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A 5-30 kg/s Orifice Plate Cooling Water Flow Meter Design

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A 5-30 kg/s Orifice Plate Cooling Water Flow Meter Design
Saleh B. Mohamed1, Mustapha S. Mansour2, Elhadi I. Dekam3

saleh_ba2004@yahoo.com; msm1975b@hotmail.com; eidakkam@hotmail.com


1Associate Professor, Faculty of Engineering, Azzaitouna University, Tarhoona, Libya, 2M. Sc. Senior Engineer,
3Professor, Mechanical and Industrial Engineering Department, Faculty of Engineering, University of Tripoli, Tripoli, Libya.

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.

2. NOMENCLATURE accuracy requirements, cost considerations, and


Symbols Description use of the flow information to obtain the required
 Fluid density, kg/m3 end results [1,5,6,7,8]. Normally, the flow meter
p Local Static Pressure, Pa measures flow indirectly by measuring a related
V Average flow velocity, m/s property such as a differential pressure across a
Z Local elevation, m flow restriction or a fluid velocity in the pipe
g Gravitational acceleration, 9.81 where the fundamental physical principles are
m/s2 used in the flow measurement devices.
A Cross-sectional area, m2

m Mass flow rate, kg/s Differential pressure flow meters infer the flow
Dt Orifice plate diameter, m rate from a pressure drop across a restriction in
D1 Pipe diameter, m the pipe, which for many years; they have been the
D2 Vena contracta diameter, m only reliable method available. They remain
 Orifice plate beta ratio (Dt/ D1) popular despite the development of higher
∆P Static Pressure difference, Pa performance modern devices, mostly on account of
Cd Orifice discharge coefficient exceptionally well researched and documented
Re Flow Reynolds number standards. These devices consist of a primary
Indices; element that restricts the flowing stream resulting
1 Upstream inlet in a pressure difference (pressure drop) across the
2 Vena contracta section element. The related secondary devices consist of
t Orifice openning section a differential pressure measuring unit with
connecting piping and other measuring units
required to define the flowing variables of the fluid,
3. INTRODUCTION
such as pressure, temperature, and composition.
Flow measurement is the determination of the
The pressure and differential-pressure transducer
quantity of the running fluid through the passage,
are often combined into a single unit, as shown in
either as a rate or as an integrated value. This can
Figure 1, [8,9,10].
be divided into several types; each type requires
specific considerations of such factors as
Page 1 of 9
design engineer should decide the design
condition for mass, volume (operating standard)
or energy. Besides that, pressure and
temperature of the fluid should be provided to
compensate for process variations in these
variables. Also, a specific gravity or density
analyzer may also be needed to account for
variability in stream composition. In considering
the cost, the total cost involve; equipment cost,
installation total cost, maintained cost, and
operating cost that must be carefully evaluated in
terms of meter size and operating pressure
[7,8,9]. For instance, a small sized Venturi might
be of comparable cost to an averaging Pitot, but
as the size increases the cost of the Venturi
Figure 1 An orifice plate flow meter with rapidly exceeds that of the averaging Pitot for a
vena contracta. given pipe size. Increasing design pressure has
the same effect.
4. TYPES OF FLOW METERS
A flow meter is then a device that meters A term used frequently in flow measurement is
movement of fluids in a conduit or an open accuracy. Accuracy is more abused than correctly
channel. Fluids could be water, chemicals, air, used. Unfortunately, it is a sales tool used
gas, steam or solids. There are various kinds of commercially by both suppliers and users of
the flow meters available in the market and metering equipment. The supplier with the best
classified into mechanical and non-mechanical number wins the bid. Likewise, the user will
types. Non-mechanical types are also known as sometimes require accuracies beyond the
pressure difference flow meter and include; capabilities of any meter available. In previous
Orifice plate, Venturi tube, Pitot tube, Nozzle and decades, accuracy was the term most commonly
variable area (Rotameter) types. Mechanical type used to describe a meter’s ability to measure
flow meters include; Positive displacement; flow. It was defined as the ratio of indicated
Velocity and mass flow meters. The Positive measurement to true measurement. The
displacement types are; Reciprocating piston; antithesis of uncertainty and is an expression of
