Types of Flow Meters for Different Applications

Author: May

Jul. 15, 2024

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Types of Flow Meters for Different Applications

What is a Flow Meter?

A flow meter (or a flow sensor) is an flow instrument that is used to indicate the amount of liquid, gas, or vapor moving through a pipe or conduit by measuring linear, non-linear, mass, or volumetric flow rates. Since flow control is often essential, measuring the flow of liquids and gasses is a critical need for many industrial applications &#; and there are many different types of flow meters that can be utilized depending on the nature of the application.

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When choosing a flow meter to buy, one should consider such intangible factors as familiarity of plant personnel, their experience with c and maintenance, spare parts availability, and meant time between failure history, etc., at the particular plant site. It is also recommended that the cost of the installation be computed only after taking these steps. One of the most common flow measurement mistakes is the reversal of this sequence: instead of selecting a sensor which will perform properly, an attempt is made to justify the use of a device because it is less expensive. Those &#;inexpensive&#; purchases can be the costliest installations.

Flow Meter Types and Uses

Differential Pressure Flow Meters

The use of differential pressure as an inferred measurement of a liquid&#;s rate of flow is well known. Differential pressure flow meters are, by far, the most common units in use today. These meters, which boast high accuracy, calculate fluid flow by reading pressure loss across a pipe restriction. Estimates are that over 50 percent of all liquid flow measurement applications use this type of unit.

The basic operating principle of differential pressure flow meters is based on the premise that the pressure drop across the meter is proportional to the square of the flow rate. The flow rate is obtained by measuring the pressure differential and extracting the square root.

Differential pressure flow meters, like most flow meters, have a primary and secondary element. The primary element causes a change in kinetic energy, which creates the differential pressure in the pipe. The unit must be properly matched to the pipe size, flow conditions, and the liquid&#;s properties. And, the measurement accuracy of the element must be good over a reasonable range. The secondary element measures the differential pressure and provides the signal or read-out that is converted to the actual flow value.

Orifice Flow Meters

Orifice flow meters are the most popular liquid flow meters in use today. An orifice is simply a flat piece of metal with a specific-sized hole bored in it. Most orifices in use are of the concentric type, but eccentric, conical (quadrant), and segmental designs are also available.

In practice, the orifice plat is installed in the pipe between two flanges. Acting as the primary device, the orifice constricts the flow of liquid to produce a differential pressure across the plate. Pressure taps on either side of the plate are used to detect the difference. Major advantages of orifices are that they have no moving parts, and their cost does not increase significantly with pipe size.

Conical and quadrant orifices are relatively new. The units were developed primarily to measure liquids with low Reynolds numbers. Essentially constant flow coefficients can be maintained at R values below . Conical orifice plates have an upstream bevel, the depth and angle of which must be calculated and machined for each application.

The segmental wedge is a variation of the segmental orifice. It is a restriction orifice primarily designed to measure the flow of liquids containing solids. The unit has the ability to measure flows at low Reynolds numbers and still maintain the desired square-root relationship. Its design is simple, and there is only one critical dimension the wedge gap. Pressure drop through the unit is only about half that of conventional orifices.

Integral wedge assemblies combine the wedge element and pressure taps into a one-piece pipe coupling bolted to a conventional pressure transmitter. No special piping or fittings are needed to install the device in a pipeline.

Metering accuracy of all orifice flowmeters depends on the installation conditions, the orifice area ratio, and the physical properties of the liquid being measured.

Venturi Flow Meters

Venturi tubes have the advantage of being able to handle large flow volumes at low pressure drops. A venturi tube is essentially a section of pipe with a tapered entrance and a straight throat. As liquid passes through the throat, its velocity increases, causing a pressure differential between the inlet and outlet regions.

The flowmeters have no moving parts. They can be installed in large diameter pipes using flanged, welded or threaded-end fittings. Four or more pressure taps are usually installed with the unit to average the measured pressure. Venturi tubes can be used with most liquids, including those having a high solids content.

Pitot Tube Flow Meter

Pitot tubes are generally installed by welding a coupling on a pipe and inserting the probe through the coupling. Use of most pitot tubes is limited to single point measurements. The units are susceptible to plugging by foreign material in the liquid. Advantages of pitot tubes are low cost, absence of moving parts, easy installation, and minimum pressure drop.

