8/5/2014 Restriction Orifice (RO) - Flow Control Instrument

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Restriction Orifice (RO) Flow Control
Instrument
1. Introduction to Restriction orifice (RO)
Restriction orifice (RO) is mainly used to achieve controlled or restricted flow of process medium. The orifice
offers a restriction to the process flow and the pressure head drops from the upstream to the downstream. The
permanent pressure loss by the device is the intended pressure drop for which it is sized. The area of the orifice
determines the rate of flow at the outlet of a given process fluid for the specified pressure and temperature.
The responsibility of final restriction orifice sizing, selection & supply rests with the supplier. Design and sizing of
restriction orifice may require review by specialist for stress and noise related evaluation.
2. Codes & Standards
Though no internationally reputed codes and standards exist which directly address a restriction orifice but there
are associated references and some are listed below:
(i) ISO 5167 Part 1: Measurement of fluid flow by means of pressure differential devices inserted in
circular cross-section conduits running full Part 1: General principles and requirements.
(ii) ISO 5167 Part 2: Measurement of fluid flow by means of pressure differential devices inserted in
circular cross-section conduits running full Part 2: Orifice plates.
(iii) IEC 60534-8-3: Industrial-process control valves Part 8-3: Noise considerations
Control valve aerodynamic noise prediction method.
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3. Types of restriction orifice plates
Here is a description of a few common type of restriction orifice plate device used in Oil and Gas applications.
(i) Single stage restriction orifice.
A single stage restriction orifice is usually a plate or a block with a bore (orifice) sized to the intended permanent
loss of pressure. It is installed between the pipe flanges. Usually it is not a thin orifice plate; it is a thick orifice
plate.
Figure 1 Single stage Restriction
Orifice Plate
(ii) Single stage multi-hole restriction orifice.
A single stage multi-hole restriction orifice plate is used to abate the noise generated by the device due to high
velocity through the bore which offers restriction to the incoming fluid. The flow at the inlet is now channeled into
several streams through the multiple holes and this reduces the noise which would be otherwise will be above the
acceptable limit if a single hole device is used.
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Figure 2 Single stage Multi-hole Restriction Orifice Plate
(iii) Multi-stage restriction orifice plate assembly.
These devices are used where the pressure reduction ratio is very high and cannot be achieved by a single stage
orifice plate. Thus a multistage device essentially consists of a number of single stage device built in a single
spool. Like a single stage device it can be of single hole multi stage design or multi-hole multi-stage design or
combination of both.
The Restriction Orifices are arranged in eccentric manner, diametrically opposite each other during fabrication of
MRO.
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Figure 3 Multistage Restriction Orifice Plate Assembly (Cutaway view)
4. Application of restriction orifice plates
Followings are a few examples of common applications where these restriction orifice devices are used to
achieve controlled flow from the upstream to the downstream. Restriction orifices are often exposed to severe
flow conditions associated with large pressure reductions and the related fluid conditions caused by liquids
flashing to a gas, cavitation, and sonic (choked) flow. Hence such conditions also are taken into consideration.
(i) Restriction Orifice (RO) at the downstream of blowdown valves.
These are used to ensure controlled flow rate in a blowdown piping or blowdown header.
When the blowdown valve (which is usually a FB or RB ball valve) opens to release the high pressure on its
upstream, the restriction orifice plate at its downstream ensures that the flow is not excessive to overload the flare
header. Usually the pressure drop in blowdown circuit across the restriction orifice could be very high say,
typically 80-100 bar. If high pressure drop is achieved through a single stage device or by a device with not too
many stages, there will be fall in temperature during the blowdown event due to Joule Thompson effect. Thus the
design of the RO needs to take care of the low temperature.
(ii) Restriction Orifice (RO) in pump recirculation line.
ROs are also used in centrifugal pumps recirculation line where a constant recirculation flow is required and
control of recirculation and forward flow rate is not important. The recirculation ensures that cavitations /
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starvation cannot happen in the pump.
(iii) Restriction Orifice (RO) to restrict gas blow-by.
A typical case is the flow of hydrocarbon condensate from the high pressure separator to the low pressure
separator. Usually a level control valve (LCV) controls the level of the high pressure separator. In case of the
valve failure, the valve needs to open fully to stop separator from overflowing. Full open of LCV is accompanied
by high rate of flow of condensate followed by flow of gas. To stop the downstream relieving system from
overloading the gas flow is controlled by a restriction orifice at the downstream of the LCV. Similar application is
seen in the heating medium flow into re-boiler to mitigate the effect of heating medium valve fail open position.
(iv) Restriction Orifice (RO) to check excess flow.
ROs are used to restrict the excessive flow in case of a rupture. Thus in Well head applications if the down holes
valves to be closed due to fire, the hydraulic power oil to the valve actuator is depressurized by the use of fusible
plug which fuses and allows the hydraulic oil to leak through a RO at a restricted flow rate.
(v) Restriction Orifice (RO) for controlled pressurization.
During the start-up of a process plant, many plant sections are required to be pressurized with the incoming
process fluid in controlled manner. This is because the upstream section will be usually at a much higher pressure
than the downstream. Thus if there is no restriction on the flow rate, the initial flow rate may be very high and
may damage the pipe line and equipment. ROs are used for gradual pressurization. To restrict the flow the ideal
condition is to design for the choked flow for gas. As during the choked flow, the rate of flow will be less as it
will be proportional to the square root of inlet pressure rather than to the differential pressure.
5. Literatures
Followings are some of the useful publications which may be referred for Restriction Orifice (RO) details.
(i) Flow Measurement Engineering Handbook, by Richard W. Miller
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