06/01/2023, 16:19 Everything You Need to Know About Flow Measurement

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Handbook : Everything You Need to Know
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Our Products INTRODUCTION
Flow measurement is an important process with diverse applications like measuring the flow rate of blood in
human beings to measuring and controlling the flow rate in an oil well useful for extraction of oil. It forms an
important part of several industries like chemical, wastewater treatment, pulp and paper, oil and gas, and
several others. The scope of flow measurement extends far beyond that covered in the following sections.
This exhaustive system spans several processes, techniques, and technologies. We have attempted to
touch the tip of the iceberg that is flow measurement.

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The accuracy of flow measurement determines the functioning of the system. A well-functioning system will
provide highly accurate results. Several new technologies are being developed in this realm to support flow
measurement systems. These systems as well as direct and indirect processes can help organizations
achieve brilliant results.
In this handbook, we will be discussing flow measurement concepts, processes, and systems that are useful
to the amateur and professional. They encompass theoretical and practical topics peppered with interesting
information and trivia about flow measurement. From the Mesopotamians to Doppler to the most recent
group findings, this handbook promises to be an interesting as well as informative read.
WHAT IS FLOW MEASUREMENT?
As the name suggests, flow measurement is the process of measuring the flow rate and volume of a liquid or
gas. This process can be employed to measure the liquid passing through an application (as seen in water
purification systems), or stored in an application (as seen in fuel injectors). Flow measurement is a vital
function used to monitor and control the rate of liquid flow in applications. This process is used to measure
the flow of versatile substances like heavy oils, abrasive chemicals, and light gases. Hence, this process is
utilized in applications across various industries.

Flow measurement is employed in critical applications where the flow rate or level of liquid stored needs to
be administered regularly. The safe functioning of applications depends on flow meters. In terms of flow
measurement, accuracy is of such importance that it can be the determining factor of a company making a
profit or loss.

WHAT ARE FLOW METERS & THEIR MAIN TYPES?

In some applications, the flow needs to be regulated within a specific range. This is achieved by using flow
meters. A flow meter is a device used to facilitate flow measurement. Flow meters are broadly classified as:

1. Differential Pressure
a. Orifice Plate
b. Venturi Tube
c. Flow Tube
d. Flow Nozzle
e. Pitot Tube
f. Elbow Tap
g. Target
h. Variable-Area (Rotameter)
2. Positive Displacement
a. Reciprocating Piston
b. Oval Gear
c. Nutating Disk
d. Rotary Vane
3. Velocity
a. Turbine
b. Vortex Shedding
c. Swirl
d. Electromagnetic
e. Ultrasonic, Doppler
f. Ultrasonic, Transit-Time
4. Mass
a. Coriolis
b. Thermal
5. Open Channel
a. Weir
b. Flume

UNITS OF FLOW MEASUREMENT

Flow meters can be used to measure the flow rate of liquids or gases. The unit is decided depending on the
function and parameters of flow measurement. The unit used varies according to the system of
measurement being followed, as well as the material being measured. Dissimilar media need to be
measured under diverse conditions and using different units.

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Units Used to Measure Flow

The following units are used to measure liquid and gas flow:

Liquids are measured based on density: liters per second or gallons per minute
Steam is measured based on weight: Tonnes/ hour and kilograms/ minute
Gases are measured based on energy content: Joules/ hour and British Thermal Unit/ day
Gases are also measured according to STP (Standard Temperature and Pressure) and NTP (Normal
Temperature and Pressure) in units like m3/hour and acm/ hour (actual cubic meters per hour).
Depending on whether the gas is measured at NTP or STP, the units will include the details. Two
examples of the symbol at STP and NTP, respectively are: Std m3/hour and Nm3/hour

The unit of measurement changes in accordance with the medium of material being measured. For example,
the units of measurement of liquids, gases, and steam could vary. This is because the change in their density
is dependent on different factors. The density of gases is dependent on pressure and temperature. On the
other hand, the volume of liquid is independent of pressure. Hence, the units used to measure the different
media change accordingly.

Flow Measurement – A Look Back At History

Mapping the history of fluid dynamics and the flow measurement process, this section takes a look at the
milestones achieved.

When: 5000 B.C.

Who: Mesopotamians
What: The earliest record of flow measurement can be found in Sumerian cities that were located near the
rivers Tigris and Euphrates. The Mesopotamians created channels from the rivers into the city to supply
water to every household (an ancient plumbing system, so to say). They used simple methods of flow
measurement to monitor the flow rate of water from the rivers into these channels.

When: 3500 B.C.

