CEA - M&I (Lab)

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Date: 12/06/2020

MEASUREMENT & INSTRUMENTATION (LAB)

COMPLEX ENGINEERING ANALYSIS (CEA)

MEASUREMENT OF YAP WATER FLOW


THROUGH ORIFICE TAPPING
TECHNIQUE

Group - II Members: Reg.#:


 Muhammad Tahman Farooqi. UW-18-ME-BSc-046
 Shahzeb Sajjad. UW-18-ME-BSc-047
 Muhammad Hamza. UW-18-ME-BSc-048
 Saad Bin Shoukat. UW-18-ME-BSc-049
Section: Submitted to:
 ME-4th-'B'. Mr. Shahid Iqbal
Submission Date :
 01-07-2020

DEPARTMENT OF MECHANICAL ENGINEERING


WAH ENGINEERING COLLEGE ( WEC)

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Submitted By: Shahzeb Sajjad Submitted to: Mam Shahid Iqbal


Reg. # : UW-18ME-BSc-047 Submission Date: 01/07/2020

MEASUREMENT & INSTRUMENTATION (LAB)


COMPLEX ENGINEERING ANALYSIS (CEA)
MEASUREMENT OF TAP WATER FLOW

Abstract/Lab Background:
 Volumetric flow for different fluids depends upon the flow rate,density and pressure concentrations along obstructed areas to achieve desired flow rate that vary
according to the nature of fluid.
 An orifice plate is a device used for measuring the volumetric flow rate. It uses the same principle as a Venturi nozzle, namely Bernoulli's principle which states that
there is a relationship between the pressure of the fluid and the velocity of the fluid.
 In this lab, suitable obstruction type volumetric flow meter is being used to measure the flow rate of incompressible test fluid along with major components
mounted on pipeline/fluid transmission line whose mode of operation is based in Pressure Differentiation.
Objective:
 To measure the water flow rate of conventional tap by employing differential pressure technique/method using suitable (obstruction type) flow meter.
 Construct the physical model of flowmeter and explain it's brief operation mechanism via procedure being performed.

Hardware (Volumetric Flow Measurement)


 Standard sized Water storage/supply tank connected with tap valve via pipe line
 Standard SCS 1/2in Lever Ball Tap (valve)
 Multihole Centric Orifice (plate) meter - Selected model for measuring flow rate.
 Orifice flange taps
 Differential Diaphragm pressure guage
 Clamp On Transit time ultrasonic flowmeter (not mandatory to be installed)
 Portable Mini Accelerometer (to change fluid's flow velocity - not necessary for installation)
 Standard test fluid with negligible compressibility factor (water - uniform density)

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Non corrosive tap water supply pipe (Stainless steel developed internal cross section)
 Digital Display/Computerized Software
Theory:
Differential Diaphragm Pressure Guage - Working Principle:
 Diaphragm is an elastic material whose mode of operation is based on Pressure Differentiation as enclosed displaces when initial pressure is applied.
It uses elastic deformation of diaphragm (I.e.membrane) instead of liquid level to measure the difference b/w the unknown pressure and a reference pressure via pointer's
deflection.
Diaphragm's translation <× Change in Gauge Pressure

Centric Orifice (Plate) Meter:


 It acts as a metal disc with a concentric hole inserted into the pipe carrying the flowing fluid.
 This flow device is created by inserting an obstructing plate, usually with a round hole in the middle, into the pipe and measuring the pressure on each side of the
orifice.
 Working Principle - Differential Pressure Measurement/Orifice Tapping (Circular Flow):
 Orifice tapping generallyacts as a Restriction Plate employed to increase/accelerate volumetric flow rate in open channels/pipes by creating obstruction against the
fluid flow.
 It involves an orifice plate (externally connected with differential diaphram pressure guage) mounted at pipe cross section that decreases area causing
temporary contraction for fluid passing through it so that volumetric flow rate accelerates linearly with gradual incress in flow velocity & decrease in
pressure simultaneously at oriface/obstruction
Specifications
 Maximum operating temperature up to 800 °C
 Maximum operating pressure up to 400 bar
 Suitable for liquid, gas and steam flow measurement
 Accuracy ≤ ±0.5 % of actual flow rate
 Repeatability of measurement of 0.1 %
Design Specifications:
 Multihole Orifice Plate
 Single plate type Multihole Centric Orifice Meter. Monohole - Single Plate type Double Plate Type

