Low-Cost Arduino Orifice Plate
Flowmeter Design
This document details the design, required materials, construction guide, and usage instructions
for a DIY differential pressure flowmeter using an Orifice Plate and an Arduino. The design is
based on the provided sketch and components list, focusing on adaptability for both liquid and
gas flow experiments.
Inferred Grade Level: University (Fluid Mechanics / Instrumentation Lab)
1. Refined Materials List and Component
Specifications
Component Quantity Specification / Purpose
Recommendation
PVC Pipe ~2m (or as needed) Schedule 40 PVC Main fluid conduit and
(1-inch diameter is test section.
ideal). Needs straight
sections for
upstream/downstream
flow.
Reservoir 1 Any plastic bin or Holds the liquid
container (5-10 liters). medium (e.g., water).
Submersible Pump 1 Low-to-medium head Provides the liquid flow
DC pump (e.g., 12V in the closed loop.
DC pump). Ensure it
can push water through
the desired height/loop.
Ball Valve 1 1-inch PVC Ball Valve. Manual control of the
flow rate (Q).
Orifice Plate 1 Custom-made from Creates the
thin plastic measurable pressure
(PVC/acrylic) or sheet drop (\Delta P).
metal. Drill a central
hole (D_o) where D_o
is 0.5D_{pipe} to
0.7D_{pipe}. Needs to
be secured between
pipe flanges.
Differential Pressure 1 MPX5100DP Measures the pressure
(DP) Sensor (Measures up to drop (\Delta P) across
100\text{ kPa}). the orifice. (Crucial for
Alternative: Two Arduino integration).
BMP180/BMP280
Component Quantity Specification / Purpose
Recommendation
sensors.
Arduino 1 Arduino Uno or Nano. Data acquisition and
sensor reading.
Tubing ~3m Clear PVC/Silicone Connects the pipe to
tubing (4\text{ mm} the DP sensor ports.
inner diameter) for
pressure taps.
Hose Clamps ~8-10 Appropriate size for the Secures flexible
PVC Pipe connections. connections to the
pump/reservoir.
Power Supply 1 9V or 12V adapter for Powering the system.
Arduino and pump.
Support Frame 1 Wood, aluminum Provides structural
extrusions, or PVC stability and leveling.
frame (as shown in the
sketch).
Other Wires, Breadboard, Flanges are Wiring and assembly.
Resistors, Mounting recommended to hold
Brackets/Flanges. the orifice plate
securely.
2. Device Design and Function
A. The Orifice Plate Principle
The device works on the principle of conservation of energy (Bernoulli's Equation) and mass
continuity.
1. The Orifice Plate is installed in the pipe, reducing the cross-sectional area of flow.
2. This reduction increases the fluid velocity at the orifice and creates a pressure difference
(\Delta P) between the points just upstream and downstream of the plate.
3. The flow rate Q is proportional to the square root of the pressure drop, \Delta P.
● Q: Volumetric flow rate
● C_d: Discharge Coefficient (determined by calibration)
● A_o: Area of the orifice hole
● \beta: Diameter ratio (D_{\text{orifice}} / D_{\text{pipe}})
● \rho: Fluid density (known for water/air)
B. Electronic Components Integration
The Arduino is the control and measurement center.
1. DP Sensor: The sensor is connected via small tubes (pressure taps) to the pipe at the
prescribed measurement points (Vena Contracta taps are common). The sensor converts
the physical pressure difference into a small electrical voltage change (analog signal).
2. Arduino: The analog signal from the DP Sensor is connected to an Analog Input Pin on
the Arduino. The Arduino's code reads this voltage, converts it to a pressure value
(\text{Pa} or \text{kPa}), and then calculates the flow rate (Q).
3. Pump Control (Optional): The pump can be connected to a relay and controlled by a
Digital Output Pin, allowing the Arduino to start/stop the flow or manage its speed (if using
a motor driver).
C. Adaptation for Gas Flow
The same differential pressure principle applies to gas.