Who: Ancient Egyptians
What: The Nilometer
The Nilometer is a structure that was built to measure water flow throughout the year. This system helped
the Ancient Egyptians predict floods, draughts, and well-balanced water flow throughout the season. It also
helped them anticipate and prepare their food and supplies according to the volume of water expected in the
upcoming season.

When: 1738
Who: Swiss Physicist Daniel Bernoulli
What: Bernoulli published Hydrodynamica, supporting his theory of conservation of energy in liquid flows.
This thought process pioneered the processes used to determine pressure drop in various processes and
equipment.

When: 1759
Who: Swiss Mathematician and Physicist Leonhard Euhler
What: Euhler applied Newton’s Second Law of Motion to fluid dynamics. He developed partial differential
equations for motion of fluids.

When: 1832
Who: English Scientist Michael Faraday
What: Faraday invented the theory of the dynamo. He has also been attributed to developing the theory
responsible for the invention of the magnetic flowmeter.

When: 1842
Who: Austrian Physicist Christian Doppler
What: Doppler discovered and established a relationship between distance and frequency of sound. Almost
a century later, his discovery enabled the invention of the Doppler flow meter.

When: 1843
Who: French Civil Engineer Gaspard Coriolis
What: Coriolis is responsible for discovering the drifting of wind and ocean currents caused by the earth’s
rotation. This drift varies depending on the location. For instance, the drift is dissimilar at the two poles. The
direction of the drift is also dependent on the hemisphere. This has helped further the field of flow
measurement greatly.

When: 1845
Who: Irish Mathematician, Physicist, Politician, and Theologian George Gabriel Stokes
What: Based on Claude Navier’s calculations and equations published for incompressible fluids, Stokes
derived equations that helped describe the motion of liquids. These equations are known as Navier–Stokes
equations. Stokes also developed theories that led him to invent the Stoke’s Law. This law helps calculate
drag force in a viscous fluid.

When: 1883
Who: British Engineer Osborne Reynolds
What: He discovered the ‘Reynolds’s Number’, which is a dimensionless ratio. This number helps us
calculate the viscosity of a liquid. This is extremely helpful in flow measurement calculation.

When: 1954
Who: Hungarian-American Aeronautical Engineer Theodore von Karman
What: Karman discovered that the vertices formed in water were always constant irrespective of the velocity
of water. His discovery facilitated the discovery of the Vortex flow meter. Based on this principle, the first
swirlmeter was made available to the public in 1968.

When: 1954
Who: Hungarian-American Applied Mathematician & Physician John Von Neumann
What: Neumann is regarded as the founding father of computational fluid dynamics. His efforts have helped
shape major inventions in the field of fluid dynamics in recent times. His theories on artificial viscosity have
also enhanced people’s understanding of shock waves.

TRIVIA: What Are Re-discoveries?

Sometimes, when discoveries are made, they are not utilized at that time. There could be several reasons
why this happens. Sometimes, people are not able to comprehend the knowledge. At other times, the
technology to support the theory has not been developed. Hence, the theory takes a backseat in the minds
of people and it can be forgotten over time. When these theories are resurrected, they are known as re-
discoveries. For example, when the sub-field of vortex dynamics within the field of fluid dynamics gained
momentum, many discoveries and re-discoveries were made.

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Why Measure Flow?

It is obvious that wherever needed, flow meters are critical to the functioning of the application. In fact, in
some applications, precise measurement of liquid and gases is needed to maintain safety. However, one too
many times, flow meters are installed when they are not needed. At other times, the requirements of the
application are not assessed correctly. This causes several problems in terms of functionality, not to mention
misdirection of company funds.

Flow meters can be used in conjunction with several types of liquids. Various configurations of these devices
are available, which allow them to be used with liquids with varying chemical and physical properties. In
terms of configurations, the flow meters can be designed with various functionalities, materials, and
capacities. The specifications can be customized according to the needs of the application and industry.

For example, specialized flow meters are available for use in wastewater treatment plants. The material used
for the construction of the flow meter will vary depending on the pH levels of the water. In addition, the flow
meter will have to be designed to accommodate the inflow of the water. In order to ensure maximum
accuracy, the capacity of the flow meter should match that of the wastewater flowing through the system.

Factors to Consider When Selecting a Flow Meter

A market survey has claimed that over 75% of industrial flow meters are not performing up to the expected
mark. This is mainly caused due to improper product selection. In the initial stages of product selection,
buyers can benefit from understanding the basic requirements of their applications. To do this, the right
questions need to be asked.

