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Flow meters
What is a Flow Meter?
Published May 10, 2019
What is a Flow Meter?

Flow Meter Types

FAQ About Flow Meters

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A flow meter (or flow sensor) is an instrument used to measure linear, nonlinear, mass or volumetric flow rate of a liquid or a gas. When choosing flowmeters, one should
experience with calibration and maintenance, spare parts availability, and mean time between failure history, etc., at the particular plant site. It is also recommended that

One of the most common flow measurement mistakes is the reversal of this sequence: instead of selecting a sensor which will perform properly, an attempt is made to jus
"inexpensive" purchases can be the most costly installations. This page will help you better understand flow meters, but you can also speak to our application engineers at

First Steps to Choose the Right Flow Meter

The first step in flow sensor selection is to determine if the flowrate information should be continuous or totalized, and whether this information is needed locally or remo
If remotely, should the transmission be analog, digital, or shared? And, if shared, what is the required (minimum) data-update frequency? Once these questions are answe
an evaluation of the properties and flow characteristics of the process fluid, and of the piping that will accommodate the flowmeter, should take place. In order to approac
this task in a systematic manner, forms have been developed, requiring that the following types of data be filled in for each application: Download the Flowmeter Evaluatio
Form.

Fluid and flow characteristics

The fluid and its given and its pressure, temperature, allowable pressure drop, density (or specific gravity), conductivity, viscosity (Newtonian or not?) and vapor pressure a
maximum operating temperature are listed, together with an indication of how these properties might vary or interact. In addition, all safety or toxicity information should
provided, together with detailed data on the fluid's composition, presence of bubbles, solids (abrasive or soft, size of particles, fibers), tendency to coat, and light transmiss
qualities (opaque, translucent or transparent?).

Pressure & Temperature Ranges

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Expected minimum and maximum pressure and temperature values should be given in addition to the normal operating values when selecting flowmeters. Whether flow c
can develop (air-solids-liquid), whether aeration or pulsation is likely, whether sudden temperature changes can occur, or whether special precautions are needed during c

Piping and Installation Area

Concerning the piping and the area where the flowmeters are to be located, consider: For the piping, its direction (avo
flange-pressure rating, accessibility, up or downstream turns, valves, regulators, and available straight-pipe run length
present or possible in the area, if electric or pneumatic power is available, if the area is classified for explosion hazard
sanitary or clean-in-place (CIP) regulations.

Flow rates and Accuracy

The next step is to determine the required meter range by identifying minimum and maximum flows (mass or volume
accuracy is determined. Typically accuracy is specified in percentage of actual reading (AR), in percentage of calibrated
requirements should be separately stated at minimum, normal, and maximum flowrates. Unless you know these requ
its full range.

In applications where products are sold or purchased on the basis of a meter reading, absolute accuracy is critical. In o
accuracy. Therefore, it is advisable to establish separately the accuracy and repeatability requirements of each applica

When a flowmeter's accuracy is stated in % CS or % FS units, its absolute error will rise as the measured flow rate drops. If meter error is stated in % AR, the error in absolu
always a larger quantity than the calibrated span (CS), a sensor with a % FS performance will always have a larger error than one with the same % CS specification. Therefo
quoted error statements into the same % AR units.

In well-prepared flow meter specifications, all accuracy statements are converted into uniform % AR units and these % AR requirements are specified separately for minim
maximum flows. All flowmeters specifications and bids should clearly state both the accuracy and the repeatability of the meter at minimum, normal, and maximum flows

Accuracy vs. Repeatability

If acceptable metering performance can be obtained from two different flow meter categories and one has no moving parts, select the one without moving parts. Moving p
potential source of problems, not only for the obvious reasons of wear, lubrication, and sensitivity to coating, but also because moving parts require clearance spaces that
introduce "slippage" into the flow being measured. Even with well maintained and calibrated meters, this unmeasured flow varies with changes in fluid viscosity and tempe
in temperature also change the internal dimensions of the meter and require compensation.

Furthermore, if one can obtain the same performance from both a full flowmeter and a point sensor, it is generally advisable to use the flowmeter. Because point sensors
full flow, they read accurately only if they are inserted to a depth where the flow velocity is the average of the velocity profile across the pipe. Even if this point is carefully d
time of calibration, it is not likely to remain unaltered, since velocity profiles change with flowrate, viscosity, temperature, and other factors.

Mass or Volumetric Units

Before specifying a flow meter, it is also advisable to determine whether the flow information will be more useful if presented in mass or volumetric units. When measurin
meaningful unless density (and sometimes also viscosity) is constant. When the velocity (volumetric flow) of incompressible liquids is measured, the presence of suspende
before the fluid reaches the meter. In other velocity sensors, pipe liners can cause problems (ultrasonic), or the meter may stop functioning if the Reynolds number is too

In view of these considerations, mass flowmeters, which are insensitive to density, pressure and viscosity variations and are not affected by changes in the Reynolds numb
are the various flumes that can measure flow in partially full pipes and can pass large floating or settleable solids.

