetic pick-up, photoelectric cell, or gears. Electrical pulses can be counted and totalized, Fig. 5. The number of electrical pulses counted for a given period of time is directly proportional to flow volume. A tachometer can be added to measure the turbine's rotational speed and to determine the liquid flow rate. Turbine meters, when properly specified and installed, have good accuracy, particularly with low-viscosity liquids. A major concern with turbine meters is bearing wear. A "bearingless" design has been developed to avoid this problem. Liquid entering the meter travels through the spiraling vanes of a stator that imparts rotation to the liquid stream. The stream acts on a sphere, causing it to orbit in the space between the first stator and a similarly spiraled second stator. The orbiting movement of the sphere is detected electronically. The frequency of the resulting pulse output is proportional to flow rate. Vortex meters make use of a natural phenomenon that occurs when a liquid flows around a bluff object. Eddies or vortices are shed alternately downstream of the object. The frequency of the vortex shedding is directly proportional to the velocity of the liquid flowing through the meter, Fig. 6. The three major components of the flowmeter are a bluff body strut- mounted across the flowmeter bore, a sensor to detect the presence of the vortex and to generate an electrical impulse, and a signal amplification and conditioning transmitter whose output is proportional to the flow rate, Fig. 7. The meter is equally suitable for flow rate or flow totalization measurements. Use for slurries or high viscosity liquids is not recommended. Electromagnetic meters can handle most liquids and slurries, providing that the material being metered is electrically conductive. ajor components are the flow tube (primary element), Fig. 8. The flow tube mounts directly in the pipe. Pressure drop across the meter is the same as it is through an equivalent length of pipe because there are no moving parts or obstructions to the flow. The voltmeter can be attached directly to the flow tube or can be mounted remotely and connected to it by a shielded cable. Electromagnetic flowmeters operate on Faraday's law of electromagnetic induction that states that a voltage will be induced when a conductor moves through a magnetic field. The liquid serves as the conductor; the magnetic field is created by energized coils outside the flow tube, Fig. 9. The amount of voltage produced is directly proportional to the flow rate. Two electrodes mounted in the pipe wall detect the voltage, which is measured by the secondary element. Electromagnetic flowmeters have major advantages: They can measure difficult and corrosive liquids and slurries; and they can measure forward as well as reverse flow with equal accuracy. Disadvantages of earlier designs were high power consumption, and the need to obtain a full pipe and no flow to initially set the meter to zero. Recent improvements have eliminated these problems. Pulse-type excitation techniques have reduced power consumption, because excitation occurs only half the time in the unit. Zero settings are no longer required. Ultrasonic flowmeters can be divided into Doppler meters and time-of-travel (or transit) meters. Doppler meters measure the frequency shifts caused by liquid flow. Two transducers are mounted in a case attached to one side of the pipe. A signal of known frequency is sent into the liquid to be measured. Solids, bubbles, or any discontinuity in the liquid, cause the pulse to be reflected to the receiver element, Fig. 10. Because the liquid causing the reflection is moving, the frequency of the returned pulse is shifted. The frequency shift is proportional to the liquid's velocity. A portable Doppler meter capable of being operated on AC power or from a rechargeable power pack has recently been developed. The sensing heads are simply clamped to the outside of the pipe, and the instrument is ready to be used. Total weight, including the case, is 22 lb. A set of 4 to 20 millampere output terminals permits the unit to be connected to a strip chart recorder or other remote device. Time-of-travel meters have transducers mounted on each side of the pipe. The configuration is such that the sound waves traveling between the devices are at a 45 deg. angle to the direction of liquid flow. The speed of the signal traveling between the transducers increases or decreases with the direction of transmission and the velocity of the liquid being measured. A time-differential relationship proportional to the flow can be obtained by transmitting the signal alternately in both directions. A limitation of time-of- travel meters is that the liquids being measured must be relatively free of entrained gas or solids to minimize signal scattering and absorption.
Mass Flowmeters The continuing need for more accurate flow measurements in mass-related processes (chemical reactions, heat transfer, etc.) has resulted in the development of mass flowmeters. Various designs are available, but the one most commonly used for liquid flow applications is the Coriolis meter. Its operation is based on the natural phenomenon called the Coriolis force, hence the name.
Coriolis meters are true mass meters that measure the mass rate of flow directly as opposed to volumetric flow. Because mass does not change, the meter is linear without having to be adjusted for variations in liquid properties. It also eliminates the need to compensate for changing temperature and pressure conditions. The meter is especially useful for measuring liquids whose viscosity varies with velocity at given temperatures and pressures. Coriolis meters are also available in various designs. A popular unit consists of a U-shaped flow tube enclosed in a sensor housing connected to an electronics unit. The sensing unit can be installed directly into any process. The electronics unit can be located up to 500 feet from the sensor. Inside the sensor housing, the U-shaped flow tube is vibrated at its natural frequency by a magnetic device located at the bend of the tube. The vibration is similar to that of a tuning fork, covering less than 0.1 in. and completing a full cycle about 80 times/sec. As the liquid flows through the tube, it is forced to take on the vertical movement of the tube, Fig. 11. When the tube is moving upward during half of its cycle, the liquid flowing into the meter resists being forced up by pushing down on the tube.
