Lecture 6

Flow Measurements in Process Fluid Flow

Dr IG Mkhize
8/05/2023
 ▪ Be able to identify and describe different devices used for measuring fluid flow,
including manometers,Venturi meters, orifice plates, and Rotameters.

▪ Be able to explain the principles behind how these devices work, including how
they measure pressure differences, create constrictions in the flow path, or
measure the position of a float.

▪ Be able to compare the different devices, including their advantages and

Learning disadvantages, and the types of fluids and flow conditions for which they are best
suited.

Outcomes ▪ Be able to calculate fluid flow rates using various equations, including Bernoulli's
equation, and apply these equations to solve problems involving fluid flow
measurement.

▪ Be able to design and select appropriate flow measurement devices for specific
applications based on considerations such as flow rate, fluid type and viscosity,
accuracy requirements, and cost.

▪ Be able to analyse and interpret flow measurement data, including identifying and
troubleshooting errors or inconsistencies in the data.

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 Introduction
▪ Importance of fluid flow measurement in chemical
engineering
▪ Overview of different flow measurement devices.
Rotameter
▪ Definition and purpose of Rotameter

Lecture ▪ Design and construction of Rotameter

▪ Calculation of flow rate based on float position in
Rotameter
Layout ▪ Advantages and limitations of Rotameter.
Orifice Plate
▪ Definition and purpose of an orifice plate
▪ Design and construction of orifice plate
▪ Calculation of flow rate based on pressure drop across
an orifice plate
▪ Advantages and limitations of an orifice plate

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 Venturi Meter
▪ Definition and purpose of Venturi meter
▪ Design and construction of Venturi meter
▪ Calculation of flow rate based on the pressure difference
across the Venturi meter
▪ Advantages and limitations of Venturi meter.

Lecture Manometer
▪ Definition and purpose of a manometer

Layout ▪ Types of manometers, including U-tube and inclined-tube

manometers
▪ How manometers are used to measure pressure
differences in fluid flow systems
▪ Advantages and limitations of manometers

Comparison of flow measurement devices

Comparison of operating principles, accuracy, range, cost, and
suitability for different types of fluids and applications

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 Flow measurement is a critical part of process control and
optimization. It enables operators to monitor the performance
of the process and make necessary adjustments to maintain
quality and productivity.
Laminar flow: In laminar flow, the fluid flows in smooth, parallel
layers with little or no mixing between them. This type of flow is
characterized by a low Reynolds number.
Types of Flow
Turbulent flow: In turbulent flow, the fluid flows in irregular
patterns with mixing and eddies. This type of flow is
characterized by a high Reynolds number.

Transitional flow: In transitional flow, the flow characteristics

are between laminar and turbulent. This type of flow is
characterized by a Reynolds number that is in between the
values for laminar and turbulent flow.

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 Flow Measurement Techniques: Rotameter
▪ A Rotameter, also known as a variable area flow meter,
is a device used for measuring the flow rate of a fluid
in a process flow system by measuring the height of a
float as it moves up and down in a tapered tube.
▪ It consists of a vertically oriented tapered tube with a
float inside that moves up and down as the fluid flows
through the tube.

▪ The float is typically made of a material that is denser

than the fluid being measured, such as a metal or
plastic ball, and is sized so that it can move freely up
and down the tube.
▪ As the fluid flows through the tapered tube, it causes
the float to rise.
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 Flow Measurement Techniques: Rotameter
▪ The position of the float is used to indicate the
flow rate of the fluid, with higher flow rates causing
the float to rise higher in the tube.
▪ As the fluid flows through the tapered tube, it
causes the float to rise.

▪ The position of the float is used to indicate the

flow rate of the fluid, with higher flow rates causing
the float to rise higher in the tube.
▪ The Rotameter is calibrated to display the flow
rate in units of volume per unit time, such as liters
per minute or gallons per hour.

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 Simplicity: Rotameters have a relatively simple design,
consisting of a tapered tube and a float, making them easy
to install and maintain.

Low-pressure drop: Rotameters cause a minimal pressure

drop in the fluid being measured, making them ideal for

Advantages of
applications where the pressure loss is a concern.

Rotameter Wide range: Rotameters can measure fluid flow rates over
a wide range, from low to high flow rates, with high
accuracy and reliability.

Visual indication: Rotameters provide a visual indication of

the flow rate, allowing for quick and easy monitoring of the
process.
 Limitations of Rotameter
▪ Fluid type: Rotameters may not be suitable for measuring fluids with
high viscosity or those containing solid particles, as these can cause
the float to stick or interfere with its movement.
▪ Accuracy: Rotameters have a lower accuracy compared to other
flow measurements devices, such as orifice plates or magnetic flow
meters.
▪ Flow profile: Rotameters require a steady and uniform flow profile
for accurate measurements, which may not be possible in certain
process conditions.
▪ Pressure and temperature limitations: Rotameters have
limitations in terms of the maximum pressure and temperature that
they can withstand, making them unsuitable for certain high-pressure
or high-temperature applications.