Choose the right Flowmeter

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Rotameters or Variable Area Flowmeter

The rotameter is a tapered tube and a float. It is the most widely used for for gases and liquids flow measurement becau
rangeability, and linear output.

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Spring and Piston Flow Meters

Piston-type flowmeters use an annular orifice formed by a piston and a tapered cone. The piston is held in place at the b
Scales are based on specific gravities of 0.84 for oil meters, and 1.0 for water meters. Their simplicity of design and the e
signals has made them an economical alternative to rotameters for flowrate indication and control.

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Mass Gas Flowmeters

Thermal-type mass flow meters operate with minor dependence on density, pressure, and fluid viscosity. This style of flo
temperature sensor or a heated sensing element and thermodynamic heat conduction principles to determine the true m
displays and analog outputs for data logging. Popular applications include leak testing and low flow measurements in the
meter.

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Ultrasonic Flowmeters
The ultrasonic doppler flow meters are commonly used in dirty applications such as wastewater and other dirty fluids an
sensors. The basic principle of operation employs the frequency shift (Doppler Effect) of an ultrasonic signal when it is re
motion.

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Turbine Flow Meters

The turbine meter can have an accuracy of 0.5% of the reading. It is a very accurate meter and can be used for clean liqu
pipe diameters of straight pipe on the inlet is required. The most common outputs are a sine wave or squarewave freque
outputs and explosion proof classifications. The meters consists of a multi-bladed rotor mounted at right angles to the flo

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Paddlewheel Sensors
One of the most popular cost effective flowmeters for water or water like fluids. Many are offered with flow fittings or ins
minimum of 10 pipe diameters of straight pipe on the inlet and 5 on the outlet. Chemical compatibility should be verified
outputs are typical but transmitters are available for integral or panel mounting. The rotor of the paddlewheel sensor is p
of the flow.

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Positive Displacement Flowmeters

These meters are used for water applications when no straight pipe is available and turbine meters and paddlewheel sen
flow meters are also used for viscous liquids.

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Vortex Meters
The main advantages of vortex meters are their low sensitivity to variations in process conditions and low wear relative to
are low. For these reasons, they have been gaining wider acceptance among users. Vortex meters do require sizing, conta

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Pitot Tubes or Differential Pressure Sensor for Liquids and Gases

The pitot tubes offer the following advantages easy, low-cost installation, much lower permanent pressure loss, low main
sizing, contact our flow engineering.

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Magnetic Flow meters for Conductive Liquids

Available in in-line or insertion style. The magnetic flowmeters do not have any moving parts and are ideal for wastewate
integral or an analog output can be used for remote monitoring or data logging.

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Anemometers for Air Flow Measurement

Hot wire anemometers are probes with no moving parts. Airflow can be measured in pipes and ducts with a hand held o
Vane anemometers are usually larger than a hot wire but are more rugged and economical. Models are available with tem

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Mass or Volumetric Flow Rate?

So you want to measure flow? The answer would seem to be to purchase a flowmeter. With fluid flow defined as the amount of fluid that travels past a given location, this
straightforward — any flowmeter would suffice. However, consider the following equation describing the flow of a fluid in a pipe.

Q=Axv

Q is flow rate, A is the crosssectional area of the pipe, and v is the average fluid velocity in the pipe. Putting this equation into action, the flow of a fluid traveling at an avera
meter per second through a pipe with a 1 square meter cross-sectional area is 1 cubic meter per second. Note that Q is a volume per unit time, so Q is commonly denoted
“volumetric” flow rate. Now consider the following equation:

W = rho x Q

Where W is flow rate (again - read on), and rho is the fluid density. Putting this equation into action, the flow rate will be 1 kilogram per second when 1 cubic meter per sec
a density of 1 kilogram per cubic meter is flowing. (The same can be done for the commonly-used “pounds”. Without getting into details — a pound is assumed to be a ma
W is a mass per unit time, so W is commonly denoted as the “mass” flow rate. Now — which flow do you want to measure? Not sure? In some applications, measuring the
the thing to do.

Consider filling a tank. Volumetric flow may be of interest to avoid overflowing a tank where liquids of differing densities can be added. (Then again, a level transmitter and
switch/shutoff may obviate the need for a flowmeter.) Consider controlling fluid flow into a process that can only accept a limited volume per unit time. Volumetric flow me
seem applicable.

In other processes, mass flow is important. Consider chemical reactions where it is desirable to react substances A, B and C. Of interest is the number of molecules presen
volume. Similarly, when buying and selling products (custody transfer) the mass is important, not its volume.

How much maintenance does a flowmeter require?

A number of factors influence maintenance requirements and the life expectancy of flowmeters. The major factor, of course, is matching the right instrument to the partic
Poorly selected devices invariably will cause problems at an early date. Flowmeters with no moving parts usually will require less attention than units with moving parts. Bu
eventually require some kind of maintenance.

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