Having been forced upward, the liquid flowing out of the meter resists having its vertical motion decreased by pushing up on the tube. This action causes the tube to twist. When the tube is moving downward during the second half of its vibration cycle, it twists in the opposite direction. Having been forced upward, the liquid flowing out of the meter resists having its vertical motion decreased by pushing up on the tube. This action causes the tube to twist. When the tube is moving downward during the second half of its vibration cycle, it twists in the opposite direction. The ammount of twist is directly proportional to the mass flow rate of the liquid flowing through the tube. agnetic sensors located on each side of the flow tube measure the tube velocities, which change as the tube twists. The sensors feed this information to the electronics unit, where it is processed and converted to a voltage proportional to mass flow rate. The meter has a wide range of applications from adhesives and coatings to liquid nitrogen. %hermal-type mass flowmeters have traditionally been used for gas measurements, but designs for liquid flow measurements are available. These mass meters also operate independent of density, pressure, and viscosity. Thermal meters use a heated sensing element isolated from the fluid flow path. The flow stream conducts heat from the sensing element. The conducted heat is directly proportional to the mass flow rate. The sensor never comes into direct contact with the liquid, Fig. 12. The electronics package includes the flow analyzer, temperature compensator, and a signal conditioner that provides a linear output directly proportional to mass flow. Open Channel Meters The "open channel" refers to any conduit in which liquid flows with a free surface. Included are tunnels, nonpressurized sewers, partially filled pipes, canals, streams, and rivers. Of the many techniques available for monitoring open- channel flows, depth-related methods are the most common. These techniques presume that the instantaneous flow rate may be determined from a measurement of the water depth, or head. Weirs and flumes are the oldest and most widely used primary devices for measuring open-channel flows. Weirs operate on the principle that an obstruction in a channel will cause water to back up, creating a high level (head) behind the barrier. The head is a function of flow velocity, and, therefore, the flow rate through the device. Weirs consist of vertical plates with sharp crests. The top of the plate can be straight or notched. Weirs are classified in accordance with the shape of the notch. The basic types are V-notch, rectangular, and trapezoidal. Flumes are generally used when head loss must be kept to a minimum, or if the flowing liquid contains large amounts of suspended solids. Flumes are to open channels what venturi tubes are to closed pipes. Popular flumes are the Parshall and Palmer-Bowlus designs. The Parshall flume consists of a converging upstream section, a throat, and a diverging downstream section. Flume walls are vertical and the floor of the throat is inclined downward. Head loss through Parshall flumes is lower than for other types of open-channel flow measuring devices. High flow velocities help make the flume self-cleaning. Flow can be measured accurately under a wide range of conditions. Palmer-Bowlus flumes have a trapezoidal throat of uniform cross section and a length about equal to the diameter of the pipe in which it is installed. It is comparable to a Parshall flume in accuracy and in ability to pass debris without cleaning. A principal advantage is the comparative ease with which it can be installed in existing circular conduits, because a rectangular approach section is not required. Discharge through weirs and flumes is a function of level, so level measurement techniques must be used with the equipment to determine flow rates. Staff gages and float-operated units are the simplest devices used for this purpose. Various electronic sensing, totalizing, and recording systems are also available. A more recent development consists of using ultrasonic pulses to measure liquid levels. easurements are made by sending sound pulses from a sensor to the surface of the liquid, and timing the echo return. Linearizing circuitry converts the height of the liquid into flow rate. A strip chart recorder logs the flow rate, and a digital totalizer registers the total gallons. Another recently introduced microprocessor-based system uses either ultrasonic or float sensors. A key-pad with an interactive liquid crystal display simplifies programming, control, and calibration tasks. SELEC%G A FLOWME%ER Experts claim that over 75 percent of the flowmeters installed in industry are not performing satisfactorily. And improper selection accounts for 90 percent of these problems. Obviously, flowmeter selection is no job for amateurs. The major steps involved in the selection process are shown in Fig. 13. The most important requirement is knowing exactly what the instrument is supposed to do. Here are some questions to consider. Is the measurement for process control (where repeatability is the major concern), or for accounting or custody transfer (where high accuracy is important)? Is local indication or a remote signal required? If a remote output is required, is it to be a proportional signal, or a contact closure to start or stop another device? Is the liquid viscous, clean, or a slurry? Is it electrically conductive? What is its specific gravity or density? What flow rates are involved in the application? What are the processes' operating temperatures and pressures? Accuracy (see glossary), range, linearity, repeatability, and piping requirements must also be considered. It is just as important to know what a flowmeter cannot do as well as what it can do before a final selection is made. Each instrument has advantages and disadvantages, and the degree of performance satisfaction is directly related to how well an instrument's capabilities and shortcomings are matched to the application's requirements. Often, users have expectations of a flowmeter's performance that are not consistent with what the supplier has provided. ost suppliers are anxious to help customers pick the right flowmeter for a particular job. any provide questionnaires, checklists, and specification sheets designed to obtain the critical information necessary to match the correct flowmeter to the job. Technological improvements of flowmeters must be considered also. For example, a common mistake is to select a design that was most popular for a given application some years ago and to assume that it is still the best instrument for the job. any changes and innovations may have occurred in recent years in the development of flowmeters for that particular application, making the choice much broader. A recent development is the availability of computer programs to perform the tedious calculations often necessary for selecting flowmeters. Calculations that used to take an hour can be performed in a matter of seconds (see accompanying section, "Selected Reference aterial"). Click Here For Questions To Ask When Selecting A Flowmeter