Installation study of effect on orifice plate

1
Palani S, Deljin Kuriackose, 3Shanmugan S and4Ganapathy Srinivasan R
2

1
Associate Professor, Department of Mechanical Engineering Vel Tech Multitech Dr. Rangarajan Dr. Sakunthala
Engineering College, Avadi, Chennai-62
2,3
Assistant Professor, Department of Mechanical Engineering Vel Tech Multitech Dr. Rangarajan Dr. Sakunthala
Engineering College, Avadi, Chennai-6
4
Assistant Professor, Department of Pyhsics, Vel Tech Multitech Dr. Rangarajan Dr. Sakunthala Engineering
College, Avadi, Chennai-6

Corresponding author e-mail: spalani@veltechmultitech.org

ABSRACT (2015) studied that the pressure distribution, pressure

Discharge coefficient of the nozzle is ratio of the
actual discharge to the theoretical discharge. The
proportion of the mass flow rate at the discharge of
nozzle is that of an ideal nozzle which expands an
identical working fluid from the similar primary
condition to the similar exit pressures. So here in our
research work we are using AIR as a medium to find
out the coefficient discharge of orifice plate by various
installations.
Key Word: orifice plate; nozzle; coefficient discharge;
mass flow rate:
1. Introduction
Fluid Control Research Institute (FCRI), an
autonomous institute was established in 1987 with
active assistance and participation from UNDP and
UNIDO under the ministry of industry (govt. of India).
At FCRI we have full-fledged NABL accredited
laboratories for the calibration of flow meters in water,
oil and air medium. The flow laboratories at FCRI are
on par with similar laboratories in Europe, as have been
proved through an inter laboratory comparison
programme with national engineering laboratory UK,
Delft hydraulic laboratory and Denmark TECH
institute.
Manish et al (2012) used Computational Fluid
Dynamics (CFD) simulation to predict the orifice flow
with better accuracy. CFD simulations have been
performed using OpenFOAM-1.6 solver and validated
with the published experimental data of Nail
(1991) and Morrison et al. (1993). CFD simulations
have been validated with pressure drop and energy
balance of our experimental data of water as fluid. The
outcomes of the CFD simulations in terms of profiles of
velocity, pressure, etc. are discussed in detail. A new
scheme has been proposed to track vena-contracta with
the help of CFD and with a suitable provision in the
hardware of orifice meter. The new scheme maintains
the existing advantages of orifice meters and provides
better accuracy and sensitivity. Mohamed A et al
fluctuation, static pressure, pressure loss and line
pressure in the flow through orifice nozzle. This
pressure is triggered by the disturbance of the flow
passed the orifice as the flow contract spinning, rotation
and circulation through which the flow transiently
causes pressure on the wall which increasingly becomes
a real concern to the designers of piping circuit. Their
study shows strong correlation between the flow
velocity and both the pressure and the stress acting on
the wall.
Prajapati et al (2010) a sudden increase in the static
pressure at the location of the orifice is shown at nearly
the location of the orifice. The maximum pressure
variation takes place at Reynolds number of 30000 as
predicted and earlier shown. The results of the velocity
and the pressure as well are in good agreement with the
findings. Song et al. (2011) stated that the laminar or
turbulent flow suffers from adding extra fittings or
modifying an existence geometrical shape of the piping
circuit including the orifice itself. As such, the flow
behavior, namely velocity and pressure distribution,
passed an orifice plate should be monitored. Monitoring
the flow characteristics is normally performed by
experimental techniques.
Aaron Xavier Fernandez’s et al (2012) studied on
waste water flow through orifice plates. Here the waste
water particles in orifice flow are investigated through
numerical simulations. They carried out to analyze the
stress variation in orifice plates. The experimental
values are compared with the standard values and
results are tabulated. The numerical study confirms that
nominal size of orifice cannot explain the particle
breakage of single orifice plate assembly compared to
that multiorifice plate assembly. However their study of
breakages of particles at various radial locations proved