● For Gas Experiments: You will need to switch the fluid source. Instead of the pump and
reservoir, connect a regulated pressurized air supply (like an air compressor or tank) to
the inlet of the PVC pipe section.
● The system becomes Open Loop (air is released after the valve, not returned to a
reservoir).
● Sensor Selection: Ensure the chosen DP sensor is sensitive enough for the typically
lower pressure drops experienced with gases compared to liquids.
3. Construction Guide (Paano Gagamitin ang mga
Materials)
Step Component(s) Procedure
1. Frame Assembly Frame Support Build the support rack/frame to
ensure the PVC pipe can be
mounted horizontally and
rigidly. Leveling is critical for
liquid flow experiments.
2. Plumbing Setup PVC Pipe, Ball Valve, Pump, Assemble the pipe loop as
Reservoir shown in your sketch. The Ball
Valve should be placed
downstream of the orifice plate
to control the flow after the
measurement point. Connect
the pump outlet to the pipe
inlet.
3. Orifice Plate Insertion Orifice Plate, Place the Orifice Plate rigidly
Flanges/Couplings in the pipe test section. Ensure
the pipe is straight for at least
\mathbf{10} pipe diameters
upstream and \mathbf{5} pipe
diameters downstream of the
plate to ensure fully developed
flow.
4. Pressure Tap Installation PVC Pipe, Tubing Connectors Drill two small holes (pressure
taps) at the recommended
distance (e.g., 1 pipe diameter
upstream, 0.5 pipe diameters
downstream) of the orifice
Step Component(s) Procedure
plate. Glue or seal small
connectors (like barb fittings)
into these holes.
5. Sensor Wiring DP Sensor, Arduino, Connect the DP sensor to the
Breadboard, Wires Arduino Analog Pin (A0),
Ground (GND), and Power
(5V). The two pressure taps
connect to the sensor's input
ports via the clear tubing.
6. Initial Liquid Test Water Fill the reservoir and turn on the
pump. Check for leaks in the
pipe, especially around the
orifice plate and the pressure
taps. Adjust the Ball Valve to
ensure stable flow.
4. Usage, Calibration, and Experimentation
A. Calibration (Critical First Step)
Since your device is custom-made, the Discharge Coefficient (C_d) of your orifice plate is
initially unknown. You must calibrate it first.
1. Setup: Use the liquid system. Place a bucket or container at the Ball Valve exit.
2. Procedure:
○ Set the Ball Valve to a specific opening (e.g., Quarter Turn).
○ Start a timer and simultaneously place the exit tube into the container.
○ Read the average Pressure Drop (\Delta P) from the Arduino LCD/Serial Monitor.
○ Stop the timer when a known volume of liquid (V) has been collected (e.g., 5\text{
Liters}).
○ Calculate the actual flow rate: Q_{\text{actual}} = V / t.
○ Repeat this for 5-10 different valve openings/flow rates.
3. Data Analysis: Plot Q_{\text{actual}} versus \sqrt{\Delta P} and use the known geometry
(pipe/orifice diameter) to solve for C_d. Use this C_d value in your Arduino code for future
measurements.
B. Experimentation Examples
Experiment Type Goal Variables to Change Data to Collect
1. Liquid Flow Study the relationship Ball Valve Position, \Delta P, Calculated Q,
between valve opening Pump Speed (if Fluid Velocity.
and flow rate. adjustable).
2. Head Loss Determine energy Pipe length, number of \Delta P across the
losses across the bends/fittings. orifice, and total
system. pressure loss in the
pipe section.
3. Gas Flow Study the difference in Air flow rate (controlled \Delta P, Calculated Q
Experiment Type Goal Variables to Change Data to Collect
(Adaptation) C_d when using air vs. by a regulator). for air.
water.
5. Arduino Code Logic (Conceptual)
The main program logic will involve continuously reading the sensor, converting the voltage to
pressure, and then converting pressure to flow rate.
