INSTRUCTION MANUAL

FM 250 Flow Measurement Test Bench

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photocopying or storing in any medium by electronic means and whether or not transiently or
incidentally to some other use of this publication) without the written permission.

EdLabQuip GmbH
Peiner Str. 157E, 30519 Hannover, Germany
www.edlabquip.com
sales@edlabquip.com
Tel: +49 511 56 37 98 70
 FM 250 Flow Measurement Test Bench

CONTENTS

RECEIPT OF THE GOODS ………………………………………….. 2

1. General Description ………………………………………….. 5
2. Introduction to Fluid Mechanics …………………………………………. 7
2.1 Laminar and Turbulent Flow …………………………………………. 7
2.2 Pressure and Heads …………………………………………………. 8
3. Flow Measuring Devices ………………………………………………… 10
3.1 Orifice Meter ………………………………………………………… 10
3.2 Venturi Meter ………………………………………………………… 12
3.3 Pitot Tube ………………………………………………………………… 14
3.4 Flow Nozzle ………………………………………………………………… 15
3.5 Variable Area Flow Meter ………………………………………………… 16
3.6 Digital Flow Indicator ………………………………………………… 17
3.7 Water Meter ………………………………………………………………… 17
3.8 Measuring Tank ………………………………………………………… 17
3.9 Priority of Measuring Devices ………………………………………… 17
4. Test Procedures ………..………………………………………………… 18
5. Results …………………………………………………………. 20
6. Sample Calculations …………………………………………………. 23
APPENDICES
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Appendix 1: Water Manometer ………………………………………… 26

Appendix 2: Mercury Manometer ………………………………………… 14
Appendix 3: Water Pump Maintenance …………………………………. 15

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 FM 250 Flow Measurement Test Bench

RECEIPT OF THE GOODS

1. On Receipt of Goods
(a) On receipt of the goods at the customer’s premises, the shipment should be inspected for any
damages or missing items. These items should be checked against the delivery note, packing list or
shipping documents.
(b) If there is any damage to the equipment or a discrepancy in missing items as listed shipping
documents, then the insurance company should be notified within three working days on receipt of
the shipment if the loss or damage was not apparent at the time of taking delivery from the port.
(c) If insurance has been arranged by the buyer then you must notify your insurer in writing of any
damage or loss of parts which was observed regarding this shipment within a specified period of time
as stated in the Terms and Conditions. This should include detailed photographs of the damaged
equipment.
(d) If insurance has been arranged by the seller you should notify the insurances representative along
with any correspondence including the insurance certificate supplied by the seller. These should
include detailed photographs for evaluation of damages or replacement parts pertaining to the
shipment.
(e) The seller will only replace damaged parts on notification by the insurance company that the claim
has been accepted.
2. Manufacturers Liability
(a) Before proceeding to install, commission or operate the equipment listed in the instruction manual, we
would like to alert the user to the health and safety aspects of people who will work on or operate our
equipment with regard to the liability of the manufacturers or suppliers.
(b) Manufacturers or suppliers are absolved of any responsibilities with regard to misuse of their
equipment causing harm or financial charges being incurred against them from clients or third parties
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for consequences of failure or damage of the equipment in any way if the equipment is not installed,
maintained and operated as outlined in the instruction manual published by the manufacturers or
suppliers.
(c) In order to safeguard the students and operators of the equipment it is vital that all safety aspects as
outlined in the instruction manual are observed.
3. Safety Guidelines
3.1 General Safety Concerns
Before proceeding to install, commission, or operate the equipment described in the instruction manual we
would like to alert you to the dangerous potential hazards that would be present if safety practices were not
performed in accordance with the local standards and governing body regulations.
- Injury would occur to the operational staff of the equipment through misuse, electric shock, rotating
equipment hazards and lack of cleanliness.
To be able to achieve the aim, of “accidents can be avoided” it must be ensured that the equipment is
installed correctly, regularly maintained and operators of the equipment are made aware of the potential
hazards associated with the particular equipment.
We would like to inform our valuable customers of the safety guide lines when using their equipment.
3.2 Awareness of Safety Hazards
(a) Before attempting to work on the equipment the personnel who are going to install, commission or
operate the equipment must be qualified and fully aware of all the manufacturers and suppliers
recommendations and instructions.
(b) Ensure that the all the recommendations specified in the instruction manuals are maintained as
stated in the contents.
4. Electrical Safety
(a) Ensure that the person who works on the equipment is a qualified electrical engineer/technician who
is competent in the safety aspects and operational mode of the equipment.

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 FM 250 Flow Measurement Test Bench

(a) (b). If the electrical supply to the equipment is supplied by means of a portable trailing cable,
protective devices such as an Earth Leakage Circuit Breaker (ELCB) must be installed.
(b) This protective device must have a very high sensitivity (20-30mA).This device is also referred to as a
residual current device(R C D) within the electrical supply circuitry for personnel protection.
(c) (c) The supply cable must be sized accordingly for all fault and physical conditions pertaining to its
use. The supply network must also incorporate a protection device that will disconnect and isolate
the supply voltage in the case of an overload in a specified period of time without causing any
damage to the equipment. (An overload relay)
5. Installation
(a) On receipt of the equipment extreme care should be used to avoid damage to the equipment on
handling and unpacking. If slings are used ensure they are held on a rigid part of the equipment, the
structure. In the case of a mechanical lift such as a fork lift ensure the lifting forks are beneath the
structure framework so that no damage will occur during the lifting operation.
(b) In some cases it is imperative that the equipment be installed on a level and solid foundation
5.1 Electrical Supply Cables
(a) The normal colour code of the power cables supplied on this equipment is as follows:
- Black -----------------------------------------Line
- Grey or white. --------------------------Neutral
- Green-Yellow --------------------------Ground
(b) The three phase power cable has five wires.
- Red, blue and black. ---------------------Line
- Light grey or white - ------------------Neutral
- Green-Yellow ------ ---------------Ground
5.2 General Precautions for Equipment with Water Including Evaporative Cooling Towers
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(a) Any water contained in the system should be drained regularly. If it is left in the system for a long
period of time without circulation it will stagnate.
(b) The equipment should be flushed regularly with clean water.
(c) Impurities in the water will cause scale or algae and must be cleaned on a regular basis. An anti rust
additive such as used in the automobile industry is recommended to inhibit this process.
(d) The water should be at temperature under 45degreesC to maintain effectiveness.
(e) Many of the problems encountered with water contamination can be reduced and prevented by
means of a water treatment programmer being introduced using the expertise available locally or on
site.