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Limitations:
 Measurement inaccuracy ranges from +/-2--5%.
 Permanent pressure loss caused in the measure between 50% and 90% of the magnitude of the pressure difference P1 - P2 via flow variation

(a) & (b) Pattern of pressure variation either side of orifice plate. (c) Pressure (flow) profile. (d) Shape based Classification

Incompressible Bernoulli equation - Precise Derivation:


 It states that the pressure of the fluid is inversely proportionate to the magnitude of velocity of the fluid.
 When the velocity increases, the pressure decreases

Mach Number < 0.3 ---> Subsonic Flow


 Flows in pipe will have a certainly amount of turbulence which acts to convert kinetic flow energy into heat.

 Flows in pipe will have a certainly amount of turbulence which acts to convert kinetic flow energy into heat. This effect is taken into account by adding a new team to
the equation called a discharge coefficient (Cd ) to measure flow rate Q.

 Since the actual flow profile at location 2 (downstream) is quite complex, making the effective value of A2 uncertain, a substitution is made and a new coefficient Cf
is put in place of the area and Cd.

-----> (A)

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 There is a slight fall in pressure in the approach section and the static pressure is at a minimum about one pipe diameter before the orifice plate. The pressure of the
fluid then rises near the face of the orifice. There is then a sudden fall of pressure as the fluid passes through the orifice, but the minimum pressure is not attained until
the venacontracta is reached.

Common Location of Differential Pressure Taps:


 Flange taps
 Venacontracta taps
 Radius taps
 Full flow or pipe taps and
 Corner taps.
Precise Summary:
 Flange Taps cannot be used for pipe size of less than 35 mm diameter. Since the vena contracts may be closer than 25 mm from the orifice plate.
 Flange taps are the most popular tap location for orifice meter runs on large pipes.
 Gradual change in the discharge coefficient occurs over a time period as the sharp edges of the hole wear away, and a tendency for any particles in the flowing fluid to
stick behind the hole and thereby gradually reduce its diameter as the particles build up.
 Venacontracta Taps offer the greatest differential pressure for any given flow rate, but require precise calculations to properly locate the downstream tap position. A
that converges to go through the small hole; the point of maximum convergence actually occurs shortly downstream of the physical orifice, at the so-called vena
contracta point.
 Radius Taps d1 = D and d2 = 1/2 D. These are similar to vena contracts taps except that downstream tap is located at one half-pipe diameter. These are generally
considered superior to the vena contracts tap because they simplify the pressure tap location dimensions and do not vary with changes in orifice β ratio

.
(a) Flange Taps (b) Venacontracta Taps. (c) Radius Taps

 Corner taps must be used on small pipe diameters where the vena contracts is so close to the downstream face of the orifice plate that a downstream flange tap
would sense pressure in the highly turbulent region (too far downstream).
 These are used for diameters of less than 50 mm.
 Pipe taps are located 2.5 pipe diameters upstream (d1 = 2.5D) and 8 diameters downstream (d2 = 8D) from the orifice plate. Because of the distance from the
orifice, the exact location is not critical, but the effects of pipe roughness, dimensional inconsistencies and so on are more severe.
 Care should be taken to avoid measuring downstream pressure in the highly turbulent region following the vena contracts. This is why the pipe tap (also known as
full-flow tap) standard calls for a downstream tap location eight pipe diameters away from the orifice: to give the flow stream room to stabilize for more consistent
pressure readings

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Corner taps Pipe Taps


Piezoelectric Accelerometer - Working Principle:
A piezoelectric accelerometer utilizes the piezoelectric effect of certain materials to measure dynamic changes in mechanical variables, such as mechanical shock, vibration
and acceleration. Like other transducers, piezoelectric accelerometers convert one form of energy into another and provide an electrical signal in response to the condition,
property or quantity. Acceleration acts upon a seismic mass that is restrained by a spring or suspended on a cantilever beam, and converts a physical force into an electrical
signal.

