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1. ABSTRACT
The importance of flow measurement in the industry has grown in the past 50 years, not just because of its widespread
use for accounting purposes, but also because of its applications in manufacturing processes. In the research
laboratory, advanced flow measurements provide new insights into a wide range of engineering flow problems in
hydrodynamics, combustion, aerodynamics, and performance predictions. The main objective of this work is to
generate an awareness and understanding of the range of contemporary flow measurement techniques available with
the emphasis on devices and techniques associated with wide applications in engineering field. Focus is devoted to
cheap meters with reasonable accuracy; the differential pressure flow meters that all infer the flow rate from a
pressure drop across a restriction in the pipe. An orifice plate meter is designed to measure the required flow rate to
cool a nuclear reactor at a design point of 20 kg/s. Meter operation at off design conditions; 5 and 30 kg/s flow rates
with maximum allowable orifice pressure drop of 200 kPa was investigated. An orifice plate meter with a diameter
ratio of 0.7 is designed to satisfy the constraints over the desired operation range.
Keywards; Flow measurement, Design of Flow meters, orifice plate meters, Behavior of differential pressure flow
meters.
Page 3 of 9
4. Frictionless flow
5. Uniform velocity at sections 1 and 2
6. No streamline curvature at sections 1 or 2,
hence, the pressure is uniform across each
section.
7. Horizontal pipe installation, i.e. z1=z2
Page 4 of 9
empirical discharge coefficient Cd such that, Where; β is the ratio of the diameters; Dt/D1, Re
replacing (Eqn. 6), we have; is the Reynolds number, and the constants
L1=0.4333 and L2=0.47 for the considered D and
D/2 taps type. The discharge coefficient, Cd,
Cd At √2ρ(p1 − p2 ) varies considerably with changes in the area
actual =
m
2 ratio and Reynolds number. The discharge
√1 − ( A t ) coefficient Cd is around the value of 0.60. This
A1
value may be taken as standard value, however,
the coefficient varies noticeably at low Reynolds
Cd At √2ρ(p1 − p2 ) numbers and high diameter ratio, as shown in
= (7)
√1 − 𝛽 4 Table 1.
2(p1 p 2 )
Qactual KA t (10)
ρ
Cd = 0.5959 + 0.0312β2.1 − 0.1840β8 There are general bench marks for the orifice
106
0.75 meter; The meter is recommended for both clean
+ 0.0029β2.5 ( ) and non-clear liquids and for some slurry
Re
+ 0.0900(L1 ⁄D)[(β4 ⁄(1 − β4 ))] services, the flow rates that can be measured
− 0.0337(L2 ⁄D)β3 (11) accurately have approximately a 4:1 range, the
pressure loss across the meter is considered to
Page 5 of 9
be pronounced, typical accuracy is within 2 to 4% More detailed expressions and discussions can
of full reading scale, the viscosity effect is be found elsewhere; Mustapha S. Mansour, M. Sc.
relatively high represented by the flow Reynolds Thesis [16].
number, and the meter relatively has low cost.
0.0025D
ex < (12)
0.1 + 2.3β4
Page 7 of 9
For a given orifice pressure drop of 100 kPa, the Also it is found that the corresponding orifice
solution converges with an orifice beta ratio (β) pressure drop is 17 kPa for measuring a flow of
of 0.66. However, this is lower than the advisable 10 kg/s.
maximum recommended value of 0.7.
Orifice plate meter off design performance
Referring to the design point beta ratio (β) of
280
0.66, the corresponding orifice pressure drop to
260
240 des= 0.7, dorf = 53.3 mm
meter 5 kg/s is 4.5 kPa, while to meter 30 kg/s,
the corresponding orifice pressure drop is 245
Orifice pressure drop, Kpa
In order to finalize the design process, the meter Accuracy and precision of flow meters are the
off design conditions are investigated at both most important metrological parameters in most
extremes; minimum and maximum off design industries. Hence, before field installation of such
mass flow rates of 5 and 30 kg/s, respectively. meters takes place, calibration test should be
conducted in order to adjust the meter readings
For the design point beta ratio (β) of 0.7, the with the actual flow rates.
calculation procedure is conducted with
minimum and maximum expected off design flow When dealing with other liquids than water the
rates of 5 and 30 kg/s, respectively. The iteration density should be replaced in the presented
process is based this time on the expected orifice mathematical model. Nozzle and venturi flow
pressure drop only. The corresponding orifice meters could be studied similarly for specific
pressure drop to measure a flow of 5 kg/s is 3.4 tasks; designed, tested, and evaluated. Evaluation
kPa, while to measure a flow of 30 kg/s, the of the mathematical model and validation should
corresponding orifice pressure drop is 180 kPa, be made including the flow rate accuracy and
which are below the maximum allowable value. sensivity to partial loads.
Figure 9 Orifice plate meter assembly. Figure 10 Orifice plate meter left flange design.
Page 8 of 9
Figure 11 Orifice plate meter right flange design. Figure 12 Orifice plate design