5.3 Rotating Equipment

(a) If the equipment is supplied with any rotating parts such as a motor, generator, fan etc these items
are provided with a protection shield or a guard to protect the operator from any dangers which may
occur when the rotating parts fail. These guards must be in place whenever the rotating parts are in
operation (rotating) and only removed for maintenance periods.
(b) After maintenance is carried out ensure that the machine guards are replaced back in service. Do not
operate any rotating parts unless machine guards are in place.
5.4 Steam Equipment
(a) When using steam equipment, there are a number of vital precautions which must be remembered by
the operators and maintenance crew and placed into operation when both operating and performing
maintenance schedules. During operation of this equipment the steam and water are at a high
temperature and pressure which can have a very damaging and hazardous effects on students if
safety precautions are not observed.
(b) Ensure that critical values of temperature and pressures listed in the instruction manual are
maintained and not exceeded on the equipment.

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 FM 250 Flow Measurement Test Bench

(c) Safety valves should be calibrated on a regular basis with mandatory service records maintained.
This should also include pressure reducing valves.
(d) Calibration of any instrumentation such as pressure gauges, thermometers and sensors should be
checked regularly.
(e) Visual inspection of the equipment should be regularly observed for leaks of steam etc and any
frameworks or joints should have the hardware checked for tightness.
(f) Always use protective clothes including gloves when carrying out maintenance on the equipment.
5.5 High Temperature Equipment
(a) When using high temperature equipment there are a number of vital precautions which must be
remembered by the operators and maintenance crew and observed when both operating and
performing maintenance schedules. During operation of this equipment the air, gas or water is at a
high temperature and pressure which can have a very damaging and hazardous effect on students if
safety precautions are not observed.
(b) Ensure that critical values of temperature and pressures listed in the instruction manual are
maintained and not exceeded on the equipment.
(c) Calibration of any instrumentation such as, thermometers and sensors must be checked regularly for
safe operation.
6. Maintenance Safety Practices
(a) Always isolate the equipment from the electrical supply when carrying out maintenance on the
equipment.
(b) Ensure that safety notices are placed on the equipment supply advising personnel that the equipment
is being worked on, inspected and should not be operated.
(c) Check the operation of any protective devices, i.e. E L C B. so that it operates in accordance with its
specifications thus ensuring the safety of all operational personnel working on the equipment. Any
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malfunction of the device must be corrected by a qualified electrician before returning the equipment
back to a service condition.
(d) Ensure on completions of the work that the equipment is returned to its original state and that no
covers, panels are left open along with loose screw drivers, spanners are left in the equipment.
(e) If water is used with the equipment then there are certain preventative mandatory regulations that
have to be taken to prevent infection from harmful micro-organisms.
7. General Safety Conditions when Operating or Maintaining the Equipment
(a) When operating or carrying out maintenance on the equipment the Health and Safety of the
students can be safeguarded in many ways by wearing protective clothing.
(b) Loose fitting clothes should never be worn in a laboratory. These clothes can cause a serious
accident if caught in rotating equipment. i.e. tie etc.
(c) Protective gloves must be used if handling toxic materials or where there is a high temperature
present.
(d) Ear protectors should be worn when operating noisy equipment.
(e) Eye protection should always be used when there is a risk to the eyes.

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 FM 250 Flow Measurement Test Bench

1. General Description

Orifice meter Pressurizing valve for hand air pump

Vent valve

Measuring tank

Venturi meter

Pitot tube Manometer

Water meter Rotameter
Flow control valve
(normally open)

Earth leakage circuit breaker (ELCB)and

Flow control valve
power circuit breaker (CB)

Figure 1: Flow Measurement Test Bench

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This is a bench-top, self-contained water circulating unit for studying various flow
measurement tools including primary flow measuring devices.
The flow measuring instruments are connected in series and all except the measuring
tank are arranged on a water-proof panel.
Measurement of flow by primary flow measuring devices is by coefficient of discharge,
which is determined from a pressure drop across the device and a flow rate. Flow rate is
obtained from a water-meter reading and a stop watch.
The pressure drop is measured via differential pressure using manometers. Pressure
tapping is provided with small ball valves with quick connection. Water tanks are at rear
side of the panel. Flow rate is varied by a flow control valve.