Cost Considerations There are a wide range of prices for flowmeters. Rotameters are usually the least expensive, with some small-sized units available for less than $100. ass flowmeters cost the most. Prices start at about $3500. However, total system costs must always be considered when selecting flowmeters. For example, an orifice plate may cost only about $50. But the transmitter may add an additional $500 or $600, and sensing line fabrication and installation may cost even more. Installation, operation, and maintenance costs are important economic factors too. Servicing can be expensive on some of the more complicated designs. As with many other products, a plant engineer generally gets what he pays for when he purchases a flowmeter. But the satisfaction that he receives with the product will depend on the care that he uses in selecting and installing the instrument. And that gets back to knowing the process, the products, and the flow-metering requirements. "Overbuying" is not uncommon. Plant engineers should not buy a flowmeter more capable or complicated than they need. WORKG W% FLOWME%ERS Although suppliers are always ready to provide flowmeter installation service, estimates are that approximately 75 percent of the users install their own equipment. But installation mistakes are made. One of the most common is not allowing sufficient upstream and downstream straight-run piping for the flowmeter. Every design has a certain amount of tolerance to nonstable velocity conditions in the pipe, but all units require proper piping configurations to operate efficiently. Proper piping provides a normal flow pattern for the device. Without it, accuracy and performance are adversely affected. Flowmeters are also installed backwards on occasion (especially true with orifice plates). Pressure-sensing lines may be reversed too. With electrical components, intrinsic safety is an important consideration in hazardous areas. ost flowmeter suppliers offer intrinsically safe designs for such uses. Stray magnetic fields exist in most industrial plants. Power lines, relays, solenoids, transformers, motors, and generators all contribute their share of interference. Users must ensure themselves that the flowmeter they have selected is immune to such interference. Problems occur primarily with the electronic components in secondary elements, which must be protected. Strict adherence to the manufacturer's recommended installation practices will usually prevent such problems. Calibration All flowmeters require an initial calibration. ost of the time, the instrument is calibrated by the manufacturer for the specified service conditions. However, if qualified personnel are available in the plant, the user can perform his own calibrations. The need to recalibrate depends to a great extent on how well the meter fits the application. Some liquids passing through flowmeters tend to be abrasive, erosive, or corrosive. In time, portions of the device will deteriorate sufficiently to affect performance. Some designs are more susceptible to damage than others. For example, wear of individual turbine blades will cause performance changes. If the application is critical, flowmeter accuracy should be checked at frequent intervals. In other cases, recalibration may not be necessary for years because the application is noncritical, or nothing will change the meter's performance. Some flowmeters require special equipment for calibration. ost manufacturers will provide such service in their plant or in the user's facility, where they will bring the equipment for on-site calibration. Maintenance A number of factors influence maintenance requirements and the life expectancy of flowmeters. The major factor, of course, is matching the right instrument to the particular application. Poorly selected devices invariably will cause problems at an early date. Flowmeters with no moving parts usually will require less attention than units with moving parts. But all flowmeters eventually require some kind of maintenance. Primary elements in differential pressure flowmeters require extensive piping, valves, and fittings when they are connected to their secondary elements, so maintenance may be a recurring effort in such installations. Impulse lines can plug or corrode and have to be cleaned or replaced. And, improper location of the secondary element can result in measurement errors. Relocating the element can be expensive. Flowmeters with moving parts require periodic internal inspection, especially if the liquid being metered is dirty or viscous. Installing filters ahead of such units will help minimize fouling and wear. Obstructionless instruments, such as ultrasonic or electromagnetic meters, may develop problems with their secondary element's electronic components. Pressure sensors associated with secondary elements should be periodically removed and inspected. Applications where coatings may occur are also potential problems for obstructionless instruments such as magnetic or ultrasonic units. If the coating is insulating, the operation of magnetic flowmeters will ultimately be impaired if the electrodes are insulated from the liquid. This condition will be prevented by periodic cleaning. With ultrasonic flowmeters, refraction angles may change and the sonic energy absorbed by the coating will cause the meter to become inoperative.
Velocity-Profile Deviations Influence Flow meter Performance Selecting the right flow meter for the liquid
Close your eyes and imagine a world in which all Iluids Ilowing down pipes are perIectly homogeneous, having no disturbances or eddies in the Ilow stream. A world in which pipes always contain Iully developed turbulent Ilow and pipe bends and obstructions are non-existent. Sounds silly right? But these are the hypothetical conditions upon which Ilowmeter accuracies are based. II deviations Irom these conditions exist, accuracy and/or repeatability will degrade. This article will discuss the Iirst oI Iour major inIluence quantities that aIIect Ilowmeter accuracy and perIormance: velocity-proIile deviations, non-homogenous Ilow, pulsating Ilow, and cavitation. With this background, we will then look at how these inIluence quantities Iactor into Ilowmeter perIormance and what can be done to minimize their eIIect. Imagine a horizontal pipe a Iew Ieet in Iront oI you at about eye level. II a vertical cut were made through the center oI the pipe to remove the Iront halI oI the pipe, it would be easy to see how "nicely behaved" Iluid Ilow develops.
I|gure 1 2ero L|qu|d V|scos|ty In the hypothet|ca| s|tuat|on shown here the ||qu|d v|scos|ty |s zero and the ve|oc|ty prof||e |s a stra|ght ||ne 1he vert|ca| sheet of f|u|d moves forward at ve|oc|ty V The cross-sectional view shown in Figure 1 illustrates a hypothetical situation in which the Iluid has zero viscosity. In this example, the velocity gradient is constant and equal across the entire cross-section. That is, the Iluid velocity at the pipe walls is equal to the Iluid velocity at the pipe center and at all points in-between. However, every liquid has some measure oI viscosity; thereIore, the velocity proIile becomes distorted Irom this "ideal case scenario."
