Flow element sizing & Design

Application & Selection

Service condition( Fluid type)
On site Accuracy ( % FS or %AF)
Reynolds variation
(Re= 3,160 * Gf *Qf/d* )
Safety
Installation
Long term repeatability
Low Installed cost
Easy Maintenance
 Magnetic flow meter
Measures velocity of an electrically conductive liquid
as it cuts magnetic field produced across the metering
tube ( Faradays Law)
No moving components ( No wear & tear on
components)
completely unobstructed bore (no pressure loss),
indifference to viscosity, pressure, temperature &
density
Linear analog output
Suitable for bidirectional flow
Extensive range of sizes, ease and rapidity of re-
ranging at site
Used for corrosive liquids, slurries, low pressure loss
application.
Limitation: Fluid must be electrically conductive
 Magnetic flow meter
Theory : E=BDV/C Where E Induced voltage
E V D ID of flow meter
Q=VA B- Magnetic field of strength
C- Constant to take proper unit
V- Linear velocity of fluid
A- Area
 Magnetic flow meter
AC excitation - Apply line voltage to magnetic coil
- signal generated is a low level AC signal
(V to mV )
-to be periodically rezeroed by stopping
flow & maintaining a full pipe to zero out
any voltages present at that time.
DC excitation - Pulsed DC signal to magnetic coil
- Eliminates the noise signal due to periodic
excitation of magnetic coil.
- establishes zero during each on/off cycle.
Dual excitation- superimposed AC and DC excitation
- Zero stability, noise rejection, high speed
of response.
 Magnetic flow meter
Design pressure: Typically 285 PSIG to 2500 PSIG.
Design temp :Upto 120 Deg.C with teflon liners and
upto 180 deg.c with ceramic liners.
Material (Liners): Ceramic, fiberglass, neoprene,
polyurethane, rubber, TEFLON, Kynar etc
( Electrodes) : Platinum, Alloy 20, Hastelloy C, SS,
tantalum, titanium, monel, etc
Minimum conductivity required : 1 to 5 S/cm . Special
design can operate at 0.05 or 0.1 S/cm (Thershold)
Flow ranges : Typically 0.04 to 3,78,000 l/m
Velocity range : 0.3 to 30 ft/s
Sizes range : 0.1 to 96 inches in diameter
Power consumption: 20W with DC excitation, 30W for a 2
& 0.3kW for a 30 AC units
Error: 1% of actual flow with pulsed DC units within a
range upto 10:1 , 1% to 2% Full scale with AC
excitation
 Magnetic flow meter
Installation :
- Flow meter must always be full to assure accurate
measurement ( Low points in Horizontal lines or
preferably vertical up flow line)
- Meter electrode must remain in electrical contact with
fluid being measured.( Electrode to be in horizontal
plane)
- Grounding is mandatory ( essential to install a ground
strap to a grounded piece of structural steel, a
grounding rod)
- straight run requirements conservatively 3D to 5D
upstream straight length and 2 or 3D downstream
length
Magnetic flow meter
Magnetic flow meter
Magnetic flow meter
 Ultrasonic flow meter
Doppler meter
-Ultrasonic pulse is beamed into the pipe and reflected by
inclusions ,such as air or dirt)
-used as clamp on device which can be fitted into existing
pipeline to measure velocity only
- Not good in accuracy
- Not suitable for clean fluids
- Low cost and independent of pipe size
Transit time flow meter
- Project an ultrasonic beam right across the pipe at an
acute angle, first with the flow & then in opposition to flow
direction.( The difference in transmit time is proportional
to flow rate.)
- More expensive , better accuracy, requires relatively clean
liquids & ideally suited for corrosive liquids,
- No obstruction to flow ( little pressure loss)
 Ultrasonic flow meter
Transit time flow meter
Tab= L/(C+VCos) Where C -speed of sound in the
liquid
Tba = L/(C-VCos) angle of the path w.r.t
pipe axis
t = Tba-Tab = 2LVcos/C, L acoustic path length
V= L. t /2cost, t- average transmit time between

= K. t /t the transducer.