1.1 Typical Experimental Capabilities

- Comparison of different pressure at various flow rates for Venturi meter, orifice
meter, Pitot tube, and variable-area flow-meter
- Determination of coefficients of discharge for Venturi meter, orifice meter and Pitot
tube and comparison of the flow rates with those from water meter, variable-area
flow-meter and measuring tank

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 FM 250 Flow Measurement Test Bench

1.2 Technical Data

Pump : 0.37 kW
Maximum flow rate : Over 80 lpm
Primary flow measuring device, clear plastics
Venture meter : 29mm diameter,
17mm throat with 21° inlet,
14° outlet taper
Orifice meter : 20mm diameter on 29mm tube
Pitot tube : On 19mm diameter tube
Other flow measuring devices
Water meter and a stop watch
Rotameter : Up to 75 lpm
Measuring tank
Differential pressure : Water manometer, 8 tubes, 950mm x 1mm graduation
Powers supply 220 V. 1 Ph. 50 Hz.

Pressurizing valve for hand air pump

Vent valve
Flow control valve
(normally open) Manometer 8 tubes
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H2 L 1
L2 H1
Hand
Measuring tank Venturi Orifice H4 air pump
40 L H3 L3 L4 Flow meter

Nozzle (optional) Pitot

Water meter

Storage tank
H 1 H2 H3 H4
L 1 L2 L 3 L4
Drain valve From measuring Pump
device Flow control valve
Low pressure manifold L1-L4 H1-H4
To manometer
To manometer

L1 H1
L2 H2
L3 H3
L4 H4 optional
Low V3
V5 V4
High pressure manifold
High
Differential pressure indicator

Figure 2: Schematic diagram of the Flow Measurement Test Bench

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 FM 250 Flow Measurement Test Bench

2. Introduction to Fluid Mechanics

2.1 Laminar and Turbulent Flow
When the flow is very slow, the particles of the fluid will move in layers parallel to the pipe
wall in the direction of the flow. The particles at the center of the pipe move faster than the
molecules near the wall. This state of flow is called “Laminar Flow.”
When the flow is very fast, the particles have an irregular motion in defused pattern but, in
general, move in the direction of flow with particles near the pipe wall move slower than
those near the centre of the pipe. This type of flow is called “turbulent flow”. Flows in
most cases of engineering applications are Turbulent.
The flow may be indicated by a dimensionless quantity called “Reynolds Number (ReD)”

= VD VD
ReD  
 ν
 = Density of the fluid kg/m3
V = Velocity m/s
D = Pipe diameter m
 = Dynamic Viscosity of fluied, Pa-s or N-s/m²

 = Kinematics Viscosity  m2/s.

Flow is laminar when ReD ≤ 2000,
and is turbulent when ReD ≥ 4000 or more.
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Transition range is when 2000 < ReD < 4000

Path of particles Velocity profile

Figure 3.1: Laminar flow

Path of particles Velocity profile

Figure 3.2: Turbulent flow

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 FM 250 Flow Measurement Test Bench

2.2 Pressure and Heads

There are several bases for measuring pressure as per below:

2.2.1 Atmospheric Pressure

It is the ratio between the weights of the atmosphere per unit area on the earth surface.
Thus one atmospheric pressure is equal to 101.325 kilo-Newton per square meter (kN/m2)
or 14.7 pound per square inch. Since barometer is used to measure atmospheric
pressure, this pressure is often referred to as Barometric pressure, pb .

kN/m² = kilo Newton per square meter

m2 = square meter
psi = pound per square inch

Pressure on pressure gauge is the pressure above atmospheric pressure.

2.2.2 Pressure Head (p/)

Pressure head is the height of the liquid that exerts pressure on a surface area. Pressure
measuring device measures pressure difference from that of atmospheric pressure. The
resulting pressure is called Gauge Pressure, pg which can be a positive or negative value.

p p

 g
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p
= Pressure head m

p = Pressure N/m2
 = Specific weight N/m3
 = Density of fluid kg/m3
g = Acceleration due to gravity m/s2

v2
2.2.3 Velocity Head ( )
2g
When liquid flows in a pipe or in an open channel, it has a kinetic energy. Kinetic energy
per unit weight of liquid is called velocity head. Kinetic energy of the object in motion is:

W 
K .E  12 mv 2  12  v 2
g
2
K .E v

W 2g

where, K.E. = kinetic energy, Nm

W = weight, N
v = velocity of the liquid, m/s
g = acceleration due to gravity, m/s

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 FM 250 Flow Measurement Test Bench

2.2.4 Elevation Head (or Static Head) (Z)

When a liquid is at an elevation, it has a potential energy. Potential energy per unit weight
of the liquid is called elevation head or static head. Potential energy of the object at an
elevation Z is:

P.E.  W .Z
P.E .
Z
W
Where, P.E. = potential energy, Nm
W = weight, N
Z = elevation, m

2.2.5 Total Head, (H)

Total energy of a liquid at any point is the total energy per unit weight of the liquid and
equal to the summation of pressure head, velocity head and elevation head of the liquid.
Thus, the total head is:

Total Head = Pressure Head + Velocity Head + Elevation Head

p v2
H  Z
 2g
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2.2.6 Friction Head; (hf)

When a liquid flows from one point to another, part of the total energy is lost due to friction
between the liquid and the wall as well as the interaction of the liquid particles. Energy
loss due to friction per unit weight of the liquid is called friction head or head lost due to
friction. Friction Head between points 1 and 2 is:

 p1 p 2   v12 v22 
h f ,12          Z1  Z 2 
     2 g 2 g 

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 FM 250 Flow Measurement Test Bench

3. Flow Measuring Devices

There are several devices commonly used for flow measurement namely: orifice meter,
Venturi meter, Pitot tube, nozzle, variable area meter, water meter, and measuring tank.
Some of these are employed in this test bench.