Oval gear; Nutating disk and Rotary vane types. the maximum possible limit of error at a defined
While the velocity types are, Turbine, Vortex confidence. Accuracy remains then very
shedding, Swirl; Electromagnetic; Ultrasonic important for flow meters because it is related to
Doppler And Ultrasonic Transit-time. The mass money. A meter station measuring product
flow meters types are; Coriolis and Thermal. worth $2 million a day, an inaccuracy of ± 0.2%
Other meter types include the optical type represents $4,000 a day, or $1,460,000 a year
meters. These meters are made of several basic and the amount that justifies considerable
technologies and each type has a niche and can investment to improve flow measurement. The
generally be used for many applications same error for a station measuring $1,000 worth
[5,7,9,10,11]. of product a day represents only $2 a day, and the
law of diminishing returns limits investment
5. SELECTION CRITERIA OF FLOW METERS justifiable to improve measurement accuracy.
It is not an easy task to select a suitable flow
meter for a particular application especially with Differential type flow meters are cheap to install
the wide variety of flow meters in the market. It and manufacture being the orifice type meters
requires considerable evaluation of the total cost, typically the less expensive with reasonable
fluid state, flowing condition, Reynolds number, accuracy. In addition, with the exception of the
density, range ability, mechanical installation orifice meter, almost all flow meters require a
constraints and accuracy requirements. The fluid flow calibration at flow and temperature
Page 2 of 9
conditions closely approximating service 7. METER WORKING PRINCIPLE
operation in order to establish accuracy As the fluid approaches the orifice the pressure
[8,9,11,12]. Thus, without requiring direct fluid increases slightly and then drops suddenly as the
flow calibration and have no moving parts, orifice orifice is passed. It continues to drop until the
meters remains simple, rugged, widely accepted, “vena contracta” is reached and then gradually
reliable and relatively inexpensive. increases until at approximately 5 to 8 diameters
downstream a maximum pressure point is
6. ORIFICE PLATE METER reached that will be lower than the pressure
An orifice plate is a very simple device installed upstream of the orifice. The decrease in pressure
in a straight run of pipe. The orifice plate is a thin as the fluid passes through the orifice is a result
plate with a hole in the middle and is usually of the increased velocity of the flow passing
placed in a pipe in which fluid flows. The flow through the reduced area of the orifice. When the
constricts experiences a pressure drop, and then velocity decreases as the fluid leaves the section
the differential pressure can be related to the of the vena contrcta the pressure increases and
flow. When the fluid reaches the orifice plate, tends to return to its original level. All of the
with the hole in the middle, the fluid is forced to pressure drop is not recovered due to friction
converge to go through the small hole; the point and turbulence losses in the stream. The
of maximum convergence actually occurs shortly differential pressure is proportional to the
downstream of the physical orifice, at the so- square of the velocity, it therefore follows that if
called vena contracta point (the point at which all other factors remain constant, then the
minimum flow area occurs), as shown in Figures differential pressure is proportional to the
1 and 4. As it does so, the velocity and the square of the rate of flow [4,6,7].
pressure changes. Beyond the vena contracta, the
fluid expands and the velocity and pressure 8. METER APPLICATIONS
change once again. By measuring the difference Orifice plates are most commonly used for
in fluid pressure between the upstream normal continuous measurement of fluid flow in pipes.
pipe section and at the vena contracta, the They are also used in some small river systems to
theoretical volumetric and mass flow rates can measure flow rates at locations where the river
be obtained directly from Bernoulli's equation passes through a culvert or drain. Only a limited
[1,8,13,14]. There are three tap arrangements; number of rivers are appropriate for the use of
corner taps, flange taps, and D & D/2 taps, as the technology since the plate must remain
indicated in Figure 2. completely immersed i.e. the approach pipe must
be full, and the river must be substantially free of
debris. This instrument is very practical also for
large tube diameters and for dirty fluid when
turbines are not applicable. Generally, the orifice
plate has three different geometries, concentric,
eccentric and segmental as shown in Figure 3,
[2,3,7,8,13].

