Flow Measurement with
Orifice Meters
Presented by :
Andi Suhanda
Agenda
Fundamentals of Orifice Measurement
Review of Mechanical Products
Product Application
Conclusion
Background
General concept of orifice metering has been around for
centuries.
Orifice measurement is one of the most widely used forms of
measurement today.
In 1797 Giovanni Venturi performed the first work using
orifices in fluid flow measurement.
Background
This type of device causes a flow restriction in the
line
1890 Professor Robinson of Ohio State University
designed the first orifice meter
Between 1924 and 1935 research & experimental
work was conducted by the American Gas
Association (AGA) / American Society of
Mechanical Engineers(ASME)
AGA & ASME Developed Orifice Meter Coefficients
& Standards
Definition Of An Orifice Meter
Primary Device That Creates A Differential Pressure (Differential
Pressure Producer)
Secondary Element Measures The Differential
Many Different Devices Create Differential
Sharp Square-Edge Orifice Plate
Venturi Tube
Flow Nozzle
Elbow
Flow Profile
Orifice Meter Measurement
Advantages
Flow Can Be Accurately Determined
Calibration
Simple To Operate
Years Of Reliable Operation
Requires Minimum Service
Widely Accepted
Relatively Inexpensive
No Moving Parts
Without A
Orifice Meter Measurement
Meter Accuracy
Reliability (Uncertainty/Accuracy)
Flange Tap Coefficient @ 0.2 & 0.7 Beta Has Uncertainty of
0.5%
Minimum Uncertainty Occurs Between 0.5 & 0.6 Beta
Beta is Orifice Bore (d) Divided by Pipe ID (D)
Orifice Meter Measurement
Meter Accuracy Continued
Rangeability
Often Referred to as Turn Down Ratio
Flow Range of 300,000 SCFH to 100,000 SCFH Would
Be 3 to 1
0.25% with Flow Calibration
Typical System Accuracy for Orifice Installation .6 to .7
%
Repeatability
Is the ability of a Flow Meter to indicate the same
reading each time, using identical flowing Conditions
Pressure Tap Locations
Flange Taps
Most widely used
Most accurate
1 upstream & 1 downstream from face of plate
Pipe Taps
1/2D upstream & 8D downstream
Permit installation of the orifice in an existing flange
Pressure tap holes should be smooth and free of rough edges
Pressure Tap Locations
Radius Taps
1D upstream & 1/2D downstream from the face of orifice plate
Corner Taps
Used on pipe sizes less than 2
Located directly at the face of the orifice plates
Orifice Measurement Standards
AGA Report # 3
AGA Report # 8
API 14.3
ISO 5167-1
Standards and Importance
AGA report #3 provides guidelines for construction and
installation of orifice meters.
AGA report # 8 provides guidelines for calculation of gas
surpercompressibility
ISO 5167 provides guidelines for construction, calculation
and installation of orifice meter in metric standard
Standards must be adhered to completely in order to
maintain accuracy.
Standards and Importance
ORIFICE GAS FLOW EQUATION
Qv= 218.527*Cd*Ev*Y1*(d)2[Tb/Pb]*[(Pf1*hw)/
(Gr*Zf1*Tf1)0.5
Where
Cd = Orifice Plate Coeficient Of Discharge
d = Orifice Bore Diameter at flowing temperature
G = Real Gas Relative Density (Specific Gravity)
hw= Orifice differential pressure at 60 0F
Ev = Velocity of approach
Pb = Base Pressure psia
Pf1= Flowing pressure upstream tap psia
Qv = Standard flowing flow rate in SCFH
Tb = Base temperature deg R
Tf = Flowing temperature deg R
Y2 = Expansion factor downstream tap
Zb = Compressibility at base condition (Pb,Tb)
Zf = Compressibility at flowing condition (Pf, Tf)
Flow Calculations
Orifice Metering
Q C '
hw P
C ' F b F r YF
pb
F tbF tf F g F pvF a F1
Fb = basic orifice flow factor
Fr = Reynolds number factor
Y = Expansion factor
Fpb = Pressure base factor
Ftb = temperature base factor
Ftf = flowing temperature factor
Fg = specific gravity factor
Fpv = supercompressibility factor
Fa = orifice thermal expansion factor
F1 = location factor
BASIC THEORY
Empirical equation base on Clean, single phase , homogeneous,
and Newtonian
Coeficient of Discharge Cd = ratio between actual flow to
theoritical flow.