3.1 Orifice Meter

When an orifice plate is placed in a pipe, the velocity of water flowing through the pipe at
or immediately after the orifice is higher than velocity before the orifice. At the same time,
static pressure before the orifice is higher than at the orifice. The pressure difference is
measured by a manometer. In this case, applying Bernoulli’s equation between point 1
and point 2 gives:

h
D D/2

D2

D1
1 2
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Figure 4: Orifice plate

p1 v12 p v2
  Z1  2  2  Z 2 (1)
 2g  2g
Subscripts 1 & 2 mean point 1 and point 2 of a liquid in the pipe respectively. Point 1 is
before the orifice plate, point 2 is at vena-contract of the jet.
Since Z1=Z2, hence,
p1 v12 p v2
  2 2
 2g  2g

v22  v12 p  p2
 1
2g 

 p  p2 
v22  v12  2 g  1  (2)
  
From continuity equation:
A1V1  A2 v2

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 FM 250 Flow Measurement Test Bench

A2 v2
v1  (3)
A1
where, A1 is the cross section area of the pipe, and
A2 is the cross-section area of the orifice.
Substituting V1 from equation (3) in equation (2) gives:
2
Av   p  p2 
v   2 2
2
  2 g  1 

2
 A1   
 Av 
2
  p  p2 
v 1   2 2
2
   2 g  1 

2
  A1    

1  p  p2 
v2  2 g  1 
A 
2
  
1   2 
 A1 
1 (4)
v2  2 g h
4
D 
1   2 
 D1 
Thus the ideal flow rate (theoretical flow rate) is:
Qth  A2 v2
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A2
Qth  2 g h (5)
4
D 
1   2 
 D1 

Since there is some energy loss between section 1 and section 2, and there is also a
vena-contract after flow through the orifice, then the actual flow rate will be:
Co Ao
Qact  2 g h (6)
4
D 
1   o 
 D1 
where, Qact = actual flow rate, m3/s
Co = coefficient of discharge the for orifice
Ao = cross-section area of the orifice, m²
D1 = pipe diameter (m) = 29mm, for this test equipment
Do = Orifice diameter (m) = 20 mm or for this test equipment
h = difference in pressure head, m
From the above equation we obtain,
4
D 
1   o 
 D1  Qact
Co  (7)
Ao 2 g h

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 FM 250 Flow Measurement Test Bench

For the test equipment:

Qact  Co k o h , ko is a constant, where,

Ao h (8)
ko 
4
D 
1   o 
 D1 
Equation (6) may be re-written in another form as:
 2 2 g h (9)
Qact  Co D1
4  D14 
 4  1
 Do 
For the apparatus FM 250, given:
Qo = actual flow rate for orifice meter, m³/s
D1 = 0.029m, D2 = 0.020m
 2 g h
Qo  Co 0.02912
4  0.029 4 
 
 0.020 4  1
 

Qo  1.583 10 3 Co h m³/s (10)

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3.2 Venturi Meter

h

p1
p2



1 2

throat
in out
Figure 5: Venturi meter

Apply Bernoulli’s equation between point 1 and point 2, we have,

p1 v12 p v2
  Z1  2  2  Z 2 (11)
 2g  2g
From continuity equation:
A1V1  A2 v2

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 FM 250 Flow Measurement Test Bench

A2 v2
v1  (12)
A1
Substitute v1 from equation (12) into equation (11) gives the ideal velocity of fluid at
throat.
 p  p 
v2 ideal  1
2 g  1  Z1    2  Z 2  (13)
    
2
A  
1   2 
 A1 
The ideal flow (theoretical flow) through Venturi meter is then,

A2  p  p  (14)
Qideal  2 g  1  Z1    2  Z 2 
     
2
A 
1   2 
 A1 
Since there is some energy loss between point 1 and point 2, then the actual flow will be
less than the above ideal flow, and after applying the coefficient of discharge CV to the
ideal flow, the actual flow will be:

CV A2  p  p 
Qact  2 g  1  Z1    2  Z 2 
     
2
A 
1   2 
 A1 

 p 
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CV A2  p (15)
Qact  2 g  1  Z1    2  Z 2 
     
4
D 
1   2 
 D1 

where, Qact = actual flow rate for Venturi meter (m3/s)

Cv = Coefficient of discharge for Venturi meter, dimensionless constant
A2 = throat cross section area, m²
D1 = pipe diameter, m (D1=29mm)
D2 = throat diameter, m (D2=17mm)
p1 = pressure at section 1, N/m²
p2 = pressure at section 1, N/m²
 = specific weight of fluid, N/m³
Z1 = elevation of section 1, m
Z2 = elevation of section 2, m
g = acceleration due to gravity, 9.81 m/s²
Since Z1 = Z2 equation (15) will be
CV A2 (16)
Qact  2 gh
4
D 
1   2 
 D1 
Where h is the pressure head difference, m.

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 FM 250 Flow Measurement Test Bench

 2 2 g h (17)
Qact  CV D1
4 D 4

  1
1
4
D o 
For FM 250 apparatus, QV = actual flow rate for Venturi meter, m³/s,
D1 = 0.029m, D2 = 0.017m
 2 g h
QV  CV 0.0292
4   0.029  4 
   1
  0.017  
 

QV  1.067 10 3 CV h (18)

Reference value for CV from ISO 5167-4:2003 (E), page 9 is:
17
  0.5862 , CV  0.995
29

3.3 Pitot Tube

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h 2  h 1  h

1 2

Figure 6: Pitot tube

Applying Bernoulli’s equation between point 1 in the pipe and the stagnation point 2 in
front of the Pitot tube gives:
p1 v12 p v2
  Z1  2  2  Z 2 (19)
 2g  2g
Since Z1 = Z2 and v2 = 0, thus

p p 
Thus v1  2 g  2  1 
   

v1  2 g h (20)
Actual flow rate is:
Qact  C P A1 2 g h (21)

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 FM 250 Flow Measurement Test Bench

where, Qact = actual flow rate of Pitot tube, m3/s

CP = coefficient of discharge for Pitot tube, dimensionless constant
A1 = cross-section area of pipe, m² , ( D12 4 ), D1 19mm
h = pressure head difference, m

For this equipment QP = actual flow rate of Pitot tube, m³/s


QP  C P 0.0192 2 g h
4
QP  1.256  10 3 C P h m³/s (22)

Reference value for CP is not available but it is assumed to be about 1.0.

