By Tapan Bhavsar May 24, 2020

Design Considerations – Orifice Plate

The Continuity equation and the Bernoulli Equation are the basis for all types of diff. pressure
flow measurement (Explanation of these equations is not included in this document).

1. Square Root Relationship:

Since, Q  √P. Where, Q = Flow rate & P = Diff. pressure across plate.

Turndown of diff. pressure smart transmitters available in the market can go up to 200:1. So, flow
rangeability (ratio of maximum to minimum flow) can be 14:1.

(Note: Rangeability of a sensor defines the measurement range over which the error statement,
in the units of a percentage of actual reading is guaranteed.)

However, standard diff. pressure transmitters available in the market with high repeatability and
advanced features can generally go up to turndown of 100:1. So, flow rangeability can be achievable
up to 10:1.

When flow rangeability required above 10:1, the use of two orifice plates of different capacities, two
differential-pressure flow transmitters with different ranges, or both is generally recommended.

Limitations arises in the accurate measurement of the corresponding extremely wide range of
differential pressure; for example, a 20:1 flow variation results in a 400:1 variation in differential
pressure.

PS: It is also desirable to have the manufacturers always state not only the inaccuracy of their
products but also the rangeability/turndown over which that inaccuracy statement is valid.

In principle, 10:1 to 14:1 flow rangeability and 100:1 to 200:1 DP turndown is the maximum limit
while selecting a single Orifice plate as a Flow element.

2. Density:

Fluid density is involved in the determination of either mass flow rate or volume flow rate. In other
words, diff. pressure type flow meters do not read out directly in either mass or volume flow.

Q = K x √∆P
ρ

Where Q = Flow rate, K = Constant, ρ = Mass density of fluid, ∆P = P1 – P2

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 By Tapan Bhavsar May 24, 2020

Another important relation is,

Mass flow rate= Density x Volume flow rate

The fact that density appears as a square root gives diff. pressure type flow metering an actual
advantage, particularly in applications where measurement of mass flow is required.

Due to this square root relationship, any error that may exist in the value of the density used to
compute mass flow is substantially reduced; a 1% error in the value of the fluid density results in a
0.5% error in calculated mass flow.

This is particularly highly important in gas flow measurement, where the density may vary over a
considerable range and where operating density is not easily determined with high accuracy.

Pressure & Temperature compensation shall be implemented in the control system when higher
accuracy is required in the gas flow measurement. Nowadays, also multivariable transmitters are
available in the market.

3. β (Beta) Ratio:

β ratio is the ratio between the diameter of the restriction and the inside diameter of pipe.

β (Beta) = Orifice Bore Diameter (d) / Pipe Internal Diameter (D)

There is no specific range of Beta ratio has been standardized. However, it is recommended to be in
range of 0.2 to 0.7 Due to following reasons.

β ratio < 0.2 Means:

 Orifice bore diameter is relatively smaller.

 Higher flow restriction.
 Higher pressure drop.
 More probability that Permanent Pressure Loss(PPL) exceeds expected PPL considered in Process
Hydraulics.
 Higher chances of Cavitation & Flashing, since higher pressure drop allow the process to go further
down below the Vapor pressure.
 Increases Uncertainties/ Decreases accuracy.

β ratio > 0.7 Means:

 Orifice bore diameter is relatively bigger.

 Lower flow restriction.
 Lower pressure drop.
 Difficult to measure lower pressure.
 Increases Uncertainties/ Decreases accuracy.

However, some Tools/Softwares calculate from 0.15 to 0.75 as long as all process parameters, Diff
Pressure Range, Permanent Pressure Loss (PPL), Flow Rangeability, and Accuracy etc. fit together
and do not give any error messages for the user.

Study, experiments and proven installations suggest that best accuracy of Orifice plate achievable
when β ratio is between 0.2 – 0.7.

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 By Tapan Bhavsar May 24, 2020

4. Reynolds Number:

Reynolds number expresses the ratio of inertial forces to viscous forces.

Re = VDρ


Where, Re = Reynolds number; V = Velocity; D = Pipe Diameter; ρ = Density;  = Absolute Viscosity

At low Reynolds numbers, Flow profile gets disturbed and flow co-efficient increases. So, Reynolds
numbers more than 10,000 are recommended. Since, discharge co-efficient is constant as shown in the
graph below.

5. Selection of Diff. Pressure Transmitter Range:

The most common differential-pressure range for orifices is 0 to 100 in. of water (0 to 2500 mmH2O or
0 to 25 kPa) for full-scale flow.

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 By Tapan Bhavsar May 24, 2020

This range is high enough to minimize errors due to change in density of liquid due to change in
Temperature.

Most differential-pressure-responsive devices develop their maximum accuracy in or near this range.
See below graph Flow vs. Error.

DP Range of β Ratio Permanent Pressure Loss Accuracy Flow

Transmitter (0.2 to 0.7) (PPL) Rangeability
0 - 50 in. H2O Higher side Lower side Lower side Lower side
0 - 100 in. H2O Moderate Moderate Moderate Moderate
0 - 200 in. H2O Lower side Higher side Higher side Higher side

Based on requirement of Permanent Pressure Los (PPL), Flow rangeability/turndown and accuracy
from Process, suitable diff. pressure range from above table can be selected.

6. Location of Pressure Taps:

Flange Taps:

 Preferred from Line size 2” and larger.

 The manufacturer of the orifice flange set drills the taps so that the centrelines are 1 in. (25 mm)
from the orifice plate surface.
 Flange taps are not recommended below 2 in. (50 mm) pipe size and cannot be used below 1.5 in.
(37.5 mm) pipe size, since the vena contracta may be closer than 1 in. (25 mm) from the orifice
plate.

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 By Tapan Bhavsar May 24, 2020

Venacontractra & Radius Taps:

 Taps at 1D upstream and a downstream tap located at the point of minimum pressure.
 Vena contracta taps offer the greatest differential pressure for any given flow rate, but require
precise calculations to properly locate the downstream tap position.
 Radius taps are an approximation of vena contracta taps for large pipe sizes (one-half pipe
diameter downstream for the low-pressure tap location).
 An unfortunate characteristic of both these taps is the requirement of drilling through the pipe wall.
 Not only does this weaken the pipe, but the practical necessity of drilling the tap holes in the
installed location rather than in a controlled manufacturing environment means there is
considerable room for installation error.

Corner Taps:

 Corner taps must be used on small pipe diameters where the vena contracta is so close to the
downstream face of the orifice plate that a downstream flange tap would sense pressure in the
highly turbulent region (too far downstream).
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7. Installation:

To avoid errors resulting from disturbance of the flow pattern due to valves, fittings, and so forth, a
straight run of smooth pipe before and after the orifice is recommended.

Required length depends on β ratio and the severity of the flow disturbance based on upstream piping
components which cause flow profile disturbances.

Upstream straight run can be from 40 D to 20D and downstream side shall be 5D.

Where it is not practical to install the orifice in a straight run of the desired length, the use of a
straightening vane to eliminate swirls or vortices is recommended.

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