Q = VA
Ultrasonic flow meter
 Ultrasonic flow meter
Spool piece or pipe section must always be full to assure
proper operation and volumetric flow indication
Straight run requirements ( Typically 10D to 20 D upstream
and 5D downstream )
Liquid must be free of solids and air bubbles
Flow velocity ranges: 1 to 50 ft/s
Process temperature : -184 to 260 deg.c
Design pressure : upto 3000 PSIG for wetted, unlimited for
clamp on type
Material of construction : Spools or transducers probes can
be steel, SS or alloys
Sizes : 0.125 to 120 inch dia.
Inaccuracy : 1% of actual flow to 2% FS.
Repeatability : 0.5% depending on velocity range &
calibration.
 Ultrasonic flow meter
Doppler flow meter
The transmitter of Doppler projects a ultrasonic beam at
0.5MHz into flowing stream & detects the reflected frequency
which is shifted in proportion to stream velocity.
The difference between transmitted & reflected velocity is
called beat frequency
V= f.Ct/(2.fo.cos) where f- difference between Tx
= f.K & Rd frequency
fo frequency of transmission
- angle of Txr & Rcr crystal w.r.t pipe axis
Ct- Velocity of sound in transducer
 Ultrasonic flow meter
Pipe must be full for accurate volumetric flow reading
Straight run requirements ( Typically 10D to 20 D upstream
and 5D downstream for clean liquids. However increase
with solid composition or solid concentration)
Used for slurries with solids ( 0.2 to 60% concentration),
liquids that are aerated or contain bubbles, gases with
sound reflecting particles
Flow velocity range : Min.velocity for solids to stay in
suspension is about 2.5ft/s, bubble requires 6ft/s,otherwise
0.2 to 60 ft/s would be usable.
Process temperature : -186 to 260 deg.c
Design pressure : unlimited for clamp on
Material of construction : usually clamp on ( pipe material
shall be sonically conductive), concrete, clay & porous cast
iron pipes not suitable.
Sizes : 0.5 to 72 inches diameter
Inaccuracy : 2 to 5% of FS
Ultrasonic flow meter
 Variable area meters
Widely used for small flow rate measurement where local
indications required
Vertical tapered tube with a float to move freely up & down with
the flow varying the area of annular passage between the float &
tube. Tube is tapered so that there is a linear relationship between
flow rate and float position.
Available in glass tube & metal tube construction
Glass tube meters
- Low cost ,
- constant low pressure loss
- Direct flow indication
- ability to detect very low flow rates of both gases & liquid
including viscous fluids
- Limitation : limited availability of transmitter, limited
in terms of higher pressure & temperature rating,
relatively low accuracy, requirement of vertical
installation.
 Variable area meters
Metal tube meter:
- readily available with transmitter
- can be obtained in large sizes and higher
pressure rating
- Provides good rangeability and linear
output.
- Indication through the conversion of linear
motion into rotary motion with the
arrangement of magnetic helix parallel to
tube and embedded magnet on the float.
- Limitation : to be used on relatively clean
liquids and must be mounted vertically
 Variable area meters
Sizing:
- convert actual flow to standard flow
- For liquid flow it is necessary to calculate flow rate water
equivalent & for gases on air equivalent.