3.4 Flow Nozzle

The nozzle used is ISA nozzle 1932 per ISO 5167

h
12.12

h1
h2

1 2
D1 D2

Figure 7: Flow nozzle

Apply Bernoulli’s equation between point 1 and point 2 as before, then the actual flow rate
through the nozzle is:
C N  A2
Qact   2 g  Δh
2
A 
1  2 
A 
 1 
C N  A2
Qact   2 g  Δh
4
 D2 
1  
D 
 1

15
 FM 250 Flow Measurement Test Bench

Qact  KA  2 g  Δh (23)
2
where,
Qact = actual Flow rate through nozzle, m3/s
CN = coefficient of discharge for nozzle, dimensionless constant
D1 = Pipe diameter (m)  29mm
D2 = Nozzle diameter (m)  21.46 mm
h = pressure head difference, m
K = flow coefficient, dimensionless, = C N / 1  D D 4  2 1
For this equipment, QN = actual flow rate through nozzle, m³/s
D1 = 0.029m, D2 = 0.0215m
 2 gh
QN  C N 0.0292  2
4  0.029 
  1
 0.0215 

QN  1.9267  10 3 C N h m³/s (24)

Reference value for CN from ISO 5167-3:2003 (E), page 26, is:
21.5
  0.74
29
CN varies from 0.9231 at Re = 2 x 104, to
12.12

0.9242 at Re = 2 x 107

3.5 Variable Area Flow Meter

The rotameter is a tube with varying cross 1. Taper tube
section area (hence variable area flow 2. Float
meter). Main components of this device 3. Float Stopper
4. Pipe connection
are: taper tube, and a float. When water 5. Upper connection
flows through this tube, part of the water 6. Gasket
will flow against the float imparting impact 7. Flow rate scale
on it and raising its level
The float can be plastic or steel
depending on the calibrated flow rate
required. The higher the flow rate the
higher the water velocity and hence the
higher the float level. To keep the float
stable and at the centre of the tube, a
small steel shaft is used as a guide.

Figure 8: Variable-area flow-meter (rotameter)

16
 FM 250 Flow Measurement Test Bench

3.6 Digital Flow Indicator

This type of device consists of 2 parts: a sensor and an indicator. The sensor employs
change in signal and the signal can be pulse type, magnetic field or ultrasonic etc.
The indicator supplies power to the sensor, and receives signal from the sensor, amplifies
the signal and indicates the value.
The indicated value can be set against a calibrated value. Different devices have different
accuracy, linearity and hysteresis.

3.7 Water Meter

Water meter is a very commonly used device due to its simplicity, reliability and
availability. Flow of water through the meter will force a wheel to turn and with gear
system, volume of water can be indicated down to as low as 1/10 l or lower. Flow rate is
obtained by timing the flow volume with a stop watch.

3.8 Measuring Tank

Measuring Tank is considered to be the most reliable means of measuring flow rate by
using the stop watch. The dimensions must be made very accurate and the tank should
be calibrated against a standard device such as a graduated cylinder.

3.9 Priority of Measuring Device

12.12

When several devices are available for use in determining the flow rate, the most reliable
choice should be:
1. Measuring Tank
2. Water Meter
3. Flow Meter

17
 FM 250 Flow Measurement Test Bench

4. Test Procedures

Orifice meter Pressurizing valve for hand air pump

Vent valve

Measuring tank

Venturi meter

Pitot tube Manometer

Water meter Rotameter
Flow control valve
(normally open)

Earth leakage circuit breaker (ELCB)and

Flow control valve
power circuit breaker (CB)

Figure 9: Flow Measurement Test Bench

- Before the Test

12.12

- Fill up the storage tank to near full.

- Connect pressure lines from manometer to the flow measuring devices.
- Open flow and pressure control valves.
- Switch the ELCB and CB to start the pump
- Adjust the flow rate by the flow control valve to be high enough to purge out air
bubbles from the system.
In case of using computer interface (optional) start the pump by clicking the “start”
button in the program and adjust flow rate by keying in the desired flow-rate value.

- Start the Test

- Open the manifold valves to manometer of the devices to be measured.
- Observe water levels in manometer and adjust the pressure in the manometer
head as per Addendum 2.
- Adjust the flow rate by the flow control valve until the rotameter reading is about 10
lpm.
For computer interface (optional) adjust the flow rate by keying a flow rate about 10
lpm.
- Record all manometer readings.
- Record rotameter reading (approximate flow rate).

18
 FM 250 Flow Measurement Test Bench

- Record volume and time for water meter. Start and stop the watch when one of the
meter pointers reads 0.
- Record volume and time for the measuring tank. Start and stop the watch when
water level reaches the pre-determined levels.
- Repeat the test at other flow rates.