Some tips to help you define your requirements:

Most Important Flow Meter Functions are:

1. Repeatability
2. Accuracy
3. Range
4. Linearity

QUESTIONS YOU SHOULD BE ASKING

Do I Need?

1. Local or Remote Operation

2. Local or Remote Output

Is The Liquid Being Measured:

1. Viscous?
2. Clean?
3. Slurry?
4. Electronically Conductive?

Also..

1. What is the density of the liquid?

2. What is the expected flow rate?
3. What will be the operating temperature?
4. How much pressure is the device expected to handle?
5. What is your budget?

Flow Meter Features that Increase Efficiency

Look for the following features within your application to ensure maximum efficiency:

Construction should ensure:

Insusceptibility to vibration
Durability
Stable output
Resistance to corrosion and abrasion
Safe operation
Small carbon footprint
Ease of installation
Should feature drainability for:
Low maintenance intervals and costs
Maximizing uptime
Improved accuracy
The following feature adds value to the application:
Automatic corrosion resistance features, which help in detection of defect or failure in components (like
pipes)

Every product has its own advantages and disadvantages. It is important to match your application’s
requirements with those of the flow meter. When the features and needs of both are in harmony, the results
are outstanding. Manufacturers and suppliers, alike are eager to assist buyers in their quest to finding the
perfect flow meter that delivers on all counts of performance and efficiency.

Flow Meter Management: Calibration

Flow meter calibration along with other installation and maintenance procedures is needed to ensure safe
operation of plants. Flow meters analyze a very important function. Hence, before purchasing a flow meter,
the buyer should consider whether the device can be installed, used, and maintained in the best possible
manner.

Why Calibrate?
Flow meters are used in critical applications and functions. Hence, they need to be calibrated to ensure
accurate measurements. With constant use, components wear out and flow meters can fall out of calibration.
This is true for the most ruggedly constructed devices. The accuracy of the measurement reduces over time.
Regular calibration will ensure that all components function efficiently, providing brilliant results.

Common Problems that Demand Regular Calibration

Why should one calibrate? Here are some problems that could occur with a flow meter. These problems
disrupt the functioning of machines. However, they can be solved by employing calibration methods. Some
of the problems you should watch out for:

1. Deposits : Dirt, salt, minerals, and foreign materials can be deposited on the interior surfaces of the
machine. This disrupts the functioning of the instrument. Even if the machine seems to be functioning well on

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the outside, internal deposits can cause major problems to the functionality of the flow meter.
2. Contamination : Several problems can occur if the material within the flow meter is contaminated. For
instance, the intricate parts within the flow meter could be blocked causing the entire operation to shut down.
Careful testing of the material flowing within the device should be carried out. In some cases, the problem
could lie with the device itself. Hence, regular maintenance should be conducted to identify possible areas
and reasons for contamination.
3. Abrasion : When harsh chemicals are used, the surface of the equipment could wear out. You must keep
your flow meter safe from chemical attacks.
4. Natural Wear & Tear : Every product has a life span. Beyond a certain time or magnitude of usage, natural
wear and tear will cause aging. Certain components within the flow meter will have to be changed after a
certain period. This information will be provided by the manufacturer. Changing the components at the right
time will ensure a longer life cycle of the flow meter.
5. Unsuitable Treatment : If the machine is not used in accordance with the manufacturer’s directives, some
parts or the machine as a whole will stop functioning. On a smaller scale, the performance of the machine will
be altered. One way or another, the machine should not be abused.
6. Improper Installation : Some problems associated with the flow meter can be traced to the installation
procedures. This will also lead to inconsistencies between the functioning and calibration of the flow meter.
7. External Influences : The environment of the application and the natural environment both will have some
effect on the functioning of the flow meter. The functioning of the flow meter could be affected by
electromagnetic radiation, vibrations, temperature and pressure changes, etc.
8. Difference in Fluid Properties : A flow meter will function optimally when used with the liquid or gas with
which it was calibrated. If there is a major inconsistency in the liquid used, the flow meter will fail to provide
accurate results.