Ball/Gate Tap Valve:


The Ball valve uses a hollow, perforated and pivoting ball to control flow through it.
Operating Principle:
The ball valve drives the valve handle to rotate by a transmission, which in turn drives the ball to rotate about an axis perpendicular to the flow. It is open when the ball’s hole
is in line with the flow and closed when it is pivoted 90-degrees by the valve handle.
Classification

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Ball Tap Valve

Gate Valve

Experimental Procedure:
 Take a standard sized water tank or water supply line/pipe line and connect it with ball (flange) tap valve
 Mount the tap pipe with orifice plate connected with differential diaphragm gauge (point pressure measurement) in order to create permanent obstruction against
incoming fluid's flow rate.
 Connect two clamp on transit time ultrasonic flowmeters vertically on either sides of pipe so that both can acts as transmitter as well as receiver for ultrasonic
frequency responces during fluid flow (use if mandatory)
 Mount a miniature piezoelectric accelerometer with small nozzle at tank's outlet and open the valve tap.
 Open tap valve onotially so that water enters diaphragm gauge through inlet & outlet causing diaphragm to expand such that;
P initial (P1= P inlet) >> P orifice (P2= P outlet}
 Note that volume flow rate /velocity of incoming water gradually increases initially via accelerometer as tap valve gradually opens to allow incoming water from
tank.
 Similarly, note the velocity of water particles as those pass through orifice plate.
 Open tap valve at different proportion so that flow rate is accelerate via accelerometer w.r.t the quantity of incoming water.

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 Take at least three readings of flow velocity via digital display/software of water flowing through pipe before and during/when it passes through orifice plate (before
water flow achieves Venacontracta Point - Pmin --> 0) such that;
Flow Velocity ×> 1/Change in Pressure
 Measure the flow rate via transit time ultrasonic flow meter & observe that transit time at upstream (along fluid flow) is lesser relative to that at downstream
(ultrasonic frequency transmission against fluid flow)
 Repeat the same process to achieve further primary/accurate reading of water's volumetric flow rate.
 Calculate the pressures with known values of velocities and substitute to above Ew. (A)
 Note the difference b/w measured & calculated primary values (via drawn table) of volumetric flowrate.
 Analyze the whole practical scenario/procedure and form precise deductions.

Observation & Calculations:


Assumptions:
 Discharge coefficient = Cd = 0.65 (Valid for 0.4 ≤ Cd ≤ 0.8)
 Standard density of water = p =998.3 kg/m^3
 Tap Inlet/pipe dia (D) = 80 mm = 0.080m
 Orifice Dia. (d) = 125mm = 0.125m

 Ao = A1= Orifice area (m^2)


 A1 = 3.14(0.0625)^2 = 12.27 × 10^-3 m^2
 Ap = A2 = Pipe area
 A2 = 3.14(0.040)^2 = 5.03 × 10^-3 m^2
 Cf = Cd × 1/√[1-(A2/A1)^2] = (0.65)× 1/[(1- (5.03/12.27)^2] = 887.74 × 10^-3= 0.887 = 0.89.

Initial Pressure Final Pressure Initial flow velocity Obstructed flow Change Calculated Measured ℅ Relative Error
(Before (After (Assumed via velocity in Volumetric Volumetric [Abs.
Obstruction) Obstruction) accelerometer) (Assumed- after Pressure Flowrate Flowrate Error/Measured
P1 P2 V1 obstruction) (w r.t. Eq.(A)) (Q measured) Value)
(KPa) (KPa) (m/s) V2 (m/s) (Q calculated or (Assumed)
Qv)

178.2 = 178 134.57 = 135 735mm/s = 847 mm/s = 43 3.205 = 3.2 3.35 15%
0.735 m/s 0.847 m/s
284.89 = 285 222.88 = 223 945mm/s = 1087mm/s = 62 3.749 = 3.75 3.83 8℅
0.945 m/s 1/087 m/s