NOTES:
1. Several flow measuring devices may be used simultaneously.
2. Flow rate measured with the measuring tank is considered to be more reliable and
accurate than the water meter and is used as the actual flow rate.
12.12

19
 FM 250 Flow Measurement Test Bench

5. Results
Data Sheet
FM 250 Flow Measurement Test Bench
Test by………………………… Date……………………………

Flow rate measuring from variable area flow meter

Measuring
10 15 20 25 30 35 40 45 50 55 60 65
MEASURING TANK

Volume (l)

Time (s)
Flow rate (l/min)

WATER METER

Volume (l)

Time (s)
Flow rate (l/min)

ORIFICE METER

Water level of manometer, left side

Water level of manometer, right side

Difference in water level

12.12

PITOT TUBE

Water level of manometer, left side

Water level of manometer, right side

Difference in water level

VENTURI METER

Water level of manometer, left side

Water level of manometer, right side

Difference in water level

ISA NOZZLE

Water level of manometer, left side

Water level of manometer, right side

Difference in water level

VARIABLE-AREA FLOW-METER

Water level of manometer, left side

Water level of manometer, right side

Difference in water level

20
 FM 250 Flow Measurement Test Bench

Sample Data
FM 250 Flow Measurement Test Bench
Test by………………………… Date……………………………

Flow rate measuring from variable area flow meter

Measuring
10 15 20 25 30 35 40 45 50 55 60 65

MEASURING TANK
Volume (l) 20 20 18 22 28 32 40 36 38 36 38
Time (sec) 120 91.78 68.06 61.81 63.97 60.,47 64.,8 48.81 44.84 37.96 36.88
Flow rate (l/min) 10 13,07 15,86 21,35 26.26 31.75 37.06 44.25 50.84 56.90 61.82
WATER METER
Volume (l) 21 26 21 23 30 32 45 50 60 60 60
Time (sec) 123.6 105.7 74.64 64.58 68.90 60.14 71.71 67.87 70.19 62.88 57.81
Flow rate (l/min) 10.19 14.75 16.,88 21.36 26.12 31.92 37.65 44.20 51.28 57.25 62.27
ORIFICE METER
Water level of manometer, left side 375 409 323 399 496 738 435 970 884 927
Water level of manometer, right side 346 360 249 278 316 457 43 438 165 25
Difference in water level 29 49 74 121 180 281 392 532 719 902
VENTURI METER
Water level of manometer, left side 311 300 166 156 144 203 345 575 823 732 905
Water level of manometer right side 290 265 113 67 11 5 79 193 323 103 158
Difference in water level 21 35 53 89 133 198 266 382 500 629 747
PITOT TUBE
Water level of manometer, left side 360 381 275 334 395 581 845 683 785 870
Water level of manometer, right side 331 330 201 217 220 317 490 188 120 58
12.12

Difference in water level 29 51 74 117 175 264 355 495 665 812
ISA NOZZLE
Water level of manometer, left side 91 108 217 209 400 715 454 599 605 527 568
Water level of manometer, right side 79 86 177 158 321 609 314 410 329 229 206
Difference in water level 12 22 40 51 79 106 140 184 276 298 362
VARIABLE AREA FLOW METER
Water level of manometer, left side 340 470 546 585 658 830 970
Water level of manometer, right side 152 93 81 108 133 93 48
Difference in water level 188 377 465 477 525 737 922

Note: The above results include optional accessories.

21
 FM 250 Flow Measurement Test Bench

Calculations Table: Coefficient of Discharge

From Orifice Meter

Q actual (l/min) Re H (m) h Co

10.00 13,242.01 0.029 0.170 0.617
13.07 17,306.02 0.049 0.221 0.620
15.86 21,000.26 0.074 0.272 0.613
Co: D1 = 29.0mm 21.35 28,269.59 0.121 0.348 0.645
D2 = 20.0 mm 26.26 34,770.93 0.180 0.424 0.650
31.75 42,040.25 0.281 0.530 0.629
37.06 49,071.24 0.392 0.626 0.622
44.25 58,591.53 0.532 0.729 0.638
50.84 67,317.37 0.719 0.848 0.630
56.90 75,341,43 0.902 0.949 0.629
From Pitot Tube

Q actual (l/min) Re H (m) h CP

10.00 13,937.92 0.021 0.144 0.917
13.07 18,216.86 0.035 0.187 0.926
15.86 22,105.54 0.053 0.230 0.913
21.35 29,757.46 0.089 0.298 0.949
CP: D1 = 19.0mm 26.26 36,600.98 0.133 0.365 0.955
31.75 44,252.90 0.198 0.445 0.946
37.06 51,653.93 0.266 0.516 0.953
44.25 61,675.30 0.382 0.618 0.949
50.84 70,860.39 0.500 0.707 0.953
56.90 79,306.39 0.629 0.793 0.951
61.82 86,164.22 0.747 0.864 0.948
12.12

From Venturi Meter

Q actual (l/min) Re H (m) h CV

10.00 15,577.68 0.029 0.170 0.917
13.07 20,360.02 0.051 0.225 0.907
15.86 24,706.19 0.074 0.272 0.910
CV: D1 = 29.0mm 21.35 33,258.34 0.117 0.342 0.975
D2 = 17.0 mm 26.26 40,906.98 0.175 0.418 0.981
31.75 49,459.12 0.264 0.514 0.965
37.06 57,730.87 0.355 0.596 0.972
44.25 68,931.22 0.495 0.704 0.982
50.84 73,196.90 0.665 0.815 0.974
56.90 88,636.98 0.812 0.901 0.986

From ISA Nozzle

Q actual (l/min) Re H (m) h CN

10.00 12,340.19 0.012 0.110 0.790
13.07 16,128.63 0.022 0.148 0.763
15.86 19,571.54 0.040 0.200 0.686
CP: D1 = 29.0mm 21.35 26,346.31 0.051 0.226 0.818
D2 = 21.5 mm 26.26 32,405.34 0.079 0.281 0.808
31.75 39,180.11 0.106 0.326 0.844
37.06 45,732.75 0.140 0.374 0.857
44.25 54,605.34 0.184 0.429 0.892
50.84 62,737.53 0.276 0.525 0.837
56.90 70,215.68 0.298 0.546 0.902
61.82 76,287.06 0.362 0.602 0.889