Best Practices of Flow Meter Calibration at a Micro Level

(Conducted at the Execution Level)
When calibrating flow meters, the following practices will allow you to get the most out of the process:

1. Accuracy of Standard : It is a good practice to make sure that your standard is extremely accurate. The
norm is to keep the accuracy of the standard four times higher than the Unit Under Test (UUT). Depending on
the application, this thumb rule could vary.
2. Traceability of Standard : As with all best calibration practices for most equipment, the standard used to
calibrate your equipment should be traceable to a known standard. Traceability is important to verify your
measurements. It also helps define the accuracy of your calibration process.
3. Real Time Calibration : Since the calibration process is conducted in real time, the flow rate of the flow
meter should not vary. The flow between the standard and test equipment should be constant throughout the
calibration process.
4. Physical Conditions :The physical conditions during the functioning of the standard and test flow meter
should not vary. A slight change in the temperature or pressure conditions can cause a major disruption in the
calibration process leading to errors. You must also ensure that there are no leaks, change in volume, or
change of medium/ material.
5. Real Time Conditions: The tests should be carried out in conditions that will be present during the
functioning of the flow meter. This will help you accurately match the application’s requirements.
6. Multiple Testing :Multiple tests should be conducted to verify your initial findings. If there is a major
difference in the findings, you will need to validate the accuracy of your standard and other processes and
equipment being used.

Industrial Dynamics Tip :

During the calibration process, the common error zone lies in the medium being measured. This zone comes
in play when there is some difference between the liquid’s viscosity, density, or heat content at both the
stages of testing.
For example, if the density of the liquid is slightly higher during the operation of the standard as compared to
the density of the liquid during the operation of the test flow meter, your results will be inaccurate.

Best Practices of Flow Meter Calibration at a Macro Level

(Conducted at a Company Level)
The following practices should be employed by a company on a macro level. It is the responsibility of the
managerial function of an organization to put these processes in place:

1. Scheduled Calibration : A regular calibration schedule should be in place. All flow meters should be
calibrated in accordance with the time of operation or life cycle of product.
2. Accessible Calibration Data : When a flow meter is calibrated, all data should be carefully recorded. This
information should be readily accessible to the person in charge. Hence, at one glance, the technician will
know when and what changes were made to the device. This will allow them to get an insight into the
maintenance procedures implemented on the product.
3. Certified Laboratory : If using a calibration lab, ensure that they possess the right experience and
certifications. You must also not shift from one lab to another as the calibration methods or standards may
defer making it difficult for you to draw a comparison between the two.
4. Reducing Down Time : Down time is a natural occurrence of the calibration process. You can reduce or
even diminish this down time by purchasing spare flow meters. Rotating the flow meters will also ensure
better functioning and allow tracking comparisons in the functioning of two flow meters.

Although the calibration of most flow meters will fall out at some time due to wear and tear of components,
the calibration could also be off due to improper installation or damaged components. Hence, regular
calibration will ensure that the flow meter functions smoothly providing precise results.

Industries Benefitting From Flow Meters

Flow meters are used across several industries. Following are some examples of industries and applications,
which use flow meters to accurately monitor and measure different liquids:

1. Industry: Chemical
Application: Monitoring Flow of Chemicals
2. Industry: Oil & Gas
Application: Measuring the Rate of Flow of Crude Oil
3. Industry: Pulp & Paper
Application: Measuring Pulp Stock
4. Industry: Petrochemical
Application: Measuring Fuel Flow in Commercial Applications
5. Industry: Food & Beverage
Application: Wine Filling
6. Industry: Refining
Application: Pump Monitoring
7. Industry: Pharmaceutical
Application: Production and Packaging of Liquids
8. Industry: Waste & Wastewater
Application: Measuring Wastewater Flowing into Water Filtration Systems
9. Industry: Power & Energy
Application: Deionised Flow Measurement
10. Industry: Agriculture
Application: Monitoring Water Used for Irrigation

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CONCLUSION
Several specifications of the application and flow meter have to be considered when finding the right fit.
Several external factors including environmental conditions, budget, etc. also need to be taken into
consideration during product selection. Factors such as the media to be measured, viscosity of media,
operating conditions (like temperature and pressure), performance expectation, installation conditions, and
material of the flow meter need to be paid attention to when selecting a flow meter. The right product will help
improve efficiency of the entire process. You can even consult your manufacturer on the best kind of product
that will integrate seamlessly with the rest of your system.

The maintenance of the product throughout its service life cycle should be taken into consideration when
outlining the budget for the product. This will reduce the surprise factor and help you in planning your
finances accordingly. Regular calibrations, among other maintenance procedures are needed to ensure
proper functioning of your flow meter. Calibration, as most flow meter owners understand is an important
process that helps mitigate any issues associated with performance. Maintaining the accuracy of a flow
meter has to be the top most priority of any organization.

Discussion of several such important topics is the need of the hour, as every organization is looking for
solutions to flow measurement issues. Understanding the basics will allow you to select, purchase, and
handle the instrument better. Flow measurement knowledge is also useful in increasing the efficiency of your
products.

Flow measurement is important for environmental sustainability, increased efficiency, safety, and process
optimization.

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