Figure 2 An orifice geometry and pressure


tap locations [7,8,13]. Figure 3 Geometries of the orifice plate.

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

From Bernoulli equation we may have;


Figure 4 The selected control volume for the
flow analysis in the flow meter [7.8.10]. ρ ρV22 V1 2
p1 − p2 = (V22 − V12 ) = [1 − ( ) ] (3)
2 2 V2
9. MATHEMATICAL MODEL
Most of the non-mechanical flow meters for
internal flows are based on the acceleration of Applying continuity equation, the static pressure
the fluid stream through some form of nozzle as drop becomes;
shown in Figure 4. Flow separation at the sharp
edge of the nozzle throat causes a recirculation ρV22 A2 2
p1 − p2 = [1 − ( ) ] (4)
zone to form a wake as shown by dashed line 2 A1
downstream from the nozzle. The main stream
flow continues to accelerate from the nozzle Solving for the theoretical velocity V2, we obtain;
throat to form a vena contracta at section 2 and
then decelerates again to fill out the duct. At the
vena contracta the flow area passes through a 2(p1 − p2 )
V2 = (5)
minimum, the flow stream lines are essentially √ A 2
straight and parallel, and hence the pressure is ρ [1 − ( 2 ) ]
A1
uniform across the channel, as shown in Figure 4.
The theoretical flow rate may be related to the
Hence, the theoretical mass flow rate is given by;
pressure drop by applying the continuity and
Bernoulli equations. The empirical correction
factors may be applied to obtain the actual flow 2  (p1  p 2 )
 theoretical  A 2
m (6)
rate. The basic integral equations according to 1  (A2 /A1 ) 2
the selected control volume can be represented
as follows [1,3,7,8,10]; As well known, the flow rate is to be directly
proportional to the square root of the pressure
  drop across the meter taps, which is the basic
0 c.v. t
dV  
c.s.
n̂.VdA (1)
idea of such devices. As indicated above, the
calculation of the actual mass flow rate through
p1 V12 p V2 the meter is affected by several factors. The
  gz1  2  2  gz 2  const (2) actual vena contracta flow area, A2, is unknown.
 2  2
The upstream velocity profiles approach uniform
flow only at large turbulent flow Reynolds
Where p is the static pressure, V is the average numbers. Frictional effects may cannot be
flow velocity, z is the local centerline elevation, ignored especially downstream region from the
is the fluid density, A is the cross sectional area, meter when the meter contours are abrupt. In
and g is the gravitational acceleration. The addition, the location of static pressure taps
considered assumptions may include the influences the differential static pressure
following; reading.

1. Steady flow Here, The theoretical equation is adjusted, for the


2. Incompressible flow above points including the effect of Reynolds
3. Flow along stream lines number and diameter ratio Dt/D1, by defining an

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.

Here, 1/√1 − 𝛽 4 is defined as the velocity of Table 1 Discharge coefficient as function of


approach factor. The combination of the Reynolds number and diameter ratio
discharge coefficient and velocity of approach [1,3,10]
factor is frequently represented by a single flow Discharge coefficient, Cd
coefficient; Diameter Reynolds number (Re)
ratio = Dt/D1 104 105 106 107
Cd 0.2 0.6 0.595 0.594 0.594
K≡ (8) 0.4 0.61 0.603 0.598 0.598
[1 − (β)4 ]
0.5 0.62 0.608 0.603 0.603
Where, Dt/D1. Hence, in terms of this flow 0.6 0.63 0.61 0.608 0.608
coefficient, the actual mass flow rate can be 0.7 0.64 0.617 0.609 0.609
expressed as;
The pressure recovery is limited for the orifice
 actual = KAt √2ρ(p1 − p2 ) (9) plates and the permanent pressure loss depends
m
primarily on the area ratio, refer to Figure 5. For
and the volumetric flow rate can be then an area ratio of 0.5, the head loss is about 70 -
determined by the following expression; 75% of the orifice differential head.