22
 FM 250 Flow Measurement Test Bench

6. Sample calculations
Typical Data
Flow rate of volumetric tank
Volume = 28 l
Time = 63.97 s
28 l
Flow rate  = 0.4377 l/s
63.97 s
Water level of manometer
Left 658mm, Right 133mm, difference = 525 mm.
Level of manometer from Orifice meter
Left 496mm, Right 316mm, difference = 180 mm.
Level of manometer from Venturi meter
Left 395mm, Right 220 mm, difference = 175 mm.
Level of manometer from Pitot tube
Left 144mm, Right 11mm, difference = 133 mm.
Level of manometer Nozzle
Left 400mm, Right 321mm, difference = 79 mm.

Calculations of the coefficient of discharge for the orifice meter.

Q acual = 0.4377 l/s
h = 180mm = 0.18 m
D1 = 29 mm = 0.029 m
D2 = 20 mm = 0.020 m
12.12

From equation (10), QO  1.583  10 3 CO h

l m3
0.4377  1.583  10 3 CO 0.18
s s
0.4377 l
From which, CO  3
= 0.652
1.583  10  0.424264 10 3 l

Calculations of the coefficient of discharge for the Venturi meter.

Qactual = 0.4377 l/s
h = 0.175 m
D1 = 29 mm = 0.029 m
D2 = 17 mm = 0.017 m
From equation (18), QV  1.067  10 3 CV h
l m3
0.4377  1.067  10 3 CV 0.175
s s
0.4377 l
From which, CV  3
 0.981
1.067  10  0.41833 10 3 l

23
 FM 250 Flow Measurement Test Bench

Calculations of the coefficient of discharge for Pitot tube.

Qactual = 0.4377 l/s
h = 0.133 m
D1 = 19 mm = 0.019 m
From equation (22), QP  1.256  10 3 C P h

l m3
0.4377  1.256  10 3 C P 0.133
s s
0.4377 l
From which, CP  3
 0.956
1.256  10  0.36469 10 3 l

Calculations of the coefficient of discharge for the Nozzle

Qactual = 0.4377 l/s
h = 0.079 m
D1 = 29 mm = 0.029 m
D2 = 21.5 mm = 0.0215 m
From equation (24), QN  1.9267  10 3 C N h

l m3
12.12

0.4377  1.9267  10 3 C N 0.079

s s
0.4377 l
From which, CN  3
 0.808
1.9267  10  0.28107 10 3 l

24
 FM 250 Flow Measurement Test Bench

Typical Graphs
Coefficients of discharge at various rate of flow for different devices may be plotted in
Graphs as below:

Coefficient of Discharge VS Flow Rate

1
Coefficient of Discharge

0.9

0.8

0.7

0.6

0.5

0.4
0 10 20 30 40 50 60 70
Flow Rate ( lpm)
12.12

25
 FM 250 Flow Measurement Test Bench

APPENDIX 1
12.12

WATER MANOMETER

26
 FM 250 Flow Measurement Test Bench

Appendix 1: Water Manometer

Description :
Water Manometer employs clear acrylic
tubes with a top common chamber. This
chamber has an air relief valve and can
Pressurising valve be pressurised by a hand air pump or may
for hand air pump be reduced by opening a vent valve.
Air bleeding valve Pressure ports are at the bottom.
Range : 0-450 or 950 mm
Graduation : 1 mm
Top chamber
Application : comparison of water
pressures
This manometer uses 2 clear acrylic tubes.
For multiple readings, the number of tubes
may be 4, 6, 8, 10 or more, which are
available as options.
Instruction for use
1. Close ball valve at the top chamber.
2. Connect pressure lines from the
pressure source to the inlet pressure
ports of the manometer. Water levels
will show on the manometer scale.
12.12

3. If the levels are too low, release

pressure from the top chamber by
using the ball valve or increase static
pressure of the system to be measured
by closing the system outlet valve. If
the levels are too high, open the outlet
valve of the system slightly more or
increase the top chamber pressure by
Pressure inlet valve the hand air pump (provided) via air
Pressure line pressuring valve.
4. If the differential pressure exceeds the
range of the water manometer, close
the water manometer inlet valves and
use the mercury manometer only.

NOTE
More than one pair of tubes may be used simultaneously if the average pressure from one
pair is not much different from the other pairs. In this case, downstream average pressure is
always lower than upstream average pressure. Thus, if any one pair of water levels is out of
the manometer range, that pair cannot be used, simply close the inlet valves of that pair or
close the pressure tapping port at the pressure source.

27
 FM 250 Flow Measurement Test Bench

APPENDIX 2
12.12

MERCURY MANOMETER

28
 FM 250 Flow Measurement Test Bench

MERCURY MANOMETER.