Reynold number = ratio of inertial force to viscous force
Reynold number > 4000 for the Cd equation to be valid
Orifice Plates
The most fundamental component of orifice measurement.
Flat, circular, and held in line by a fitting or flanges.
Two basic styles of Orifice Plates:
Catalog No. 500 Universal Size for use in Orifice Fittings and
Ring-Joint Plate Holders
Catalog No. 520 Paddle Type for use in Orifice Flanges
Universal Orifice Plate
Paddle-Type Orifice Plate
Orifice Plates - Continued
AGA Report #3 Requirements:
Concentricity of the orifice bore
Edge Thickness
Plate Flatness
Plate Finish
Edge must be square and sharp, will
not reflect a beam of light
Orifice Plate Dimensions
Orifice Devices
Three Types
Orifice Flange Union - Dead Line Device
Single Chamber - Dead Line Device
Dual Chamber - Allows Plate Change Under Line Pressure
Orifice Flange Unions
Features
Most Economical Means Of Measuring Flow
Line Sizes 1/2 - 60
150 - 2500 # ANSI
Standard 1/2 Flange Pressure Taps
Equipped with Jack Screw
Styles- Weldnek- Threaded- Slip-On
Bi-Directional Flow
Orifice Flange Unions
Disadvantages
Plate Change Requires Depressurizing
Plate Removal Requires Flange Spreading
Product Spillage Occurs In Liquid Service
Pressure Tap Location
Flange Taps
Most Widely Used
Most Accurate
1 U/S & 1 D/S From Face Of Plate
Orifice Flange Unions
Simplex Orifice Fitting
Advantages
1 1/2 - 8
Economical Measuring Device
Simple To Operate
ANSI 150 #- 2500 #
No Flanges To Spread Apart
Plate Removal without Spillage
Meets AGA 3, API 14.3, ISO 5167
Bi Directional Flow
Simplex Orifice Fitting
Junior Orifice Fitting
Advantages
Rack and Pinion is added to assist in lifting the
plate carrier for larger line sizes
10 to 42 in 150-600# ANSI and up to 2500# in
certain sizes
Designed For Large Volume Applications
Gathering System,Compressor Stations
City Gates, Power Plants
No Spillage In Liquid Service
Bi-Directional Flow
Junior Orifice Fitting
10
Junior Orifice Fitting
Disadvantages
Plate Change Requires Depressurizing The Line Or Using
Bypass Piping
Senior Orifice Fitting
Features
Proven Technology
Simple To Operate
Field Repairable
NACE Trim Available
Plate Removal Without De-Pressurizing the line
Extensive Product Range
Bi-Directional Flow
Senior Orifice Fitting
Senior Orifice Fitting
Senior Orifice Fitting
Senior Orifice Fitting
Senior Orifice Fitting
Senior Orifice Fitting
Senior Orifice Fitting
Orifice Plates Sealing Units
DSC & DS
SSRC & SSR
TSC & TS
Dual Seal
Snap Seal Ring
Teflon Seal
MSC & MS
Metal Seal
C
2 thru 8 sizes (New API
14.3)
DSC & DS Seal
Simplest & most popular
70-80 Shore Nitrile Synthetic
Rubber
Optional Metallic-Oxide
Coating
3DVS 12 or larger (80-90
shore)
Pressure ratings to ANSI 600#
Temperatures from -20 to 275
DegF
Also available in Viton
TSC & TS Teflon Seal
Used for corrosive & high
temperature service
Pressure ratings from 900#
- 2500# ANSI
Application - Diluted
sulfuric acid/nitric
acid/liquid oxygen
Special compression lip
helps seal off the plate
Line sizes 2 - 18
MSC Metal Seal
Stainless or CadmiumPlated steel clip ring
Recommended for high
pressures and
temperatures
Recessed groove with
compression leaf spring to
effect a seal
Temperature from 600 to
1200 DegF
SSR Snap Seal Ring
Designed where elastomer
swelling is a problem
Application such as Ethylene or
carbon dioxide
Two symmetrical metal rings