2(p1  p 2 )
Qactual  KA t (10)
ρ

The flow discharge coefficient found in the


literature have been determined for fully
developed turbulent velocity distribution at the
upstream section of the meter entrance (section
1). Various relations for the coefficient are
available under certain conditions. Here, the
discharge coefficient, Cd, can be calculated by
employing the following selected empirical Figure 5 Associated pressure drop and
equation (ISO); pressure loss in the flow meter.

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.

10. METER DESIGN CONSTRAINTS


[1,3,7,8,10]
1. The orifice beta ratio (β) should lie in the
range of 0.2-0.8. However, it is advised
to remain below the value of 0.7 and
above 0.2, as this affect strongly the
percentage of uncertainty of the
discharge coefficient.
2. The orifice plate is a thin plate with
circular concentric hole and with sharp
edges.
3. The eccentricity of the orifice bore
diameter Dt to the upstream pipe bore D1
can result in an error in the discharge
coefficient. The following equation can
be used to maintain the maximum
permissible eccentricity;

0.0025D
ex < (12)
0.1 + 2.3β4

While in line sizes of nominal 75 mm or less, the


eccentricity should be no greater than 0.8 mm.
4. The minimum edge thickness of the
orifice e of the orifice shall be equal or
greater than 0.1 Dt but not less than
0.125mm. The maximum shall be equal
to or less than 0.02D1 or equal to or less Figure 6 Standard orifice plate [1,3,8]
than 0.125Dt whichever is smaller, but
not greater than e (the plate thickness), 11. METER DESIGN POINT INPUT DATA
as shown in Figure 6. To be able to design an orifice plate meter, some
5. The orifice edge thickness, e, should be important input data should be provided such as;
uniform over the plate area. the required range of the flow rate to be
6. The bevel angle shown in Figure 6 measured; the pressure drop permissible range;
should be approximately 45. the tap type and accordingly the sensors
7. For D and ½ D taps arrangement, the position; the liquid type and accordingly its
center line of taps shall meet the pipe density; the installation pipe inside diameter; the
center line at right angles to it (±2 deg). liquid kinematic or dynamic viscosity and finally
For nominal pipe size 50 – 75 mm, the the off design conditions. All required data for the
maximum diameter of tap holes is 10 desired design process was summarized as
mm. While nominal pipe sizes > 100 mm, follows [15];
the maximum diameter of tap holes is 13
mm. 1. The required flow rate to cool a nuclear
reactor at the design point is 20 kg/s
2. The off design conditions are such; The
maximum and minimum water flow
Page 6 of 9
rates required are 30 kg/s and 5 kg/s,
respectively. The maximum permissible
pressure drop is 200 kPa
3. The water temperature is 20 oC, thus its
density is 1000 kg/m3, and the
kinematic viscosity (υ) is 1.03x10-6 m2/s.
4. The pipe line inside diameter is 76 mm.

The design equations were already detailed


above. The sequence and procedure of the design
point calculation has to go with iterations, peer in
mind the contrains including the limitation of the
allawable pressure drop. Once the convergence is
reached the orifice size is obtained with the
desied flow rate range under different set of
conditions. Since, the nature of the design
calculation process is iterative, and in order to
speed up and facilitate the process all relevant
meter, An iteration-based Fortran language
subroutine is written taking into account the
design constraints. The program flow chart is
illustrated in Figure 7.

12. METER DESIGN POINT CALCULATION


In order to finalize and confirm the design
calculations i.e. to select the proper orifice beta
ratio (β) (orifice size) with suitable orifice
pressure drop, it is required to check the meter
at off design conditions by the following
Figure 7 The Orifice plate meter design
procedure;
iteration process chart.
1. Since the meter geometry and the off
13. RESULTS, DISCUSSIONS AND
design conditions are set, the calculation
CONCLUSIONS
procedure is repeated with the design
The calculations for the design point mass flow
orifice beta ratio (β) (i.e. the obtained
rate of 20 kg/s were carried out with different
meter size) by iterating this time the
values of orifice pressure drop of 50, 75 and 100
orifice pressure drop only until the
kPa. Here For an orifice pressure drop of 50 kPa,
orifice beta ratio (β) (i.e. orifice plate
the solution converged with an orifice beta ratio
diameter) design point value is obtained.
(β) of 0.76. This is exceeding the advisable
2. On the meantime, the converged orifice
maximum recommended value of 0.7 and thus
pressure drop should be ≤ the maximum
excluded from the design compromization.
off design allowable value. When this
requirement is fulfilled (i.e. design point
However, the solution converges for an orifice
orifice beta ratio (β) (i.e. size) with its
beta ratio (β) of 0.7 with a given orifice pressure
corresponding orifice pressure drop, the
drop of 75 kPa. This orifice beta ratio (β)
design calculations are valid and
consides exactly with the advisable maximum
accordingly, the design drawings of the
recommended value of 0.7, which is the optimum
meter can be prepared for production
recommended maximum value found in
purposes.
literature that does not affect the pressure drop
coefficient.

