GROUP 2 - FLOW METERS

1. Concepts and Terminologies

In many industrial applications, measuring the flow of liquids is crucial. Accurate flow
measurements are so crucial in some processes that they might be the difference between
making a profit and losing money. In other circumstances, incorrect flow measurements - or a
failure to take measures - might have major or even disastrous consequences.Therefore, the
flow rate is calculated inferentially by monitoring the liquid's velocity or the change in kinetic
energy with most liquid flow measurement equipment.

● Flow meters, also known as flow sensors, are instruments used to measure the
amount of fluid flowing or passing through a pipe or any other type of conduit.

● These can provide accurate and reliable measurements of fluid flow, which is
essential for controlling processes, optimizing efficiency, and ensuring the quality
of the final product.

● Their accuracy is crucial in ensuring that processes are controlled effectively and
that the final product meets the required specifications.

● The accuracy and reliability of the measurement depend on the quality of these
components and their proper installation and maintenance.

● A flow meter is a complex device that consists of several components that work
together to measure the flow rate of a fluid such as:

○ Principal device - the part of the flow meter that comes into contact with
the fluid being measured. It measures the flow rate of the fluid and sends
this information to the flow meter's electronics.
○ Transmitter - task is to receive the signal from the flow sensor and
convert it into an electrical signal that can be transmitted to a display or
another device.
○ Display - shows the flow rate reading in a format that is easy to read
and understand.
○ Signal processor - receives electrical signal from the transmitter and
processes it to provide an accurate measurement of the flow rate.
○ Housing - for protection of the other components from external
elements such as dust, moisture, and temperature changes.
○ Output - is the signal from the flow meter that is sent to other devices,
such as a computer or a control system which can be an analog signal or
a digital signal.
 ○ Calibration adjustment - allows the flow meter to be calibrated to ensure
accurate measurements. This adjustment can be done manually or
automatically.

To understand more about flow meters, some common concepts and terminologies
associated with flow meters include:

1. Flow rate - the amount of fluid that passes through a given point in a system per unit
time.

2. Differential pressure - the difference in pressure between two points in a system, which
can be used to calculate flow rate.

3. Fluid viscosity - the thickness or resistance of a fluid to flow, which can affect the
accuracy of flow measurement.

4. Flow profile - the distribution of fluid velocity across the cross-section of a pipe or
channel, which can affect the accuracy of flow meter measurements.

5. Reynolds number - a dimensionless value that provides information about the flow
regime of a fluid, which can affect the type of flow meter used.

6. Turbulent flow - a type of flow where the fluid exhibits chaotic and irregular behavior,
which can make flow measurement more difficult.

7. Laminar flow - a type of flow where the fluid moves in parallel layers and is predictable,
allowing for more accurate flow measurement.

8. Turndown ratio - the range of flow rates that a flow meter can accurately measure,
expressed as a ratio of the maximum to minimum measurable flow rate.
2. Classifications and Examples

Flow meters observe the flow of fluid substances passing through a media. Relatively,
they are classified differently according to their purpose and function. Accordingly, they are
divided into two distinct categories:
A. Volumetric Flow Meters
- Flow meters that measure fluid volume passing through, particularly describing
the volumetric flow rate inside the media they are passing through. Relatively,
there are different volumetric flow meters available commercially.
a. Differential Pressure Flow Meters
i. Flow meters that provide readings on pressure change across a selected
pipe restriction; is distinctive on three different types:
1. Orifice Plate Flow Meter
- Flow meter utilized on measuring pressure differential on
clean liquids, gases, and stream mass flow.

2. Venturi Flow Meter

- Flow meter utilized in measuring pressure difference at two
distinct points in the same pipe. The pressure difference
measured by this type of flow meter is caused by the
change in pipe diameter
3. Variable Area Flow Meters
- They are the simplest differential flow meters that
effectively operate under constant pressure change to
provide flow rate.

4. Pitot Tubes
- A type of flow meter used as an alternative for an orifice
plate, is commonly utilized in measuring air flow speed on
pipes, ducks, and/or stacks as well as liquid flow
measurement on pipes, weirs, and open channels.
5. Rotameter
- A device under variable area flow meters, rotameters are
operated by utilizing the fluid’s pressure to make a material
float, determining the pressure by how high the floating
material is from its base point.