689.14 = 689 616.36 = 616 1135mm/s = 2175mm/s = 73 3.953 = 3.95 3.98 3%


1.135 m/s 2.175 m/s

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724.75= 743 704.63 = 705 1187.08mm/s = 2198.23mm/s = 38 2.178 = 2.18 2.373 = 2.37 19℅
1.187m/s 2.198m/s
773.37 = 773 747.89 =748 2133.54 = 2134 2206.67 = 2207 25 2.634 = 2.63 2.859 = 2.77 14%
Sum = 15.71 Sum = 16.30 Total % error = 59%
 True Measured Reading = 3.35
 Estimated Primary Reading = 3.32
Mean/Average Reading = Total Flow rate/No. of primary readings
 Avg. Reading = 16.3/5 = 3.28
Accuracy Analysis: (Volumetric Flow rate)
Accurate Measurement = Estimated Measylured Reading - Estimated Primary Calculated reading
= 3.35 - 3.32 =0.03
Precision Analysis: (Volumetric Flow rate)
Precise Measurement = Estimated Measured Reading - Average Reading
= 3.35 - 3.28 = 0.07
Overall Analysis:
 Orifice plate has partially flexible surface that is good enough to achieve larger flow rates corresponding to the pipe diameter ratio.
 However for highly accelerated fluids, the obstruction against fluid flow causes vortices shedding (circular fluid flow) after passing through orifice plate that leads to
deflections and vibration the pipeline ultimately causing permanent malfunction of the flow meter inside pipe's cross section.

Advantages (PROs) Drawbacks (CONs) Industrial Applications
 Orifice plates flexible body anables flange to  Prone to corrosion , erosion unlike steel plates .  Orifice plates act as flow regulators in
achieve larger volumetric flow as per requirement.  Prone to damage in case of large deflections via vortex long distant sewarage water pipelines.
 Low cost with precise calibration shedding.  Waste water treatment plants
 Orifice (plate) meter can be installed easily  Larger flow rate causes pressure loss.  Petrochemical & natural gas production
between flanges for open channel pipe flows.  Large power loss can occurs to achieve higher flow velocity. facilities.
 Suitable for incompressible fluids  Ultrasonic flowmeter are unable to receive ultrasonic waves  Aviation - To measure the speed of the
 Orifice plate's simple construction is preferable for case if pipe's internal surface is non reflecting. air around the plane.
less denser fluids & gases however it often  Requires homogenous & single faced fluid with axial  Automotive - To measure the fuel and air
requires diaphragm guage's mounting. velocity (vector) flow. distribution in carburettor
 Suitable for slurries in order to achieve desired  Higher Fluid velocity limits measuring range.  Medical - To measure the Volume flow
reflection from transmission ultrasonic waves.  Demands straight pipeline assembly to maintain accuracy of blood through vessels.
good enough to be unaffected by fluid's medium density  Chamical - To measure the Flow rate of
velocity chemical through pipes

Conclusion:
 Analyzing the procedure regarding whole volumetric flow measuring mechanism, it can be stated that flow velocity of homogenous, incompressible
test fluid depends upon variation/flow concentration in pressure and pipe's internal area (inlet + obstruction/orifice) area both as a requirement for
speedy/highly accelerated fluid.
 However, regarding transitional/turbulent flows, more response time is taken by transit time ultrasonic flowmeters (operating as alternatives) to
receive ultrasonic waves (generally down stream penetration) faced resistance against the fluid flow such that;

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Flow Velocity ×> 1/Pressure Variation ×> Respoce Timing ×> 1/Pipe cross sectional area
 For compressible fluids, density & kinematic viscosity play an integral role as volumetric flow rate decreases for viscous & denser fluids.
Volumetric Flow rate ×> 1/density (p) ×> 1/Kinematic Viscosity ×> 1/Vortex Shedding
 On the whole, orifice meters are suitable for larger pipes with straight supply line/internal cross section.

<<<---- THE END! ----->>>

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