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

220 des=0.66, dorf = 50.3 mm


200
180
kPa, which exceeds the allowable maximum
160 value of 200 kPa. Also to meter 10 kg/s, the
140
120
corresponding orifice pressure drop is 24 kPa.
100 The variation of the desired mass flow rate with
80 the cooresponding orifice pressure drop is
60
40 plotted in Figure 9. It is clear that the orifice plate
20 meter with a beta ratio (β) of 0.7 is the most
0
-20
suitable geometry that satisfies all design
2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0 27.5 30.0 32.5
contraints and covers the documented
Mass Flow rate, kg/sec
recommendations. The meter design drawings;
the orifice plate meter assembly, left flange, right
Figure 8 Orifice plate meter off design flange, and orifice plate design, are shown below
performance. in Figures 9, 10, 11 and 12, respevtively.

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

13- USDA Soil Conservation Service., Measurement


14. REFERENCES of irrigation water. SCS National Engineering
1- ASME MFC-3M, Measurement of Fluid Flow in Handbook, Section 15,Chapter 9, pp. 9-5 to 9-9,
Pipes using, Orifice, Nozzle, and Venturi, An 1962
American National Standard, revised 1995. 14- Tom Bruce, Fluid Mechanics 3 Flow
2- Daniel Measurement and Control, Inc., Measurement Methods The University of
Fundamentals of Orifice Meter Measurement, Edinburgh, School of Engineering and
2010, www. daniel.com. Electronics, February 2006.
3- Engineering Tool Box, Orifice, Venturi and 15- UK Environment Agency, Cooling Water Options
Nozzle flow rate meters, 2012.www. for the New Generation of Nuclear Power
Engineering ToolBox.com. Stations in the UK, 2010.
4- Fangmeier, D. D., and M. K. Ramsey, Intake 16- Mansour, M. S., “Design And Evaluation Of
characteristics of irrigated furrows. Orifice Meters Of Fluid Flow In Pipelines”, M. Sc.
Transactions of the ASAE 21(4);696-700, 1978. Thesis, Mechanical and Industrial Engineering
5- KLM Technology group, Fluid Flow Department, Faculty of Engineering, University
Measurement Selection and Sizing (Engineering Of Tripoli, Tripoli, Libya, 2017.
design guideline, March 2007.
6- Omega Engineering technical reference,
Introduction to Flow Meters, 2012.
7- International Standard Organization (ISO),
Measurement of fluid flow; Estimation of
uncertainty of a flow rate measurement, 1978.
8- International Standards ISO, Available from
ANSI, 1430 Broadway, New York, NY 10018,
1978.
9- Ree, W. 0., How accurate are shop-made orifice
plates. Transactions of the ASAE 20(2);298-300.
1977.
10- Robinson, A. R., Orifice plates for furrow flow
measurement. Unpublished report of the USDA-
ARS Soil and Water Conservation Research
Division and Colorado Agric. Exp. Station, 1959.
11- Trout, Thomas I., and Bruce E. Mackey, Inflow-
outflow infiltration measurement accuracy.
Unpublished report to be submitted to
Transactions of the ASAE, 1985.
12- Trout, Thomas I, Orifice plates for furrow flow
measurement; Calibration. Transactions of the
ASAE, 29(1);103-107, 111 (this issue), 1986.
Page 9 of 9

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