-ewton|an Ve|oc|ty rof||es xamples oI Newtonian Iluids include water, milk, sugar solutions and mineral oils. Distortions can occur Ior homogeneous Newtonian Iluids Ior a number oI reasons. The viscosity oI a Newtonian Iluid is dependent only on temperature, but not on shear rate and time. The Ilow oI a Newtonian Iluid will exhibit a "sticking" eIIect on the walls oI the pipe. In Iact, the boundary conditions placed on the stationary pipe wall demand that the Iluid in direct contact with the pipe walls have zero velocity (or at least that is what is assumed in the calculations within this article). It is this boundary condition that distorts a Newtonian Iluid's velocity proIile. II the velocity vector at the pipe wall is zero, the maximum velocity occurring in the pipe can be worked out mathematically.
I|gure 2 Samp|e -ewton|an I|u|d Ve|oc|ty rof||e Ior steady f|ow |n a p|pe of rad|us k conta|n|ng a sma||er cy||ndr|ca| e|ement of ||qu|d rad|us r a shear force deve|ops equa| and oppos|te to the cy||ndr|ca| water e|ement pressure Consider a pipe oI radius "R" that contains a smaller cylindrical element oI liquid oI radius "r." See Figure 2. Assuming the cylindrical element oI Iluid is moving uniIormly through the pipe, at constant velocity, the shearing Iorce on the pipe wall is equal to the pressure Iorce oI the liquid moving through. The shear Iorce, which is directly proportional to the velocity gradient, is given by: (dv/dy) where: is the shear Iorce or shear pressure. dv/dy is the velocity gradient (where y is the distance Irom the pipe wall). is the constant oI proportionality, also reIerred to as the dynamic viscosity. Because the Iluid pressure can be simply given as the pressure diIIerential through the pipe times the cross-sectional Iluid area, and because the Iluid pressure Iorce is equal to the oppositely directed shear Iorce on the pipe wall, the equation can be written: Shear Wall Force (2nr)L 2nrL(dv/dy) APA APnr 2 Fluid Pressure where: r is the radius oI the cylindrical Iluid element. L is the length oI the cylindrical Iluid element. AP is the pressure diIIerential through the pipe. A is the cross-sectional area oI the Iluid element Solving Ior t, we get APr/2L It is more convenient in this example to give the shear Iorce as a Iunction oI the pipe center instead oI the pipe wall. This is easily accomplished easily by rewriting the shear Iorce as: -(dv/dr) (dv/dy) quating these two expressions Ior the shear stress t gives us the Iollowing relationship: APr/2L -(dv/dr) Solving Ior the velocity gradient yields: dv/dr -APr/2L By integrating this expression across the pipe to radius R, the velocity (V) as a Iunction oI the radius r can be determined. V AP/4L(R 2 - r 2 ) Now it can be seen mathematically that the maximum velocity in the pipe occurs at the center oI the pipe, or when r 0. Actually, these two Iactsthat the velocity at the pipe wall is zero and the maximum velocity occurs at the pipe centerare the boundary conditions used to determine the constant oI proportionality Ior the above integration. This equation is in the Iorm oI a parabola. Graphing it gives the velocity proIile shown in Figure 3.
I|gure 3 Lam|nar I|ow rof||e for -ewton|an I|u|d 1he ve|oc|ty |s zero at the p|pe wa|| and |ncreases parabo||ca||y w|th f|ow reach|ng |ts max|mum at the p|pes center This proIile develops at certain velocities Ior Newtonian Iluids and is called laminar Ilow. Laminar Ilow is characterized by Iluid movement in layers or streamlines with very little mixing occurring between those layers. The Iluid layers are restrained Irom mixing by the viscous Iorces within the liquid. Laminar Ilow is very well behaved and predictable. However, as the velocity oI the Iluid increases within the pipe, inertial Iorces start to overcome the viscous Iorces, and small eddies and Iluid oscillations will Iorm, causing the Iluid layers to start mixing. For a while, the Iluid might shiIt to being somewhat laminar, but the eddies keep working to mix the Iluid layers. This partial mixing oI the streamlined layers is known as transitional Ilow. Transitional Ilow is not really laminar Ilow but it is not Iully turbulent Ilow either. In Iact, the Iluid may exhibit laminar Ilow at some pipe radii and turbulent Ilow at other radii. II a dye stream were to be injected into the pipe, it would waver and mix slightly as it moves down the pipe. The velocity proIile Ior transitional Ilow is diIIicult to predict because it changes with time, being laminar-like in some instances and turbulent-like in others. As the velocity oI the Iluid within the pipe increases Iurther, Iully turbulent Ilow develops. Turbulent Ilow is characterized by the laminar Ilow streams completely breaking up and mixing together as the Ilow moves down the pipe. Although the average Ilow still moves down the pipe, there will be small Ilow velocities in the radial r direction as well. As eddies Iorm in the Iluid stream, they will break down randomly into smaller eddies, swirls and vortices, leading to increased shear within the liquid. Is there any way to predict when each oI these regimeslaminar, transitional and turbulent Ilowwill dominate the Iluid Ilow? The answer, oI course, is yes. The Reynolds number helps determine what type oI Ilow can be expected. Named aIter the Iluid dynamics research oI Osborne Reynolds, the Reynolds number is simply the ratio oI momentum to viscous Iorces. It takes into account the Iluid density, viscosity, and pipeline velocity. II the viscous Iorces are large (low Reynolds number), the viscous eIIects oI the Iluid will dampen out any tendency oI streamline mixing. For large inertial Iorces, there will not be enough viscous damping Ior laminar Ilow to continue, and the Ilow will become transitional or turbulent. The equation Ior the Reynolds number is: R vD/ where: v is the average velocity. D is the pipe diameter. is the density. is the dynamic viscosity. Using SI units, it becomes apparent that the Reynolds number is dimensionless. The units oI vDp are (meters/sec) x (meters) x (kg/meters 3 ), and the units oI are (kg/meters x sec). The rule oI thumb is that the Ilow will be laminar below an R oI 2,000. Between an R oI 2,000 and 4,000, the Ilow is transitional; above 4,000, the Ilow is turbulent. In actuality, there are no distinct breaks between laminar, transitional, and turbulent Ilows. For example, depending on the Iluid, Iully developed transitional Ilow might not occur until R equals roughly 7,000. So, what is the velocity proIile Ior turbulent Ilow? This is a diIIicult question as the proIile is not a Iixed geometry. It changes with the wall roughness and Reynolds number. The velocity equation Ior homogeneous Newtonian Ilow in the turbulent regime (see Figure 4) is: V r V av 1 + 1.44\f + 2.15\f log 10 (1-r/R)] where: V r is the velocity at radius r. V av is the average Ilow velocity. R is the radius oI the pipe. f is the Iriction Iactor. The Iriction Iactor is diIIicult to calculate because turbulent Ilow is unpredictable, but a lot oI experimental data exist on this subject. The Iriction Iactor comes into play when the pipe wall is not smooth. For a rough pipe interior, the Iluid closer to the walls is held back because oI the additional shear. This, in turn, causes the velocity proIile to become Ilatter and blunter in Iront.