Liquids (Volume rate ):
GPM water equivalent = (GPM)()(2.65)/ ((f- ))
Gas or Vapors ( standard volume rate):
SCFM air Eqv = (SCFM (g std)(10.34)/(f(g act))
Where GPM - max flow of liquid at metering condition
density of flowing liquid at metering
f - density of float in units of grams per cubic centimeter
SCFM- Max flow of gas to a standard condition.
g std- density of gas @14.7 PSAI & 70 deg F
g act density of gas @ metering condition (pound per
cubic feet)
 Variable area meters
Standard design pressure : 350 PSIG for glass tube
720 PSIG for metal tube
Standard design temperature : 204 deg C for glass tube
538 deg.c for metal tube
Fluids : Liquids, gases and vapors
Flow range : 0.01cc/m to 4000GPM of liquids
0.3cc/m to 1300SCFM of gases
Inaccuracy : 1% to 2% of full scale over 10:1 range
Material of construction :
(Tube ) Borosilicate glass, SS, Hastelloy,Monel , Alloy 20
(Float) - brass, SS, Hasteolly, Monel, alloy20 etc
Variable area meters
 Mass flow meter
Coriolis
- Ability to measure the mass flow directly with high accuracy
& rangeability. Measure wide variety of fluids.
- Capable to measure process fluid density & temperature
Theory: An element of fluid having mass (m )moving
outward with velocity (v)through a tube that is rotating
about a fixed axis perpendicular to the centerline of the tube
imparts a coriolis acceleration to the moving element.
- Two acceleration components exists (a) result of rotation
of tube which cause the directional change in the fluid
element velocity (v) , a= V ( where V- fluid element
velocity , - angular velocity of tube)
(b) result of change in linear velocity (Vt) of the tube with
changing distance (r) from the rotation axis. Vt=r
( At the axis the, Linear velocity of the tube and elements is
zero).
 Mass flow meter
- As the fluid moving outwards, r & Vt increases, causing
fluid element to be accelerated. at= dVt/dt results of rate
of change in distance r is the fluid element velocity V ,
Hence a= V . Coriolis acceleration= 2V;
Coriolis force Fc= 2mV
- Coriolis force is proportional to the to the mass of the fluid
element & to the fluid velocity.
Fc= m2l where l is the fluid element length.
m= Fc/2l d: Oscillation frequency
m= K/d ,K- depends on Geometry &MOC
= Kt

Primary components
- Flow tube Assembly
( sensor)
- electronic assembly
 Mass flow meter
Sensor
- Flow tube,
- a driving mechanism for oscillating the flow tube,
- flow detector mounted on either side of the driving
mechanism for measuring the time or phase difference
between two sides of the flow tube.
- The function of sensor is to react to the coriolis force
produced by fluid flowing through oscillating tubes. The
electronics provides the energy to oscillate the flow tubes,
process the signals from flow detectors.
Flow detectors uses electromagnetic sensor.
Effect of temperature changes: Mass flow rate is adequately
compensated for, as long as flow tube temperature is
measured and effect of temperature of the tube stiffness
have been characterized.
 Mass flow meter
Effect on density change which can alter the mass balance
of the sensor. Requires different calibration factors at
different fluid densities.
Effect of increasing pressure causes deformation of flow
tube which will tend to reduce the generated time or phase
difference causing error in measurement.
Care to be taken for meter subject to natural vibration, pipe
stress etc.
Sensor should remain full of process fluid, Two phase flow
should be avoided.
Sizes : 1/16 to 6 inches
Flow range : 0 to 25000 lb/m
Fluids : Liquids, slurries, compressed gas, liquefied gas
Operating pressure : Typically standard 1800 PSIG,
5000 PSIG typically high pressure
 Mass flow meter
Pressure drop required: under 10 psig to 100 psig
Operating temperature : -73 to 204 deg.c typical standard
0 to 426 deg.c typical high pressure
Material of construction : SS, Hastelloy, Titanium, etc.,
Inaccuracy : 0.15% to 0.5% of rate
Repeatability: 0.05 to 0.2 % of rate
Rangeability : 20:1 calibration range
Limitations: - Not available for larger pipelines
- Some flow meter requires extremely high
fluid velocity to achieve significant time of
phase difference.( thereby high pressure drop)
- Expensive
Difficulty in measuring the flow rate of low
pressure gas ( marginally @ 150 psig)
Mass flow meter
Mass flow meter
Mass flow meter
 Turbine flow meter
The speed of rotation of bladed turbine , driven by fluid,
provides a digital output linear with flow rate
available for liquids, gases, for very low flow rates
Offers good rangeability 10:1
Suitable for high pressures & high & low temperatures
application
Speed of response is fast
Linear frequency outputs
Less pressure drop ( 3 to 5 psig)
Limitation : incompatibility with high viscosity or dirty
liquids, Filtration is recommended
 Turbine flow meter
Turbine meter:
- It consists of a multibladed
rotor suspended in fluid stream
on a free running bearing.