6. Flow Nozzle Flow Meters

- Functions nearly similar with the orifice, flow nozzles act
more stable than it especially in high temperature and
velocity instances which is commonly used in measuring
high flow rates of superheated steam.
b. Electromagnetic Flow Meter
- A type of flow meter that operates using Faraday’s Law of Induction using
an electromagnetic coil to produce a field and electrodes that capture
electromotive forces that are converted into electricity. A good
representation is when an indicator light shines brighter as electricity
supply increases due to the pressure that is converted into energy.

c. Ultrasonic Flow Meters

- Are intrusive volumetric flow meters designed to utilize acoustic vibrations
to measure fluid flow, allowing a non contact measurement procedure of
volumetric flow rate of fluids in a media.
d. Turbine Flow Meters
- use flow to measure the speed of the turbine through the use of the
passing liquid’s mechanical energy to rotate a rotor, and are used with
clean and viscous liquids with an accuracy of 0.5% of the reading. They
have a multi-blade rotor mounted at right angles to the flow. Outputs are a
sine wave or square wave frequency. Signal conditioners can be mounted
on them but are only found on explosion proof classifications.

e. Vortex Flow Meters

- measure flow rate by placing an obstruction directly in the flow path
forcing liquids or gasses to move around it. The flow around the
obstruction produces two symmetrical vortices on the opposite side,
 which changes the pressure of the flow. A flow sensor, between the
vortices, measures pressure changes.

f. Positive Displacement Meters

- that provides high accuracy and good repeatability. These meters do not
require a power supply for their operation and do not require straight
upstream and downstream pipe runs for their installation. They are ideal
for flow measurement of viscous fluids, such as oils, fuels, and solvents
that are difficult for other types of flow meters to measure. They are
divided into two distinct types:
- Nutating Disk Meters
- that provides high accuracy (±0.1% of actual flow rate in
some cases) and good repeatability (as high as 0.05% of
reading). These meters do not require a power supply for
their operation and do not require straight upstream and
downstream pipe runs for their installation. They are ideal
for flow measurement of viscous fluids, such as oils, fuels,
and solvents that are difficult for other types of flow meters
to measure.
 - Osciillating Piston Flow Meters
- typically are used in viscous fluid services such as oil
metering on engine test stands where turndown is not
critical. These meters also can be used on residential
water service and can pass limited quantities of dirt, such
as pipe scale and fine sand, but not large particle size or
abrasive solids.

B. Mass Flow Meters

A mass flow meter measures the volumetric flow rate by dividing the mass flow rate by
the density of the fluid. It uses Coriolis Effect, which is an inertial force that acts on objects in
motion within a reference point.

● Thermal Mass Flow Meter uses two sensors to take temperature measurements with an
active heat sensor to measure heat loss in the liquid and a flow meter to determine the
flow rate.
 ● Mass Gas Flow Meter, or Coriolis flow meters, work on the basis of the Coriolis Effect,
motion mechanics. When the fluid enters the sensor, it is split and the tubes of the
sensor oscillate creating a sine wave. The time delay between the oscillation of the two
tubes produces a mass flow rate. They are used for leak testing and low flow
measurements.

C. Open Channel Flow Meters

Open Channel Flow Meters check the height of the liquid and are used with flows that
are exposed to the open air.

● Spring and Piston Flow Meters measure the annular flow through an orifice that is
formed by a tapered cone and piston. Scales are based on gravities of fluids, where oil is
0.84, and water is 1.0. They have a simple design and are an alternative to rotameters
since they can be easily installed to transmit electrical signals.
● Flow Switches are not flow meters but simple mechanical instruments for monitoring the
flow of air and fluids. They are set to a predesignated level and activate when there is a
fluctuation in the level. Once activated, they remain on until the error in the system is
corrected.

● Digital Flow Meters are defined as any flow measurement device with a digital display. A
common digital meter is used by power companies to measure the flow of electricity to
your home and sends your usage data to the electrical company, which uses the data to
bill you.
Additional Flow Meter Types
● Water Flow Meters measure the volume of slurries, water, or other closed pipe fluids.
The flow rate is measured in cubic meters or liters.

● Fuel Flow Meters measure the amount of fluid being transferred. They have a digital or
mechanical visual display that lets the user know how much fuel has been transferred
during a transaction.
● Peak Flow Meters are used for breathing disorders and measure the lungs capacity.
They are handheld and an inexpensive device that measures lung capacity by blowing
into the mouthpiece, which measures, in liters, the amount of air taken in each minute.

● Flow Indicators allow an operator to view a liquid as it moves through a pipe. They are
often called sight flow indicators and are a part of an industrial process that requires an
instant and inside look at the flow inside a pipe. Flow indicators do not take calculations
or measurements regarding mass or speed. Also known as plain sight indicators, they
are the simplest form of flow meter and have no moving parts.