Positive Displacement Flow Meters

Operation of these units consists of separating liquids into accurately measured increments and moving them on. Each segment is counted by a connecting register. Because every increment represents a discrete volume, positive-displacement units are popular for automatic batching and accounting applications. Positive-displacement meters are good candidates for measuring the flows of viscous liquids or for use where a simple mechanical meter system is needed.

Reciprocating piston meters are of the single and multiple-piston types. The specific choice depends on the range of flow rates required in the particular application. Piston meters can be used to handle a wide variety of liquids. A magnetically driven, oscillating piston meter is shown in Fig. 1. Liquid never comes in contact with gears or other parts that might clog or corrode.


Figure 1: Oscillating-piston meter operates on magnetic drive principle so that liquid will not come in contact with parts. A partition plate between inlet and outlet ports forces incoming liquid to flow around a cylindrical measuring chamber and through the outlet port. The motion of the oscillating piston in the unit is transferred to a magnetic assembly in the measuring chamber, which is coupled to a follower magnet on the other side of the chamber wall.


Oval-gear meters have two rotating, oval-shaped gears with synchronized, close fitting teeth. A fixed quantity of liquid passes through the meter for each revolution. Shaft rotation can be monitored to obtain specific flow rates.

Nutating-disk meters have a moveable disk mounted on a concentric sphere located in a spherical side-walled chamber. The pressure of the liquid passing through the measuring chamber causes the disk to rock in a circulating path without rotating about its own axis. It is the only moving part in the measuring chamber.

A pin extending perpendicularly from the disk is connected to a mechanical counter that monitors the disk's rocking motions. Each cycle is proportional to a specific quantity of flow. As is true with all positive-displacement meters, viscosity variations below a given threshold will affect measuring accuracies. Many sizes and capacities are available. The units can be made from a wide selection of construction materials.

Rotary-vane meters are available in several designs, but they all operate on the same principle. The basic unit consists of an equally divided, rotating impeller (containing two or more compartments) mounted inside the meter's housing. The impeller is in continuous contact with the casing. A fixed volume of liquid is swept to the meter's outlet from each compartment as the impeller rotates. The revolutions of the impeller are counted and registered in volumetric units.

Helix flow meters consist of two radically pitched helical rotors geared together, with a small clearance between the rotors and the casing. The two rotors displace liquid axially from one end of the chamber to the other.

Volumetric Flow Meters

These instruments operate linearly with respect to the volume flow rate. Because there is no square-root relationship (as with differential pressure devices), their rangeability is greater. Volumetric meters have minimum sensitivity to viscosity changes when used at Reynolds numbers above 10,000. Most velocity-type meter housings are equipped with flanges or fittings to permit them to be connected directly into pipelines.

Turbine Flow Meters

Turbine meters have found widespread use for accurate liquid measurement applications. The unit consists of a multiple-bladed rotor mounted with a pipe, perpendicular to the liquid flow. The rotor spins as the liquid passes through the blades. The rotational speed is a direct function of flow rate and can be sensed by magnetic pick-up, photoelectric cell, or gears. Electrical pulses can be counted and totalized, Fig. 2.


Figure 2: Turbine flow meter consists of a multiple-bladed, free-spinning, permeable metal rotor housed in a non-magnetic stainless-steel body. In operation, the rotating blades generate a frequency signal proportional to the liquid flow rate, which is sensed by the magnetic pickup and transferred to a read-out indicator.


The number of electrical pulses counted for a given period of time is directly proportional to flow volume. A tachometer can be added to measure the turbine's rotational speed and to determine the liquid flow rate. Turbine meters, when properly specified and installed, have good accuracy, particularly with low-viscosity liquids.

A major concern with turbine meters is bearing wear. A "bearingless" design has been developed to avoid this problem. Liquid entering the meter travels through the spiraling vanes of a stator that imparts rotation to the liquid stream. The stream acts on a sphere, causing it to orbit in the space between the first stator and a similarly spiraled second stator. The orbiting movement of the sphere is detected electronically. The frequency of the resulting pulse output is proportional to flow rate.

Vortex Flow Meters

Vortex meters make use of a natural phenomenon that occurs when a liquid flows around a bluff object. Eddies or vortices are shed alternately downstream of the object. The frequency of the vortex shedding is directly proportional to the velocity of the liquid flowing through the meter, Fig. 3.


