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Introduction
? Flow measurement is the quantification of bulk fluid movement (gas & liquid). It can be measured in a variety of ways. Both gas & liquid flow can be measured in volumetric flow rates (Q) or mass flow rates ()such as litres per second or kilograms per second.
Reynolds's Number The Reynoldss number is a very important reference number in the accurate determination of flow. It is used to determine the point at which the flow goes from the viscous stage to the turbulent stage. As flow changes from the viscous stage to the turbulent stage, there is a large change in the value of the flow co-effcient, but there is very little change for further increase in speed The Reynoldss number is a very important reference number in the accurate determination of flow.
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In differential pressure flow meters, for higher accuracy, Reynolds's number is very important. The Reynolds's number is given by the equation:
Re= VD/ where Re= Reynolds's number V = Avg. velocity. D = Inside pipe diameter. =Density of flowing fluid. = Absolute viscosity
Differential pressure based flow metera) orifice flow meter. b) venturi flow meter. c) flow nozzles
Magnetic
U=K.B.v.D , where
K= Instrumental constant B= strength of magnetic field v = Avg. velocity D= pipe diameter During the electromagnetic flow measurement the fluid passes through a magnetic field applied normally to the direction of flow
The induced voltage is taken to a converter by means of 2 electrodes which are in direct contact with the fluid. The converter then transmits a standard output signal (current). The output current is in the range of 4-20 mA. The movement of the liquid (electrically are conductive) induces an electric voltage which is proportional to the average flow velocity & therefore to the volume flow.
protruding parts inside the measuring tube, so no additional pressure loss. Only the lining of the pipe walls & and the electrodes are in contact with the measuring fluid. Measurement is independent of the flow profile and other characteristics of the fluid.
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A vortex-shedding body is installed perpendicularly to the axis of the flow. Due to which vortex-shedding is generated, called karman vortex street, with alternating pressure conditions. The frequency , f , of the karman vortex street is directly proportional to the flow velocity (v).
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The relationship between vortex shedding frequency (f in hz) with the diameter of the pipe (D) & the max. flow velocity (v) is given by:f= S.v/D where S is the proportionality constant. The vibrations of the vortex shedding body are picked up by sensors and then analysed in signal converters. The vibration frequency varies between 10hz & 7000 hz.
Ultrasonic flowmeter
ultrasonic flowmeters works in 2 different kind of principles: 1) Doppler Effect Ultrasonic Flowmeter The Doppler Effect Ultrasonic Flowmeter uses reflected ultrasonic sound to measure the fluid velocity. By measuring the frequency shift between the ultrasonic frequency source, the receiver and the fluid carrier. In this the relative motion are measured. The resulting frequency shift is named the Doppler Effect. 2) Transit Time Difference Ultrasonic Flowmeter With the Time of Flight Ultrasonic Flowmeter the time for the sound to travel between a transmitter and a receiver is measured. This method is not dependable on the particles in the fluid.
These are also called variable head flow meters. Types of D.P flow meters:1)orifice flow meters. 2)venturi flow meters 3)flow nozzles. The d.p flow meters operates on the principle that an obstruction in the pipe of a flowing fluid produces a differential pressure across the obstruction.
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This differential pressure is proportional to the flow rate. The flow rate is proportional to the square root of the differential pressure. This relationship is derived from Bernoullis theorem. Bernoulli theorem states that in a flowing stream, the sum of pressure head, velocity head & elevation head at one point is equal to their sum at another point
Cost is relatively low for large lines. It is accurate and reliable. It can be easily removed without shutting down the process. It is adaptable to any pipe size and flow rate. It offers the widest applicational coverage of any type of flow meter.
There is high pressure loss in it. It is difficult to use for slurry services. It exhibits a square root relationship head & flow rate , rather than linear characteristics. Low flow rates are not easily measured with these meters. Its accuracy is dependent on fixed fluid characteristics such as temp., pressure, specific gravity, etc.
2) Converging conical system: The converging takes place at an angle of 21 2. The velocity increases & pressure falls. 3) Throat: It is a cylindrical section of minimum area At this point velocity is max. & pressure is minimum. 4) Diverging conical system: Here there is a change of stream area back to the entrance area. The recovery of kinetic energy by its conversion to pressure is complete & overall pressure loss is small.
Advantages:Loss of head due to installation in the pipelines is small. High coefficient of discharge. Less likelihood of becoming clogged by sediments.
