Topic 4 Differential Pressure and Flow Sensors (Bernoulli Principle Venturi Effect)

Topic 4: Differential Pressure and flow sensors (Bernoulli principle)
In fluid dynamics, Bernoulli's principle states that an increase in the speed of a fluid
occurs simultaneously with a decrease in static pressure or a decrease in the fluid's
potential energy.
Gases and liquids prefer to flow in straight lines. Any obstruction, which disturbs the fluid flow
path, creates a differential pressure or “Head” in the fluid.
By measuring the differential pressure generated by fluid flowing through a known

(calibrated) obstruction, the flow rate can be calculated.
There are two important and fundamental characteristics of head-type flow meters:
• The flow rate is proportional to the square root of the
differential pressure.
• The relationship between differential pressure and both the volume flow
rate and the mass flow rate is dependent on the density of the flowing
fluid.
There are a number of different types of obstructions used for disturbing the flow path to
produce the all important measurable quantity – the differential pressure head. The
name given to the flow meter is derived from the type of obstructing device used.
If a restriction is placed in a pipeline and the pressure drop across it is measured this
will give an output proportional to the flow rate.
The position within the pipe to the left of the orifice plate is known as upstream and the
point to the right is known as downstream.
The orifice plate (figure 5) is not only the most popular version of the head type of flow
meter but also the most commonly used of all types of industrial flow meters.
Pressure
Distance along pipe
Figure 51 – Typical Orifice Plate Assembly
An orifice plate, which is simply a plate with a hole (or orifice) machined through it is
inserted into the process line.
Vena Contracta
After passing the orifice plate, the cross sectional area of the flow (CSA) continues to
contract before expanding again.
The point of minimum CSA lies between:
• 0.4 to 0.8 pipe diameters downstream of the orifice plate, as shown in

figure 62
Flow rate Q = Flow factor x √differential pressure ∆P
Vena Contracta
Figure 6 - Flow through an Orifice (showing Vena Contracta)
The Vena Contracta can be defined as the point of lowest pressure at the highest
velocity within the pipeline.
2.3. PRACTICAL IMPLEMENTATION
There are many variations on the basic orifice plate design (see figure 7).
Concentric Orifice Eccentric Orifice Segmental Orifice

Plate Plate Plate
Vent hole
Figure 8
The conventional concentric, sharp edged orifice plate has several major advantages:
• It is relatively easy and economical to manufacture to close tolerances.
• It is simple to install and replace.
• It is well established and supported by a great deal of tried and tested

calibration and usage information.
The basic orifice plate is a circular disc, usually of stainless steel between 1/8" and 1/2"
thick. The plate thickness and hole diameter are determined by the pipe diameter and
expected flow velocity range. Data relating to the orifice plate calibration and
characteristics are engraved on the upstream side of the Data tab, which can be seen
projecting from the side of the plate in figure 9.
Figure 10
Sizing
The hole is sized usually to produce a differential pressure at a known flow rate such as
250mbar at maximum flow. Because the sizing calculations are tedious, computer
methods have been developed, which can predict the pressure flow rate characteristic
accurately and reliably.
2.4. INSTALLATION
The orifice plate is usually installed either between two flanges, with a carrier assembly
or in a retractable housing to allow on-line removal of the plate. The differential
pressure pick-up points (tappings) can be located either in the flanges (flange tappings
or corner tappings) or in the upstream and downstream pipework, usually at distances
of D and D/2 or full flow tappings 2½D and 8D from the plate.
D & D/2 tappings
• Provide greatest pressure difference
Flange and Corner Tappings
• Preferred for convience and space savings
• Although higher Reynolds number valves required – 100, 000 minimum
Figure 11
3.5.1. VENTURI TUBE
To overcome problems or erosion or blockages caused by slurry or solids build-up, or

where net pressure loss across the meter must be minimum, a venturi can be used.
A Venturi is usually formed using a section of the pipe work in line with the process, with
the necessary pressure tapping in place.
The inlet cone tapers down from the pipe diameter to the throat section of smaller area.
With a restriction such as a Venturi placed in a pipeline there is a change in the fluid
velocity.
HP Tapping LP Tapping Transmitter
Inlet Flow Outlet Flow
Throat
Figure 17 – Venturi Tube
• The flow restriction point is known as the throat.
• Inlet pressure is measured at the entrance
• Static pressure in the throat section.
• A DP Transmitter measures the difference in pressure across the

tapping points.
• The greater the flow, the greater the difference in pressure measured by
the transmitter.
• Differential pressure is proportional to flowrate.
• Flow rate Q = Flow factor x √differential pressure ∆P
Venturi tubes are available in sizes up to 72", and can pass 25 to 50% more flow than
an orifice with the same pressure drop.
The initial cost of venturi tubes is high, so they are primarily used on larger flows or on
more difficult or demanding flow applications.
This change in fluid velocity causes a change in differential pressure.
The shape of the Venturi is approximately that of the flow stream through a restriction,
i.e. Vena Contracta.

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Topic 4: Differential Pressure and flow sensors (Bernoulli principle)

By measuring the differential pressure generated by fluid flowing through a known

• The flow rate is proportional to the square root of the

Distance along pipe

Figure 51 – Typical Orifice Plate Assembly

The point of minimum CSA lies between:

• 0.4 to 0.8 pipe diameters downstream of the orifice plate, as shown in

Figure 6 - Flow through an Orifice (showing Vena Contracta)

2.3. PRACTICAL IMPLEMENTATION

Concentric Orifice Eccentric Orifice Segmental Orifice

• It is simple to install and replace.

• It is well established and supported by a great deal of tried and tested

D & D/2 tappings

• Provide greatest pressure difference

Flange and Corner Tappings

• Preferred for convience and space savings

• Although higher Reynolds number valves required – 100, 000 minimum

3.5.1. VENTURI TUBE

To overcome problems or erosion or blockages caused by slurry or solids build-up, or

Inlet Flow Outlet Flow

Figure 17 – Venturi Tube

• The flow restriction point is known as the throat.

• Inlet pressure is measured at the entrance

• Static pressure in the throat section.

• A DP Transmitter measures the difference in pressure across the

• Differential pressure is proportional to flowrate.

• Flow rate Q = Flow factor x √differential pressure ∆P

This change in fluid velocity causes a change in differential pressure.

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