Figure 3: Vortex meters operate on the principle that when a non-streamlined object is placed in the middle of a flow stream, a series of vortices are shed alternately downstream of the object. The frequency of the vortex shedding is directly proportional to the velocity of the liquid flowing in the pipeline.


The three major components of the flowmeter are a bluff body strut-mounted across the flowmeter bore, a sensor to detect the presence of the vortex and to generate an electrical impulse, and a signal amplification and conditioning transmitter whose output is proportional to the flow rate, Fig. 4. The meter is equally suitable for flow rate or flow totalization measurements. Use for slurries or high viscosity liquids is not recommended.


Figure 4


Magmeter

Electromagnetic meters can handle most liquids and slurries, providing that the material being metered is electrically conductive. The flow tube mounts directly in the pipe. Pressure drop across the meter is the same as it is through an equivalent length of pipe because there are no moving parts or obstructions to the flow. The voltmeter can be attached directly to the flow tube or can be mounted remotely and connected to it by a shielded cable.

Electromagnetic flow meters operate on Faraday's law of electromagnetic induction that states that a voltage will be induced when a conductor moves through a magnetic field. The liquid serves as the conductor; the magnetic field is created by energized coils outside the flow tube, Fig. 5. The amount of voltage produced is directly proportional to the flow rate. Two electrodes mounted in the pipe wall detect the voltage, which is measured by the secondary element.


Figure 5: Major components of obstruction-free electromagnetic flow meter&#;s flow tube include electrodes and coils.


Electromagnetic flow meters have major advantages: They can measure difficult and corrosive liquids and slurries; and they can measure forward as well as reverse flow with equal accuracy. Disadvantages of earlier designs were high power consumption, and the need to obtain a full pipe and no flow to initially set the meter to zero. Recent improvements have eliminated these problems. Pulse-type excitation techniques have reduced power consumption, because excitation occurs only half the time in the unit. Zero settings are no longer required.

Ultrasonic Flow Meters

Ultrasonic flow meters can be divided into Doppler meters and Time-of-Travel (or Transit) meters. Doppler meters measure the frequency shifts caused by liquid flow. Two transducers are mounted in a case attached to one side of the pipe. A signal of known frequency is sent into the liquid to be measured. Solids, bubbles, or any discontinuity in the liquid, cause the pulse to be reflected to the receiver element, Fig. 6. Because the liquid causing the reflection is moving, the frequency of the returned pulse is shifted. The frequency shift is proportional to the liquid's velocity.


Figure 6


A portable Doppler meter capable of being operated on AC power or from a rechargeable power pack has recently been developed. The sensing heads are simply clamped to the outside of the pipe, and the instrument is ready to be used. Total weight, including the case, is 22 lb. A set of 4 to 20 millampere output terminals permits the unit to be connected to a strip chart recorder or other remote device.

Time-of-travel meters have transducers mounted on each side of the pipe. The configuration is such that the sound waves traveling between the devices are at a 45 deg. angle to the direction of liquid flow. The speed of the signal traveling between the transducers increases or decreases with the direction of transmission and the velocity of the liquid being measured. A time-differential relationship proportional to the flow can be obtained by transmitting the signal alternately in both directions. A limitation of time-of-travel meters is that the liquids being measured must be relatively free of entrained gas or solids to minimize signal scattering and absorption.

Mass Flow Meters

The continuing need for more accurate flow measurements in mass-related processes (chemical reactions, heat transfer, etc.) has resulted in the development of mass flowmeters. Various designs are available, but the one most commonly used for liquid flow applications is the Coriolis mass flow meter. Its operation is based on the natural phenomenon called the Coriolis force, hence the name.

Coriolis flow meters are true mass meters that measure the mass rate of flow directly as opposed to volumetric flow. Because mass does not change, the meter is linear without having to be adjusted for variations in liquid properties. It also eliminates the need to compensate for changing temperature and pressure conditions. The meter is especially useful for measuring liquids whose viscosity varies with velocity at given temperatures and pressures. Coriolis flow meters are true mass meters that measure the mass rate of flow directly as opposed to volumetric flow. Because mass does not change, the meter is linear without having to be adjusted for variations in liquid properties. It also eliminates the need to compensate for changing temperature and pressure conditions. The meter is especially useful for measuring liquids whose viscosity varies with velocity at given temperatures and pressures.