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 Flow Measurement Techniques: Orifice plate
▪ An orifice plate is a device that measures the flow
rate of a fluid by creating a constriction in the flow
path.
▪ It consists of a flat, circular plate with a hole, known as
the orifice, in the centre.
▪ When fluid flows through the orifice, its velocity
increases, and its pressure decreases, as described by
Bernoulli's equation.
▪ The size of the orifice plate, the diameter of the
orifice, and the location of the pressure taps are all
important factors that can affect the accuracy of the
flow measurement.

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Advantages of an Orifice Plate

▪ Simplicity: Orifice plates are simple and easy to install and

maintain, with no moving parts.
▪ Accuracy: Orifice plates have a high level of accuracy,
especially for large pipe sizes and high flow rates.
▪ Low cost: Orifice plates are relatively inexpensive compared
to other flow measurement devices, such as magnetic flow
meters.
▪ Wide range: Orifice plates can measure a wide range of fluid
flow rates and can be used for both liquids and gases.

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 Limitations of an Orifice Plate
▪ Pressure drop: Orifice plates can cause a significant pressure drop
in the fluid being measured, which can affect the overall process
efficiency and require additional pumping power.
▪ Flow profile: Orifice plates require a stable and uniform flow
profile to achieve accurate measurements, which may not be
achievable in certain process conditions.
▪ Installation requirements: Orifice plates require specific
installation requirements, such as straight upstream and
downstream pipe lengths and proper orientation and alignment, to
ensure accurate measurement.
▪ Sensitivity to fluid properties: Orifice plates are sensitive to
changes in fluid density, viscosity, and temperature, which can affect
the accuracy of the measurement.

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 Flow Measurement Techniques:Venturi meter
▪ A venturi meter is a device that measures the flow rate
of a fluid by creating a constriction in the flow path.
▪ As fluid flows through the converging section, its
velocity increases and its pressure decreases.
▪ At the throat, the fluid velocity reaches a maximum,
and the pressure reaches a minimum.
▪ As the fluid flows through the diverging section, its
velocity decreases and its pressure increases.
▪ By measuring the pressure difference between the
converging section and the throat or between the
throat and the diverging section, the flow rate of the
fluid can be calculated using Bernoulli's equation.

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Advantages of Venturi meters
▪ High accuracy: Venturi meters have a high level of accuracy in measuring fluid flow
rates, with errors typically less than 1%.
▪ Wide range: Venturi meters can measure fluid flow rates over a wide range, from low
to high flow rates, making them suitable for a variety of applications.
▪ Low-pressure drop: Venturi meters have a low-pressure drop compared to other
differential pressure meters, reducing energy losses and making them suitable for use in
low-pressure systems.
▪ Low maintenance: Venturi meters are relatively simple in design, making them easy to
install and maintain.

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Limitations of Venturi meters
▪ High cost: Venturi meters are more expensive than other types of flow meters, such as
orifice plates or flow nozzles, due to their complex design and precision manufacturing
process.
▪ Space requirements: Venturi meters require a relatively long straight pipe section
upstream and downstream of the meter to maintain the flow profile, making them
unsuitable for use in confined spaces or where space is limited.
▪ Limited fluid types: Venturi meters are typically only suitable for use with clean fluids,
as fluids containing solids or particles can cause blockages and affect the accuracy of the
measurement.
▪ Limited turndown ratio: Venturi meters have a limited turndown ratio, which is the
range of flow rates that can be accurately measured. This can make them unsuitable for
applications where flow rates may vary widely.

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 Flow Measurement Techniques: Manometer
▪ A manometer is a device that measures fluid
pressure. It typically consists of a U-shaped
tube partially filled with a liquid, such as
water or mercury, and the pressure
difference between two points in the fluid
system causes the liquid level to rise or fall
in one arm of the tube.
▪ Manometers are often used to measure
pressure drops across an orifice plate, a pitot
tube, or a Venturi meter.

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Advantages of Manometers
▪ Simple and inexpensive: Manometers are a simple and inexpensive flow measurement
device consisting of a U-shaped tube filled with a liquid, making them easy to install and
use.
▪ High sensitivity: Manometers have a high sensitivity to changes in pressure, making
them ideal for measuring low-pressure differences.
▪ No moving parts: Manometers have no moving parts, which means they are less prone
to wear and tear and require less maintenance than other flow measurement devices.
▪ Suitable for both gases and liquids: Manometers can be used to measure the
pressure and flow rate of both gases and liquids.