I|gure 4 1urbu|ent I|ow rof||e for a -ewton|an I|u|d 1he ve|oc|ty |s zero at the p|pe wa|| but the face ve|oc|ty |s stra|ghter and squared up One widely used method oI determining the Iriction Iactor is the Moody diagram. Moody-diagram- related reIerences are included in the bibliography. The velocity equation shows that the maximum Ilow will occur at r 0, just like it did Ior laminar Ilow. At r 0, the equation becomes: V max V av (1 + 1.43\f) Figure 4 shows that the Iace velocity is more uniIorm and squared up. As the velocity oI the Iluid continues to increases, the Iace velocity will continue to straighten up until all particles are moving at the same velocity (except at the pipe walls, where the Ilow will remain at zero). This hypothetical situation, where the Iace velocity is completely Ilat, is known as inIinite Reynolds number proIile, or plug Ilow.
-on-ewton|an I|u|ds How does the velocity proIile change when the ratio oI shear stress to shear strain is no longer constant? BeIore attempting to answer this question, it is helpIul to outline the diIIerent types oI non-Newtonian Iluids. lass I: time-independent non-Newtonian fluids. These Iluids have a viscosity at a given shear stress that does not vary with time. Class 1 nonNewtonian Iluids include pseudoplastic, dilatant and plastic Iluids. Pseudoplastic Iluids, also known as shear-thinning Iluids, decrease in viscosity as the shear rate increases. xamples include paints, shampoos and water suspensions oI clay. Dilatant Iluids, also known as shear-thickening Iluids, increase in viscosity as the shear rate increases. xamples include corn starch in water, titanium dioxide, and wet sand. Plastic Iluids, also called Bingham or plug-Ilow Iluids, behave as a solid until a critical shear ratecalled the yield valueis reached. At the yield value, the Iluid will start to Ilow. As the shear rate continues to increase, the Iluid then might exhibit Newtonian, dilatent or pseudoplastic characteristics. xamples include tomato paste, toothpaste, hand cream, chocolate, mayonnaise, and grease. lass II: time-dependent non-Newtonian fluids. These Iluids have a viscosity at a given shear stress that will vary with time. They include thixotropic and rheopectic Iluids. Thixotropic Iluids, also known as time-thinning Iluids, experience a decrease in viscosity over time while the rate oI shear is constant. xamples include yogurt and paint. Rheopectic Iluids, also called time-thickening Iluids, exhibit an increase in viscosity over time as the shear remains constant. Rheopectic Iluids are pretty rare. xamples include gypsum paste and printers ink. What makes the Ilow oI nonNewtonian Iluids so interesting is the required boundary condition oI zero Ilow at the pipe walls. This boundary condition imparts a varying shear rate into the Iluid as the Iluid velocity changes. And because a nonNewtonian Iluid exhibits changing viscosity with changing shear rates, the Iluid can react in a wide variety oI ways. Like Newtonian Iluids, non-Newtonian Iluids have laminar, transitional, and turbulent Ilow patterns. For time-independent nonNewtonian Iluids, the Iluid viscosity does not change with time, assuming a nonchanging shear rate. As the Iluid moves down the pipe, the velocity distribution between the Iluid layers varies and changes with the varying shear that results Irom the zero velocity boundary condition at the walls oI the pipe. Another important condition is the apparent viscosity oI the liquid. Because the Iluid viscosity changes with the shear rate, the apparent viscositythe viscosity at a particular rate oI shearmust be used to calculate the Ilow proIile instead oI the dynamic or absolute viscosity discussed Ior Newtonian Iluids. This makes the velocity proIile impossible to predict completely and correctly.