- Axis of rotation of rotor is
perpendicular to the flow
direction
- Angular speed of rotation is
proportional to volumetric flow
rate. The speed of rotation is
monitored by electromagnetic
pick up coil fitted outside the
meter housing.
 Turbine flow meter
Meter sizing
Meters are sized by volumetric flow rates
Each meter has a specified minimum & maximum linear
flow figures & meter should not be used outside these
values
Typical flow capacities for the range of turbine meters
shall be considered.
When sizing the meter, it is recommended that maximum
flow rate of the application should fall @ 70 to 80% meter
maximum. ( Good rangeability ( 8:1) )
Design for maximum velocity ( 30 ft/s) for optimum
performance & flow range
If the turbine meter is same as pipeline, meter flow range
limited to 2:1 or 3:1. Hence to be sized on the basis of
volumetric flow rate & not on basis of Pipe diameter.
 Turbine flow meter
Another aspect is available line pressure. TM have a typical
pressure loss of 3 to 5 psig @ maximum flow rates.
Pressure loss reduces with square of flow rate.
Consequently if the meter is operating @50% of maximum
capacity, pressure loss is 25% of that at maximum flow
rate.
Minimum pressure point occurs in the region of rotor, It is
essential to provide sufficient line pressure to prevent liquid
cavitations .( Downstream line pressure must be at least 2
times the net meter pressure loss plus 1.25 times vapor
pressure at its maximum operating temperature)
Alternatively increase the back pressure or increase the
meter size
Straight run requirement ( 10 D upstream and 5 D
downstream)
Sizes: 1/16 to 24 inches in flow through design
 Turbine flow meter
Operating pressure : 1500 psig standard & 5000 psig in
special design.
Operating temperature : -50 to 150 deg.c standard
-200 to 450 degc in extended pick up design.
Material of construction : Normally stainless steel housing &
rotor with tungsten carbide sleeve bearing. Hastelloy body
and ceramic or PTFE bearing also available.
Inaccuracy : Linearity is 0.25% of actual flow for meters
larger than 3/4 inches & 0.5 % for smaller units.
Repeatability : 0.02% of actual flow ( under constant
viscosity 0.3 to 3 cps, density & proper installation )
 V-cone flow meter
In a Venturi cone or V- cone meter, a cone is
positioned in the centre of metering tube.
This cone reduces the cross sectional area
available for process flow( similar to orifice
restriction) , generates a low pressure region
down stream of flow element.
The square root of these differential
pressure is related to flow through the meter
On liquid service,
Q= 29.808 *(* D) * P /1- 4
Where Q= Liquid flow in GPM , = D-d/D
D= Pipe ID in Inches d= Cone OD
in inches
P= pressure drop at full flow in PSID
 V-cone flow meter
The main difference between orifice plate & v cone is that
at lower Reynolds number where the velocity profile is no
longer flat ( high turbulent region) , cone element tends to
flattens the velocity profile and thereby results in true
square root relationship.
Rangeability : 30: 1
High accuracy : 0.5% of actual flow
Less maintenance as flow is directly away from cone edge
and therefore edge is not likely to wear.
Eliminates stagnant areas and prevents gas accumulation or
solid entrapment
Straight run requirement substantially low ( 2D upstream
and 5D downstream)
Meter should be installed horizontally so that pressure taps
are at same elevation.