Disadvantages:
Due to long lying length, space requirement is high. Quite expensive in installation & replacement.
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The minimum area is called vena contracta. It is the area where the minimum pressure is obtained. The location of the vena contracta depends on Reynolds number, area ratio between orifice and pipe, the roughness of the pipe & the compressibility of the fluid. By measuring the difference in the fluid pressure between the normal pipe section & the vena contracta, the flow rate can be determined from the Bernoullis equation
Flow nozzle:
Cojet system is used in Electric arc Furnace for shrouding & oxygen lancing. In cojet system, we have:1) Flow valves. (on-off valves). 2) Flow transmitter. 3) Flow control valves. 4) Pressure transmitters. Firstly, the flow valves are opened. The flow valve can only be in either on state (100% open) or off state(0% open).
The flow transmitter measures the flow of the fluid & sends electrical signals corresponding to the flow of the fluid. The flow control valve controls the flow of the fluid passing through the pipeline. The flow control valve can be of 2 types. 1) Air to open. 2) Air to close. The pressure transmitter measures the back pressure,if any,in the pipeline & sends signals corresponding to the magnitude of back pressure
The back pressure is caused by chocking of the pipeline due to solid particles present in the fluid. There are three main lines which enters injector 1. 1) Main oxygen line. 2) Post combustion line. 3) Shroud oxygen line. The post combustion line is not in use. Similarly there is one propane line which also consists of flow valves, flow transmitter, flow control valve & pressure transmitter,
In oxygen line, after flow valves , there is one pressure transmitter & one RTD ( Resistance Temperature Detector). This pressure transmitter is used to measure the pressure in the pipeline before oxygen is released in the pipes & RTD measures the temperature. There is one air line which is connected to the flow control valves as it is operated by air.
Installations
Pressure transmitter:At cojet:Company Siemens Measuring span - 0.63-68 bar Output- 4-20mA Supply- 10.5 45 V d.c Installed at- Propane line
Differential pressure transmitter: Company: Yokogawa Calibration: 0 to 250 mmwc Pressure Transmitter: At steam & water line:Company Yokogawa Output- 4-20mA Supply- 10.5 45 V d.c
At Argon line (S.M.S):Company Rosemount Measuring span - 0- 10 torr Output- 4-20mA Supply- 10.5 45 V d.c
Flow transmitter:-
At cojet:Company Yokogawa Output- 4-20mA Supply- 10.5 45 V d.c Range - 0.-100 Nm3/hr. At CCM (primary water line):Company Yokogawa Fluid temp- -40 to 60C Ambient temp- -20 to 60C Supply- 10.5 45 V d.c Range - 0 to 2200 LPM
Flow valves:
At cojet: Max. pressure: 8 bar Output torque: 4 bar Max. flow : 216 Nm Min. flow : 132 Nm Solenoid valve: Company : AVCO Input: 24V d.c Range : 2 to 10 bar, temp: 80C
If the multimeter reading is not equal to 4 mA then the flow transmitter is needed to be calibrated. Then the low side & high side of the flow transmitter is maintained at atmospheric pressure & the zero pot of flow meter is adjusted till 4 mA appears at the multimeter. Then the high side is maintained at the highest pressure ( i.e at 1200 mmwc ,for a flow transmitter of range 0-1200mmwc
Then the span pot of the flow transmitter is adjusted till we get 20 mA at the multimeter. In different flow meters , there are different provisions for the adjustment of zero & span pot. The master calibrator is used for applying pressure at the high side of the transmitter. Make- Yokogawa & range is 200kPa. The master calibrator works on the pneumatic principle.
The calibration of flow meters is also done with the help of brain terminal device & heart terminal device. Some flow meters can be calibrated by brain terminal ( having suffix D) & Some flow meters can be calibrated by heart terminal ( having suffix E). With the help of brain terminal device & heart terminal device , we can also change the operating range of the flowmeter.
For flow measurement, the pressure tapping are taken before & after the obstruction in the flow of the fluid. Both the tapping are mounted on the meter itself. For pressure measurement, only one tapping is taken from the meter. The other tapping is held in air for the atmospheric pressure. For flow measurement, the difference between the pressure of the fluid before & after the obstruction is taken
For pressure measurement, the difference between the fluid pressure & the atmospheric pressure is taken. Flow meters are used for flow measurement. Pressure gauges or vacuum gauges are used for pressure measurement