I|gure S 1|meIndependent -on-ewton|an Lam|nar I|ow rof||es Shown are prof||es of pseudop|ast|c d||atant and p|ast|c ||qu|ds over the prof||e of a -ewton|an ||qu|d However, the velocity proIile still has some inherent symmetry. For the laminar Ilow region, the velocity proIile is calculated as a deviation or departure Irom the laminar Newtonian proIile. Figure 5 lays the typical velocity proIiles oI pseudoplastic, dilatant, and plastic liquids over the proIile oI a Newtonian liquid, revealing the distortions that can occur Ior time-independent nonNewtonian laminar Ilows. The Iace proIile Ior a plastic Iluid is very Ilat. The entire Ilat Iace is known as the plug diameter and can vary greatly, depending on the type oI plastic Iluid moving down the pipe, as well as on the upstream pressure. Remember, plastic Iluids will behave as a solid until shear stress reaches the critical yield value. They then will start Ilowing. NonNewtonian Iluids can be characterized by a Reynolds number whereby they will move Irom laminar to transitional to turbulent Ilows. This Reynolds number, however, is calculated diIIerently Ior pseudoplastic, dilatant, and plastic Iluids. For Iully developed turbulent Ilow, Ilow proIiles are similar enough to Newtonian Iluids that the Newtonian Reynolds number equation can be used iI apparent viscosity is substituted Ior dynamic viscosity. Thixotropic Iluids can experience some interesting eIIects, depending on whether the shear increases, decreases, or stays constant. A thixotropic Iluid that increases in shear rate up to a constant value, dwelling at that value Ior a time beIore dropping back down to zero shear, can experience a decrease in apparent viscosity during the dwell time. When the shear rate is brought back down to zero, a yield value can be reached that will mimic the eIIects oI a plastic Iluid. The Ilow proIile will go Irom parabolic shaped to plug-Ilow shaped. OI course, this type oI pipeline scenario is extremely rare. Because rheopectic Iluids increase in apparent viscosity with time at constant shear, they are sometimes known as negative thixotropic Iluids. Rheopectic Iluids will exhibit the same type hysteresis curve as thixotropic Iluids, but generally return to the same initial viscosity once the rate oI shear drops to zero. Like thixotropic Iluids, rheopectic Iluids moving through a pipe are normally in the laminar regime and will typically exhibit the normal-to-slightly distorted parabolic curves already discussed, assuming that the Ilow has had enough time to Iully develop through a straight section oI pipe. An excellent and much deeper discussion oI Ilow prIiles and how they develop in pipe Ilow can be Iound in the Flow Measurement and ngineering Handbook, written by Richard Miller (Cole-Parmer #00545-08).
I|owmeter erformance and I|ow rof||e D|stort|ons In each case discussed previously, the Ilow is through a long, straight section oI piping, and the velocity proIile had time to develop and stabilize as it moved down the pipe. This stabilization and development oI the velocity proIile is known as Iully developed Ilow. Although it is great Ior doing Iluid dynamics calculations, in the real world, pipes undergo bends, turns, reductions, and enlargements as they twist their way through a typical plant. What happens to these velocity proIiles under some oI these conditions, and how do the velocity proIiles aIIect Ilowmeter placement and Ilowmeter perIormance? In general, because the Ilow proIile is smooth and Ilat over most oI the pipe diameter, turbulent Ilow is preIerred Ior a Ilowmeter over laminar and transitional Ilows. It's much easier to calibrate and check the repeatability oI a Ilowmeter using a Iully developed turbulent Ilow proIile than it is using the parabolic Ilow proIile oI laminar Ilow or the unstable Ilow proIile oI transitional Ilow. This is not mean laminar Ilow is bad Ior Ilowmeters. In Iact, stable laminar Ilow is Iairly easy to measure accurately, providing the appropriate technology is used. The Iirst step in choosing a particular Ilow technology is to Iind out its acceptable Reynolds number range and then to calculate the Reynolds extremes oI the application. A minimum Reynolds number is calculated by using the minimum expected Iluid Ilow and density and the maximum expected viscosity. A maximum Reynolds number is calculated using the maximum expected Iluid Ilow and density and the minimum expected viscosity. Another way to assess the conditions oI a Ilow application is through use oI Doppler or transit-time Ilow technologies. Paddle-Wheel Flowmeters: These use a small rotor usually having Iour blades embedded with magnets. The paddle is inserted into the pipe at a Iixed depth; the rate at which it turns is proportional to the Ilowrate. One oI the advantages oI the paddle-wheel meter is it will work with a large range oI pipe sizes. Typically, the paddle-wheel sensor can be installed in plastic or metal pipes Irom 1/2 inch (in.) up to 36 in. or larger. The paddlewheel itselI is only an inch or so in diameter, so iI it is installed in a large pipe, it would have problems measuring laminar Ilow (see Figure 6).
I|gure 6 add|eWhee| I|owmeter Insta||at|on Lxamp|e A|though they can be used |n stab|e |am|nar f|ow app||cat|ons to read max|mum or average f|ow padd|ewhee| f|owmeters are more accurate when used w|th fu||y deve|oped turbu|ent f|ow Adjustable insertion depth sensors are available to allow exact positioning oI the paddle-wheel within the pipe, but they have limited value with laminar Ilow and assume that the ratio between the measured velocity and the average Iluid velocity is stable, which is not always the case. II an insertion sensor must be used in a laminar Ilow application, plant operators should try to Iind the point where the Iluid velocity is related to the average velocity on a one-to-one basis. This point will be roughly one- eighth oI the pipe diameter Irom the inside pipe wall, and should be Iairly independent oI the Reynolds number. For smaller pipe sizes oI a Iew inches or so, this is a lesser problem, and center-line insertion might be the best option. For a 20-inch pipe however, the Ilow proIile gradient can be too sharp to allow accurate or consistent measurement by correlating a speciIic velocity within the pipe to an average pipe velocity. Similarly, Ior transitional Ilow, because the Ilow proIile is unstable, the paddle-wheel design does not oIIer accurate or repeatable results. Because turbulent Ilow proIile is blunted, Ilat and stableassuming it has had time to Iully stabilize while Ilowing down the pipeit is the best proIile when using a paddle-wheel sensor. In Iact, manuIacturers will calibrate their paddle sensors to Iully developed turbulent Ilow within their Ilow calibration loop; thereIore, paddle-wheel manuIacturers have very speciIic upstream and downstream straight piping requirements. Venturi-one Differential Pressure Flowmeters: These Ilowmeters oIIer quite a design contrast to paddle-wheel Ilowmeters. Developed in the early 1980's, the Venturi-cone, or V-cone Ior short, uses a cone positioned in the pipe's center. The cone geometry and placement Iorce the Iluid to move around the cone, generating a pressure drop across the length oI the cone. See Figure 7. This pressure drop is proportional to the Ilow velocity within the pipe.