Description:

U-Tubes Mercury Manometer This manometer employs clear acrylic tubes

with top reservoirs for mercury overspill and vent
valves. Pressure ports are at the top.
Vent valve

Pressure inlet valve Range : 950 mm

Graduation : 1 mm
Application: Hight differential pressure of
water or air
The manometer uses 2 clear acrylic tubes
connected as a U-tube. The top part of each tube has a
chamber which acts as the mercury reservoir incase of a
pressure surge. Connected to the chamber is pressure
inlet port with a valve and a vent valves. These valves
are used to bleed out air in the system.
Instruction for use.
1. Differential pressure for air.
1.1 Make sure there is nothing above both mercury
tubes. If there is any water in any tube, only
the manometer tubes and refill with mercury
abort half full.
1.2 Close both vent valves.
1.3 Connect the pressures from the pressure
sources to the manometer inlet valves using
flexible hoses.
1.4 The differential pressure is the difference in
12.12

height of the two manometer columns. The

equivalent height of water column for the
differential pressure is calculated as follows:
Water column height = 13.6  mercury column height
difference.
2. Differential pressure of water
2.1 Connect the pressure inlet valves to the
differential pressure source to be measured.
2.2 Slightly open one of the valve at the pressure
source and at the water manometer. Water will
flow into the connected tube of the manometer
and push the mercury to a higher level in the
other tube.
2.3 Slowly open the vent valve of the second tube
to allow air bubbles in the system (if any) out.
Continue 2.2 until all air bubbles in this tube
are removed, then close the vent valve.
2.4 Repeat 2.2 and 2.3 for the other tube of the
manometer. Now only water remain on top of
the mercury in the manometer. The manometer
is ready to record differential pressure.
Equivalent height of water column for the
differential pressure is calculated as follows
Water column height = (13.6-1) mercury column height
difference.

29
 FM 250 Flow Measurement Test Bench

APPENDIX 3
12.12

WATER PUMP MAINTENANCE

30
 FM 250 Flow Measurement Test Bench

Appendix 3: Water Pump Maintenance

When using a pump, the following should be observed and corrected:
Water Supply
Water used in fluid mechanics experiments should always be clear and clean water. Rust inhibitor
fluid such as used in automobile radiator may be added to minimize rusting.
Water Becomes Rusty
1. If the pump is made of cast iron, the pump casing will get rusted on the initial use with water.
This is normal.
2. After a few weeks of use, the rust is fully developed and prevents the casing from further
rusting.
3. The circulating water should then be drained and replaced with new clean water.
Pump Use
1. Do not run a pump when there is no water since this can damage the pump seal.
2. If the pump is not in used for long period of time, drain all water inside the pump by opening
the drain plug at the bottom of the pump casing.

Top plug
12.12

Drain plug

Figure 1 Plugs at the pump

3. Before running the pump, check that the check valve is not stuck and fill the pump up fully
with water.
4. The motor and the pump are aligned at the factory. If they are separated, care must be taken
when reconnecting. Otherwise, the shaft vibration will cause serious damage to the bearings
and the seals.

Pump Seized
 Leaving water in the pump without use for along period of time may cause pump shaft seizing.
 Turn on the main power supply switch and turn on the pump.
 If there is no flow make sure the flow control valve at the rotameter is open.

31
 FM 250 Flow Measurement Test Bench

Multi Speed Pump

If pump does not turn, the shaft may be seized. Turn off the pump and open the plug at the top of
the pump and turn the shaft with a screw driver. Once turn, close the plug (see figures below).

Figure 2 Opening plug with screw driver Figure 3 Plug opened

12.12

Figure 4 Turn pump shaft with screw driver

If the pump turns but no water flow (make sure the flow control valve before the flow meter is
open), there is a chance that air bubble is trapped in the pump.
In the case of Heat Exchanger unit:
 Connect the drain valve next to the pump discharge to outside water supply, open the drain
valve and close the flow control valve before the rotameter. The water supply will purge out air
bubbles.
 Close the drain valve and remove the outside water connection.
 Turn on the pump again to ensure water is circulating.
In the case of Series and Parallel Pump, multi speed:
 Connect the pump discharge hose to the Hydraulics Bench discharge.
 Remove the check valve on the pump suction hose.
 Open all valves and turn on the Hydraulics Bench pump to purge out air bubbles from the multi
speed pump.
 After 1-2 minute, turn off the Hydraulics Bench pump and immediately put back the check
valve on the suction hose.
 Remove the discharge hose from the Hydraulics Bench and turn on the multi speed pump to
ensure normal flow.

32
 FM 250 Flow Measurement Test Bench

Drain valve

Figure 5 Show the drain valve

Leaving water in the pump without use for a long period of time may cause pump shaft seizing.

Pump without Coupling

Small pump is without coupling. If the pump does not turn when it is turned on, the shaft may be
seized. Turn off the pump and use a wrench to turn the extended hex head bolt at the back of the
motor to loosen the shaft as per below.

Water pump
12.12

Hex head bolt

Figure 6 Show the hex head bolt

Drain plug at the bottom of the pump or a plug at the top of the pump, and use a screw driver to
turn the impeller (hence the shaft).

Medium Pump
For medium size pump, e.g. 2.5kW, 3.75kW is normally without coupling. The hex head bolts as
the above may not be provided, the pump shaft may be turned by removing a drain plug at the
bottom of the pump or a plug at the top of the pump, and use a screw driver to turn the impeller
(hence the shaft).

Pump with Coupling

Large pump normally uses coupling for connection to motor. If the pump does not turn, the shaft
may be seized. Turn off the pump and remove the pump coupling cover. Pump shaft will be then
exposed. Use a pipe wrench to turn the pump shaft loose.

33
 FM 250 Flow Measurement Test Bench

Figure 7 Pump coupling cover and pump shaft

Gear Pump
The gear pump is designed to be used with oil. If it is used with water, it will get rusted and will
seize.
12.12

Reciprocating Pump
Check oil in the oil crank with the dipstick to make sure that there is enough oil.

Water Pump Motor

1. In case of motor is equipped with a gearbox, chick oil level regularly and refill with
specified lubricating oil as required.
2. In case of an AC motor, adjustment of speed must be followed in accordance with the
inverter’s manual.

34