 V-cone flow meter
Suitable for liquids, gases and steam services
Sizes : 0.5 to 72 inches
Material of construction : 316 SS or PVC with cone made
out of stainless steel,
Design pressure : 150 to 600 psig
Design temperature : from cryogenic to 371 deg.c
Pressure differential : 0 to 50 mm H20 Lower range,
0 to 762 mmH20 higher range
Beta ratio: 0.35 to 0.85 recommended
 Vortex meter
Utilizes fluid oscillation to provide meter with no moving
components
Suitable for gas, steam a or liquid services
Have wide flow range capability, minimum maintenance
Frequency or linear analog output
Good accuracy & long term repeatability
Limitation: -Unsuitable for use on viscous or dirty fluids
- Limited to Line size ( The frequency of fluid oscillation
drops off as line size increases. Meter in excess to 8 to 12
inches are not very practical)
- Limits to Reynolds number ( Vortices form only at
Reynolds number exceeding 10,000 and therefore meter
not suitable under these limits
 Vortex meter
When an obstruction (non-streamlined object) is placed in
the path of flowing stream, the fluid is remain unattached
to the object on its downstream side and will alternatively
separate from one side & then the other. Slow moving fluid
in boundary gets rolls into eddies and vortices. (karman
discovery)
Distance between the shed vortices is constant , regardless
of flow velocity.
Flow velocity= f*d/0.17
Where f=vortex frequency
d= shedder width
Ratio between shedder width(d)
& vortex interval (l) is 0.17 ( Stouhal no)
 Vortex meter
The frequency of vortex shedding is directly
proportional to the velocity of the fluid flowing though
flow meter
 Vortex meter
Manufacturer usually selects obstruction width(d) as one
quarter of Pipe ID.
Detector: As the vortex is shed from one of the bluff body,
the fluid velocity on that side increases & pressure
decreases. On the opposite side, velocity decreases &
pressure increases, thus causing net pressure change
across the bluff body. Entire effect is reversed as next
vertex is shed from the opposite side. Consequently the
velocity & pressure distribution changes at the same
frequency as the vortex shedding frequency.
Various detectors can be used to measure any of the
following
- oscillating flow across the face of the bluff body( a flow
sensitive detector like heated thermistor element)
- oscillating pressure difference across sides of bluff body.
( detectors that are sensitive to pressure use either metal
diaphragm( capacitance/strain gauge/piezo-electric or
vanes)
 Vortex meter
Sizing
Operating conditions ( process fluid temperature, amb
temperature, line pressure )to be compared with meter
specification
Meter wetted material & sensor should be checked for
compatibility with process fluid w.r.t chemical reaction and
safety
Large concentration of solids, two phase flow or pulsating
flow should be avoided.
Meter minimum and maximum flow rates for given
application should be established.
( Meter minimum flow rate is established by Reynolds
number, fluid density & minimum shedding frequency for
the electronics)
( Meter maximum is governed by meter pressure loss, onset
of cavitations with liquids, sonic velocities with gases)
 Vortex meter
Rangeability is 20:1 with pressure loss of 4 PSIG
Meter good accuracy & digital linear o/p makes it
application over wide flow ranges ( rangeability declines
with increase in viscosity, decrease in density)
In liquid cases, avoid cavitations ( upstream pressure >
1.3 times vapor pressure + 2.5 times net pressure loss)
Straight run requirements ( 15D upstream & 5D
downstream)
Sizes: 0.5 to 12 inches
Flow velocity range : liquids ( 1 to 33 ft/s)
Gas & steam(20 to 262 ft/s)
Design pressure: 2000 psig; Design temp:-201 to 400 degc
Material of construction : Mostly stainless steel,
Inaccuracy: 0.5 to 1% rate for liquids, 1 to 1.5% for gases
& steam
Flow element sizing & design

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