I|gure 7 Vent ur|Cone I|owmeter Insta||at|on Lxamp|e In th|s |nsta||at|on the suspended cone reshapes the approach|ng f|ow prof||e upstream The cone is always suspended at the pipe center, so Ior laminar Ilow, the maximum Iluid Ilow is driven into the "point" oI the cone. This eIIectively Iorces the high-velocity portion oI the laminar Ilow stream to mix with the lower velocity layers, causing the upstream Ilow proIile to mix and Ilatten into a more well-developed turbulent pattern. The V-cone's ability to Ilatten irregular Ilow proIiles is quite strong and even allows the V-cone meter to be installed Iairly close to pipe elbows and bends, something usually avoided with other Ilow technologies. The meter acts as its own Ilow conditioner, shaping irregular or laminar Ilow proIiles into more stable turbulent-like Ilow proIiles. This allows the technology to be used over a wide range oI Reynolds number. %urbine Flowmeters: These Ilowmeters use a rotating turbine placed directly in the Iluid path. Although designs vary, a pulsing signal usually is generated as the turbine blades pass a magnetic pickup coil. The Irequency oI the pulses is proportional to the Iluid velocity in the pipe. For laminar and transitional Ilow patterns (i.e., having low Reynolds numbers), the number oI pulses per unit volume, the K-Iactor, can vary, causing a loss oI accuracy and repeatability. For this reason, turbine meters are best used in turbulent Ilow conditions. Many turbine manuIacturers that build Ilow straighteners directly into the body oI the Ilowmeter to minimize any upstream swirls generated by pipe bends, which also can degrade accuracy and repeatability. Insertion turbine meters, like the paddle-wheel sensors, will measure the velocity at only a particular point within the pipe. ThereIore, they are better suited to Iully developed turbulent Ilow. Magnetic Flowmeters: These Ilowmeters measure the average Ilow over the pipe diameter and show very little perIormance change in going Irom laminar to transitional to Iully turbulent Ilow. Insertion mag meters will measure the Ilow within a localized point around the sensor. In both designs, however, swirling eddies or vortices that occur in pipe bends and turns can pose problems. Also, because velocity proIile distortions can occur in several Iluid planes simultaneously, velocity averaging Ior Iull-bore magnetic Ilowmeters has its limitations. For this reason, manuIacturers usually recommend Iive pipe diameters oI straight run pipe upstream and two pipe diameters downstream to stabilize any variations in the Ilow proIile. Gear Flowmeters: These Ilowmeters work by Iorcing speciIic volumes oI Iluid between two coupled gears. The Iluid normally is trapped between the gear and the inner Ilowmeter housing. AIter the number oI Iluid pockets passing through in a particular time period is determined, the Ilow can be calculated. See Figure 8.
I|gure 8 Gear I|owmeter W|th each gear rotat|on a pocket of prec|se|y measured f|u|d |s formed he|d t|ght|y aga|nst the chamber wa|| then re|eased This positive-displacement Ilowmeter has an accuracy that is independent oI the Reynolds number. It typically works best when there is a little back-pressure downstream. This can be achieved by the use oI a control valve downstream, throttled just enough to allow a slight back-pressure. The back-pressure, in turn, helps ensure that the Iluid pockets within the Ilow cavity are Iull throughout meter operation. Because the Ilowmeter is grabbing speciIic volumes oI Iluid and moving them Irom the inlet to the outlet, the meter is not aIIected by the Reynolds number. The Ilow can be laminar, transitional, or turbulent and still work well with gear design. One caution, however: Because thin, water-like Iluids have the ability to slip past the gears, accuracy will not be as high as it is when the Iluid is thicker. A general rule oI thumb is not to use gear meters Ior liquids under 5 centipoise. Co Lo 1op
Assess|ng |pe I|ow Cond|t|ons lbows, reducers, chemical injection ports, Iilters, screens and valves also can cause radial, tangential and axial swirling eIIects within the pipe. In combination, these changes can rapidly distort the velocity proIile, degrading the Ilowmeter's accuracy and repeatability. This is one reason why manuIacturers give straight-length upstream and downstream piping requirements Ior installation. It is important to gain an understanding oI the conditions oI a pipe's Ilow to select a Ilowmeter that will be acceptable Ior worst-case conditions. II the Iluid conditions within a pipe are unkown or the actual Ilow proIile in certain piping sections needs to be studied, a special type oI non-contact ultrasonic Ilowmeter can be oI great beneIit. Known as pulsed-Doppler Ilowmeters, the devices work by allowing true velocity measurements to be made at multiple points along the pipe diameter. This can help assess the Ilow proIile in larger pipes, but because the pulses are typically a Iew centimeters long, they are oI little help in smaller pipes. Also, the Iluid within the pipe must contain either particulate matter or bubbles Ior the Doppler signal to reIlect properly. An insertion meter also can be used to help determine the Ilow proIile in a pipe. It measures the point velocity at several transverse locations within the pipe. Although the meter does a pretty good job in determining the velocity proIile, any change in the Ilow conditions can alter the Ilow proIile itselI. Once some inIormation on the Ilow proIile has been gleaned, meter selection and installation will be improved. II proIiling the Ilow within the pipe is not practical or not desired, the Ilow must be stable enough to get the maximum accuracy possible with the Ilow technology being used. This can be accomplished through strict adherence to the manuIacturer's recommended upstream and downstream piping requirements. II these straight-length requirements are not practical in the plant, Ilow conditioners and straighteners could be used. Co Lo 1op
I|ow Cond|t|oners A stable Ilow proIile can be compromised quickly iI any pipe bends, reducers, valves, strainers, or a variety oI other velocity-proIile killers exist. See Figure 9. In addition, it is not always possible to adhere strictly to the manuIacturer's recommended straight-piping requirements because many plants have minimized production spaces to eIIect cost-eIIiciency.