each having an O-Ring
Line sizes 2 - 16
Temperature ranges from -67 437 Deg F (Viton O-Ring)
Available in 316SS and
Cadmium-Plated mild steel
Meter Tubes
Consists Of Upstream And Downstream Pipe And A Fitting or
Orifice Flange Union
AGA Report # 3 Requirements Include
Minimum Upstream And Downstream Lengths
Wall I.D. Smoothness, Roundness
Senior Meter Tube
Straightening Vanes
Bundle Of Small Tubes Placed Inside Upstream Section
Flanged Or Line Type
Purpose
Remove Swirls From Flow
Shorten The Upstream Section
Straightening Vanes
Flow Conditioner
Generally a perforated plate
Removes or significantly reduces swirl
Designed to redistribute the velocity
profile to produce ideal flow conditions
Flow Conditioner Daniel Profiler
Flow Conditioner Daniel Profiler
Secondary Devices
Orifice fitting/plate is known as the primary device
Secondary devices receive the raw information
Then it's converted to a proportional signal - electrical or
pneumatic
Corrected volumes are then calculated
Secondary Devices
Types:
Transmitters - DP, P, & T
Flow Computers
Chart Recorders
METERING SYSTEM
Metering System Components
Applications
Configuration
Instrumentation
System functionality
What is a Measurement Station?
Meters selected for application
Measurement instruments
Hardware
Software
Integrated system
ORIFICE METERING SKID
MECHANICAL PIPING & SKID
Piping Standard & Code
ANSI B31.3 or B31.8
ASME
Skid Standard
AWS
AISC
Material
Carbon Steel ASTM A104/API 5L
Alloy
GAS ORIIFICE P&ID DRAWING
METER RUN
INLET BLOCK VALVE
FLOW CONDITIONING
FLOW ELEMENT
TWO STREAMS ORIFICE METER
OUTLET BLOCK VALVE
Flow Computers/Chart
Recorders
Flow computers have increased in demand
over recent years
Requirements for real time measurement
Input signals from DP, P, T
Calculate corrected flow volumes
Chart Recorders have to be Changed
frequently and must be integrated
Flow computers, unlike charts, do not have to
be integrated
TYPICAL SYSTEM CONFIGURATION
Flow Computers
DCS / SCADA Communications
Supervisory
RS232 or Ethernet
Differential
Pressure
Input
Ethernet
Temperature
Pressure
HUB
HMI
Ethernet
Gas
Chromatograp
h
Digital I/O
Alarms
Ethernet
Reports
Orifice Flange Union With Flow Computer
Senior Orifice Fitting with Flow Computers Attached
GAS CHROMATOGRAPH APPLICATION
Gas composition
Heating value
Specific gravity
Compressibility
Correction
C6+ or C9+
MOISTURE & H2S ANALYZER
Moisture Content
PPMv
No calorific value
H2S Content
PPMv
Toxic
Renormalization
Pure Hydrocarbon Content
Corrected BTU flow rate
Measurement System Performance
Careful selection of components
Minimize measurement uncertainty
Proper operation
Periodic maintenance & calibration
Conclusion
The new AGA #3/API 14.3 measurement standard has
greatly tightened the tolerances for the manufacture
of orifice devices and meter tubes
To insure the best possible accuracy of the metering
installation, it is imperative that regular scheduled
maintenance be performed.
The primary device, whether a fitting or flange,
cannot be expected to provide accurate, reliable flow
information if the orifice plate is bowed or otherwise
degraded in some way
Conclusion
The vast body of data supporting Orifice measurement over
the years becomes meaningless if the guidelines for the
design, manufacture, installation, and maintenance of these
devices are not followed
Question ?
The End
and
Thanks for attention