Coriolis meters are also available in various designs. A popular unit consists of a U-shaped flow tube enclosed in a sensor housing connected to an electronics unit. The sensing unit can be installed directly into any process. The electronics unit can be located up to 500 feet from the sensor.

Inside the sensor housing, the U-shaped flow tube is vibrated at its natural frequency by a magnetic device located at the bend of the tube. The vibration is similar to that of a tuning fork, covering less than 0.1 in. and completing a full cycle about 80 times/sec. As the liquid flows through the tube, it is forced to take on the vertical movement of the tube, Fig. 7. When the tube is moving upward during half of its cycle, the liquid flowing into the meter resists being forced up by pushing down on the tube.


Figure 7


Having been forced upward, the liquid flowing out of the meter resists having its vertical motion decreased by pushing up on the tube. This action causes the tube to twist. When the tube is moving downward during the second half of its vibration cycle, it twists in the opposite direction.

Having been forced upward, the liquid flowing out of the meter resists having its vertical motion decreased by pushing up on the tube. This action causes the tube to twist. When the tube is moving downward during the second half of its vibration cycle, it twists in the opposite direction. The ammount of twist is directly proportional to the mass flow rate of the liquid flowing through the tube. Magnetic sensors located on each side of the flow tube measure the tube velocities, which change as the tube twists. The sensors feed this information to the electronics unit, where it is processed and converted to a voltage proportional to mass flow rate. The meter has a wide range of applications from adhesives and coatings to liquid nitrogen.

Thermal-type mass flowmeters have traditionally been used for gas measurements, but designs for liquid flow measurements are available. These mass meters also operate independent of density, pressure, and viscosity. Thermal meters use a heated sensing element isolated from the fluid flow path. The flow stream conducts heat from the sensing element. The conducted heat is directly proportional to the mass flow rate. The sensor never comes into direct contact with the liquid. The electronics package includes the flow analyzer, temperature compensator, and a signal conditioner that provides a linear output directly proportional to mass flow.

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Flow Meter Types & Their Functions

Welcome to the Blue-White guide to flow meters and their functions. Flow meters are devices used to measure the flow of fluids, such as fuel, water, and other liquids. They are essential for many industries and applications, including industrial process control, medical diagnostics, and energy management. This guide will provide an overview of the different types of flow meters available from Blue-White and information on how to use and maintain them properly.

Flow Meter

A flow meter is a device used to measure the flow rate or quantity of a gas or liquid moving through a pipe. Flow meters measure the volumetric or mass flow rate of a liquid or gas. They are used to measure how much of a substance passes through a pipe over a period of time. Flow meters can measure flow in many applications, including water, oil, fuel, air, and steam.

They have applications in many industries, including water treatment, heating and air conditioning, industrial manufacturing, process control, and waste management.

For Starters, What is Flow?

Flow is a term used to describe the movement of materials or energy from one place to another in a continuous and organized manner. This can refer to the flow of fluids such as water, gas, and oil. Flow is an important concept in engineering and manufacturing in understanding how systems and processes work.

In this case, we will refer to flow as it applies to fluids in pipes. And in this application, flow is typically divided into two types: Open channel flow and closed conduit flow.

Open Channel Flow

Open channels are streams with an exposed surface and unrestricted access to the atmosphere. For example, canals and pipelines that are not completely full, such as drains and sewers.

In open channel flow, gravity is responsible for the motion of the liquid. The water level will gradually decrease down the stream as the flow progresses.

Closed Conduit Flow

Closed conduit flow is the flow of a liquid or gas through a pipe, channel, or another closed vessel. Closed conduit flow typically occurs at a constant velocity and depends on factors such as the pressure difference between the ends of the conduit and its length.

F-420 Acrylic Flow Meter

Water supply and district heating pipes are common places to observe closed conduit flow. Even drinking straws are a simple but efficient example of this. The flow rate here is largely determined by the pressure difference between the two ends, the distance between them, and the area of the conduit. Additionally, the hydraulics of the pipeline &#; such as its shape, roughness, and bends &#; also have an impact. All these factors come together to create the rate of flow.