I|gure 9 Common I|owrof||e D|stort|on Cu|pr|ts |pe e|bows reducers and a var|ety of other ve|oc|typrof||e k|||ers qu|ck|y can comprom|se a stab|e f|ow prof||e Normal upstream piping requirements aIter a 90 degree elbow can range Irom 15 to 25 pipe diameters. For two 90 degree elbows in diIIerent planes, the straight piping run beIore the Ilowmeter can rise to 50 or more pipe diameters. Through Ilow straightener use, these straight-piping runs can be it can be decreased by a Iactor oI Iour or more. Downstream piping runs are normally Iar less than upstream requirements and are in the range oI 5 to 10 pipe diameters. A properly installed Ilow conditioner will isolate the liquid Ilow disturbances Irom the Ilowmeter while minimizing the pressure drop across the conditioner. A good Ilow conditioner will remove swirls Irom the Iluid stream and allow the proIile velocity to come up to Iully turbulent Ilowor at least a stable acceptable geometryquickly. The popular honeycomb/tube Ilow conditioners are great at eliminating swirl, but their small size makes them prone to becoming clogged. In general, as the eIIiciency oI a Ilow conditioner correcting Ilow proIile distortions goes up, so does the corresponding pressure drop. Remember, although Ilow conditioners can reduce the amount oI straight piping required signiIicantly, they should not be used to cut corners. The manuIacturer's requirements Ior straight piping beIore and aIter the Ilow conditioner should be Iollowed. Co Lo 1op
Conc|us|on and kecommendat|ons In many cases, the Iluid Ilow through a pipe will be Iast enough to be in the turbulent regime. Allowing the required straight piping runs will eliminate swirls and vortices and will allow the velocity proIile to be stable and well blunted. This is the perIect condition Ior Ilow measurement. But, as discussed previously, many Iactors can alter this ideal condition. Here are some items to keep in mind as you assess the conditions within your pipe: Pipe Assessment: How old is the pipe in which the meter will be installed? II the pipe is old, what is the inside surIace condition? II the pipe has a rough interior or scale or coating buildup, the Ilow proIile will be distorted and the accuracy oI the meter could be degraded. II the velocity proIile is in question, you can use a pulse-Doppler meter or an adjustable insertion meter to measure the velocity at diIIerent pipe depths. This will allow you to see iI there is a stable correlation between the measured point velocity and the average velocity Ilowing through the pipe. The expected minimum and maximum Reynolds numbers should be calculated. The manuIacturer should provide the recommended Reynolds number range Ior its Ilowmeter design. A minimum Reynolds number is calculated by using the minimum expected Iluid Ilow and density while using the maximum expected viscosity. A maximum Reynolds number is calculated using the maximum expected Iluid Ilow and density while using the minimum expected viscosity Accuracy and Repeatability: What accuracy and repeatability are needed? Is repeatability more important? II so, the plant will have more leeway in selecting a less-expensive Ilow technology such as an insertion meter. In general, a Iull bore in-line meter is more accurate than an insertion meter, especially in situations in which velocity proIile distortions are present. However, Ior larger pipes, an insertion meter is less expensive, and the lower accuracy may still be suIIicient Ior the application at hand. Remember, in some applications, it is repeatability that is the critical Iactor, not necessarily accuracy. Both insertion meters and Iull-bore meters can provide excellent repeatability. II necessary, in-line Ilow conditioners should be used Ior liquid swirling and/or Ilow proIile instability that occurs aIter pipe bends; otherwise, the manuIacturers recommended upstream and downstream piping requirements should be Iollowed strictly. II it is possible, plants should pick a point in the piping system that ensures major disturbances are at least Iive pipe diameters downstream instead oI upstream. For example, a valve should be placed downstream oI the Ilowmeter instead oI upstream whenever possible. The same is true Ior pipe bends, expanders or reducers. Positioning Within the Pipe: For insertion meters, it is important Ior plants to Iind out whether the manuIacturer recommends center-line positioning or an oII-center installation where the velocity point corresponds to the average velocity. Positioning Ior best accuracy will change, based on the Reynolds number. In some cases, more than one insertion sensor can be used at diIIerent depths to provide a more complete picture. Sensor arrays that stretch across a large pipe are available Ior just this purpose. Remember, even iI the Ilow proIile isn't completely stable, it is possible with a little work and patienceto use an insertion meter in a large pipe and attain very stable repeatability and an indication oI the average pipe Ilow.
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