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Limitations of Manometers
▪ Limited range: Manometers are typically limited in their ability to measure pressure
and flow rate over a narrow range, which may not be suitable for some applications.
▪ Requires constant maintenance: Manometers require regular maintenance to ensure
that the readings are accurate and to prevent any leaks or spills.
▪ Limited accuracy: Manometers have limited accuracy compared to other flow
measurements devices, such as orifice plates or flow meters, and may not be suitable for
applications that require high accuracy.
▪ Not suitable for high-pressure applications: Manometers may not be suitable for
high-pressure applications, as they are limited by the pressure that the liquid in the U-
tube can withstand.

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The Pitot Tube
▪ A Pitot tube is a device used in the process of fluid flow to
measure the velocity of a fluid. It consists of a small tube, called
a Pitot tube, that is inserted into the fluid flow stream, with an
open end facing the direction of the flow.
▪ When the fluid flows past the open end of the tube, it
generates a pressure difference between the open end and the
other end of the tube, which is typically left open to the
surrounding fluid.
▪ This pressure difference, known as dynamic pressure, is
proportional to the velocity of the fluid.

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The Pitot Tube
▪ If the dynamic pressure can be measured by stopping the fluid,
the upstream velocity can be calculated.
▪ Shows a device known as a Pitot tube, which may be used to
determine the velocity of a fluid at a point.
▪ The tube is aligned, pointing into the flow; consequently, the
fluid approaching it is brought to rest at the nose of the Pitot
tube.
▪ By placing a pressure tapping at the nose of the Pitot tube, the
pressure at the stagnation point can be measured.
▪ If the pressure in the undisturbed fluid upstream of the Pitot
tube and that at the stagnation point at the nose are denoted
by P1 and P2, respectively, then they are related by equation (1)

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 The Pitot-Static Tube
▪ It will be seen from this example why the total
pressure is also called the stagnation pressure.
▪ The so-called static pressure of the flowing fluid can be
measured by placing a pressure tapping either in the
wall of the pipe.
▪ As shown or in the wall of the Pitot tube just
downstream of the nose; in the latter case, the device
is known as a Pitot-static tube.
▪ The Pitot-Static Tube is a device used in the process of
fluid flow to measure the velocity and pressure of a
fluid

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 The Pitot-Static Tube
▪ It consists of two tubes - a Pitot tube and a static tube - that
are merged together into a single instrument.
▪ The Pitot tube measures the dynamic pressure of the fluid,
which is the pressure generated by the fluid's velocity.
▪ The static tube, on the other hand, measures the static
pressure of the fluid, which is the pressure that remains
constant in the absence of motion.
▪ By combining the readings from the Pitot tube and the static
tube, the Pitot-Static Tube can be used to calculate both the
velocity and pressure of the fluid.
▪ Thus, the pressure difference P2 - P1 can be measured and
the fluid's velocity v1 calculated from equation 1

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Factors Affecting Flow Measurement

▪ Fluid properties (e.g., density, viscosity, and temperature)

▪ Flow profile (e.g., laminar, turbulent, or transitional)
▪ Instrumentation limitations (e.g., accuracy, resolution, and
range)
▪ Installation effects (e.g., piping configuration, orientation, and
upstream/downstream disturbances)
▪ Operational conditions (e.g., pressure, temperature, and
flow rate)

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Comparison of Flow Measurement Devices
• Operating principles: Different flow measurement devices work based on different physical
principles, such as Bernoulli's equation, magnetic induction, thermal flow, ultrasonic flow, and others.
• Understanding the underlying operating principle can help in selecting the most appropriate device for
a given application.
• Accuracy: The accuracy of flow measurement devices can vary depending on the device type, design,
size, and application.
• Some devices are highly accurate but require careful installation and calibration, while others may have
lower accuracy but are easier to install and use.
• Range: Flow measurement devices have different flow rate ranges that they can accurately measure,
which can be affected by factors such as the device size, operating principle, and fluid viscosity.
• Selecting a device with an appropriate range is important to ensure accurate measurements.

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Comparison of Flow Measurement Devices
▪ Cost: Flow measurement devices can vary widely in cost, depending on the device type,
design, materials, and features.
▪ Considerations of cost may be important in selecting a device that is suitable for a given
application and budget.
▪ Suitability for different types of fluids and applications: Different flow
measurement devices may be more suitable for measuring different types of fluids, such
as liquids, gases, slurries, or multiphase flows.
▪ Different devices may be better suited for different applications, such as process control,
custody transfer, environmental monitoring, or research and development.

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 Textbook
Title: "Process Dynamics and Control"
Author: Dale E. Seborg, Thomas F. Edgar, Duncan A. Mellichamp, and
Francis J. Doyle III
Publisher: John Wiley & Sons, Inc.
Edition: 3rd Edition
Year: 2010
ISBN: 978-0-471-72359-0

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