Ranges of Flow Pressure

Flow pressure measures how much force is needed to move a liquid or gas through a system. It is measured in pounds per square inch (PSI) or kilopascals (KPa). The flow pressure range can vary greatly depending on the type of system, the size of the pipes, and the type of liquid or gas being pumped. For example, a residential water system typically operates at a much lower flow pressure than an industrial system. Flow pressure can also be increased or decreased by changing the size of the pipes, the number of fittings, and the type of pump.

Ranges of Temperature

Any flow will also have a temperature, with the typical range in most industries where they are used being from -40°F to +400°F (-40°C to +204°C). And to measure this, flow meters are designed to measure the flow rate in fluids with a wide range of viscosities, temperatures, and pressures. Flow meters can also detect changes in flow rates and can be used to detect leaks or other irregularities in the system.

Another term is thermal flow measurement, which reads how much heat is transferred while a gas passes a surface. The two main measurements taken with regard to temperature are simple readings via a temperature sensor and a heated flow sensor that measures the heat transfer from the flow of any given material inside the system.

F-460 Polysulfone Flow Meter

What Does a Flow Meter Do?

As mentioned above, a flow meter is an instrument used to measure the flow rate of liquid or gas. It measures the flow rate by detecting and monitoring changes in pressure, level, or another variable caused by fluid passage through pipes.

Types of Flow Meters and Their Functions

Flow meters measure fluids, but fluids can be any liquid, viscous, or gas known to us. Hence, a wide range of flow meters is available on the market. All of these types vary in function and application.

Differential Pressure Flow Meters

Differential pressure flow meters employ the Bernoulli Equation, which states that a fluid&#;s pressure decreases while its speed increases. These types of flow meters report the difference between the two measurements. The first measurement causes a shift in kinetic energy when the air is forced through a hole in the flow meter, which is then measured by the second element.

The sub-types of differential pressure flow meters are rotameters / variable area flow meters, orifice plates, venturi flow meters, and pitot tube flow meters. These meters measure the pressure difference between two points, allowing for a precise calculation of the fluid flow rate.

Rotameters / Variable Area

A variable area flow meter is a differential pressure flow meter. Variable area flow meters are simple, versatile, and cost-effective devices that operate at a relatively constant pressure drop and measure liquids, gases, and steam flow. The variable area flow meter is popular for industrial and commercial flow indication because it has a linear scale, a relatively long measurement range, and a low-pressure drop &#; plus, they are simple to install and maintain.

Orifice Flow Meter

The orifice plate flow meter is a differential pressure flow meter used in clean liquid, gas, and stream mass flow measurements. It is available for a wide range of pipe sizes and allows for measuring fluid flows in larger pipes (over 6&#; in diameter).

Venturi Flow Meter

Venturi flow meters allow the fluid to flow through a constricted section of pipe called a throat, where a pressure difference is created. The liquid speeds up and creates a pressure differential as it passes through, which is then used to calculate the volumetric flow rate of the fluid. Venturi meters are often used in applications requiring high precision levels with large volumes of liquid at low-pressure drops. They&#;re also suitable for liquids with a high solids content. Additionally, they are relatively easy to install because they have no moving parts. They can be fitted via flanged, welded, or threaded-end fittings, making them a popular choice for many applications.

Pitot Tube Flow Meter

Pitot tube flow meters are a common and cost-effective tool for measuring fluid flow rate in a pipe or duct. The pitot tube is inserted into the pipe to measure the difference in pressure between the upstream and downstream of the flowing fluid.

The installation process for a pitot tube is relatively straightforward, as it typically involves drilling a hole into a pipe and inserting the pitot tube into the fluid path with its impact port facing directly into the fluid flow.

Pitot tube flow meters remain attractive for many applications due to their low cost and easy installation process. They&#;re frequently used in HVAC and commercial aquatics systems, for example. Moreover, they offer minimal pressure drop, meaning they do not significantly impede the flow rate of the fluid.

F-300 Pitot Tube Acrylic Flow Meter

Positive Displacement Flow Meter

A Positive Displacement Flow Meter is a device that measures the flow rate of a fluid by measuring the amount of fluid that is displaced by a series of chambers or rotors. This type of flow meter is highly accurate, durable, and efficient and is commonly used in industries such as oil and gas, food and beverage, and chemical processing.

PD or Positive Displacement flowmeters utilize a rotating mechanism within a precision-engineered chamber to capture fluid pockets, like filling a beaker with liquid and pouring it down an aisle, counting each fill.

  • Reciprocating Piston Meter:

A reciprocating piston meter is a positive displacement flow meter that measures the volumetric flow rate of liquids and gases. It consists of a chamber with a piston, an inlet and an outlet valve, and a pressure transducer. The piston is driven by an external power source, such as an electric motor, magnetic field, or pneumatic cylinder, and moves back and forth in the chamber. As the piston moves, it displaces a fixed volume of liquid or gas, and the flow rate is calculated based on the speed of the piston and the volume displaced. The inlet and outlet valves open and close to control the flow rate, and the pressure transducer measures the pressure inside the chamber.

  • Oval-Gear Meter:

An oval-gear meter is a positive displacement flow meter that measures fluid or gas flow through two oval-shaped gears with close-fitting teeth. The gears are connected to each other and are placed in a chamber that has a known volume. As the fluid or gas passes through the chamber, the gears rotate, and the volume of the chamber is displaced. The displacement of the volume is measured, and the flow rate of the fluid or gas is calculated.

  • Nutating-Disk Meter:

A nutating-disk flow meter works by passing fluid through a disk that is mounted on a shaft, which is connected to a motor. The disk is free to rotate around the shaft as the fluid passes through, causing the disk to rotate, or nutate, at a rate proportional to the flow rate. The rate of rotation and nutation is then measured and converted into a flow rate.

  • Rotary-Vane Meter:

A rotary-vane flow meter uses a rotary vane, a type of impeller, to create a pressure differential across the meter, which is then used to calculate the flow rate. The inner part of the rotary vane meter consists of several vanes, each connected to a central shaft. As the fluid passes through the meter, the vanes rotate, causing a series of gears to turn. The gears are connected to a mechanical counter that records the total flow rate. The rotary vane meter is highly accurate and reliable, often used in the automotive industry to measure fuel and oil flow rates. The rotary vane meter is also used in medical applications, such as anesthetic delivery systems. The design of the rotary vane meter allows it to be used in a wide range of temperatures and pressure ranges.

SONIC-PRO® S6A Digital Ultrasonic Flow Meter

Volumetric Flow Meter

Volumetric flow meters measure the speed of the flow rather than the actual volumetric rate directly. The volumetric flow rate is calculated by multiplying the measured velocity by the cross-sectional area at which it&#;s installed, accurately representing how much material passes through in a given time period. Flow meter technology has become more advanced, with digital displays becoming more commonplace with improved accuracy due to better calibration technology and new sensing methods.

Ultrasonic Flow Meter

Ultrasonic flow meters measure flow rate by detecting fluctuations in ultrasonic oscillations. They come in two varieties: time difference and Doppler. Time difference type meters, also called time-of-travel meters or transit meters, measure the time taken for ultrasonic waves to travel from one point to another, while Doppler-type meters measure the frequency shift of soundwaves reflected from the moving particles in the medium. Both are used for accurate flow rate measurement.

Mass Flow Meter

Mass flow meters measure the mass of a material that passes through the system in a given period of time. They measure the mass per unit of time, typically expressed in kilograms per second (kg/s). Mass flow meters measure the speed and density of the material as it passes through the device. This data is then used to calculate the mass flow rate. Mass flow meters are typically used to measure the flow of liquids, gases, and solids in industrial processes, such as the chemical, food, and pharmaceutical industries. Coriolis flow meters are the most popular mass flow meters used in industries today.

Blue-White Flow Meters For Any System

Flow meters are an incredibly important and versatile tool for measuring the flow of liquids, gases, and solids in a variety of industries. There is an ideal meter for any application, from ultrasonic flow meters to variable area flow meters.

Blue-White has you covered when it comes to fluid control processes. We manufacture industrial-grade flow meters that are accurate and robust, so you can depend on them to keep your processes running smoothly, safely, and cost-effectively. From rotameters / variable area flow meters to paddlewheel flow meters to ultrasonic flow meters, all our products are Made in the USA and ready to ship! Get peace of mind by knowing your flow meters are reliable and of the highest quality. Trust Blue-White for all your flow meter needs.

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