to be inconclusive. At last it is concluded that single
orifice plate is ideal for strong particles,Multi-orifice
may be effective in breaking of weak particles.
Smith et al (2008) stated that almost all industrial
applications such as food industry, petrochemical, and
oil/gas processing require certain accuracy, however
when it comes to very high accuracy such as in
pharmaceutical field, the experimental, theoretical, and the square of the rate of flow.
simulation techniques are to be carefully conducted.
Errors in flow measurement can result in significant 3. Experimentation
cost losses and inefficiency repercussions or damaging The specifications of orifice plate are 3 Inch orifice
the system itself. Consequently, attempts are now being plate; D = 77.920 mm; d = 55.11 mm (pipe
made to improve the accuracy of existing orifice dia).Instruments used are, Inside micrometers ( 5 – 50
metering facilities. Most prior efforts toward this goal MM); Rod type inside micrometers ( 50 –750 mm);
have concentrated on determination of discharge Electronic micrometers of suitable range; Vernier
coefficients [6]. calipers (150 – 600 mm); Flat steel scales or rules (300
Our research work is using air as a medium to find
– 1200 mm); Steel tape (50 ft); Tap holegauge /
out the coefficient discharge of orifice plate by various
Micrometer for checking the distance between taps.
installations.
Testing methods:
2. Orifice Plate
Figure 1 shows the sonic nozzles
Orifice meters are one of the oldest and most
trusted meters in use in flow measurement. Like any
differential meter, the orifice meter uses calculations
based on the Bernoulli Principle. The Bernoulli
Principle states that there is a relationship between the
pressure in the pipe and the velocity of the flowing
fluid. The orifice plate provides a restriction in the
flowing area that causes the fluid to accelerate. This
acceleration can be measured by measuring the pressure
drop across the orifice plate. There are several
important components of an orifice metering system.
The actual meter is not just the orifice plate, but
includes the upstream and downstream lengths as well
as any taps, thermo walls and flow conditioners. Other
components in an orifice measurement system include
pressure and differential sensors (transducers), RTDs, Figure 1: Sonic Nozzles
and flow computers. All components of an orifice
system must be evaluated when evaluating the system. Figure 2 shows (a) orifice and (b) orifice with single
Major benefits to using orifice meters include: price of bend
the metering system, reliability, repeatability, and the
common acceptance of the technology.
2.1 Principles of Orifice Plate
As the fluid approaches the orifice the pressure
increases slightly and then drops suddenly as the orifice
is passed. It continues to drop until the “vena contracta”
is reached and then gradually increases until at
approximately 5 to 8 diameters downstream a
maximum pressure point is reached that will be lower
than the pressure upstream of the orifice. The decrease Figure 2: (a) orifice (b) orifice with single bend
in pressure as the fluid passes thru the orifice is a result
of the increased velocity of the gas passing thru the
reduced area of the orifice. When the velocity decreases
as the fluid leaves the orifice the pressure increases and
tends to return to its original level. All of the pressure
loss is not recovered because of friction and turbulence
losses in the stream. The pressure drop across the
orifice plate increases when the rate of flow increases.
When there is no flow there is no differential. The
differential pressure is proportional to the square of the
velocity, it therefore follows that if all other factors
remain constant, then the differential is proportional to
Figure 3: a) orifice with bend in same plane (b) bend
in perpendicular plane
Figure 3 shows (a) orifice with bend in same plane (b)
bend in perpendicular plane
Figure 4 shows the orifice plate model
Figure 4: Orifice plate model
Model Calculation
ß= Pipe diameter/Orifice diameter; Pipe
diameter=55.11 mm; Orifice diameter=77.92 mm;
So, ß=55.11/77.92; = .707
Area of pipe = (π/4) × d² mm²
D= Pipe diameter
So, Area = (π/4) × (55.11)²= 2385.34 mm²
Y= 1-[{0.351 + (0.256 × ß^4) + (0.93 × ß^8)} × {1-(1-
(Δptc/ptc)^(1/1.4)}]
Y= Expansion factor; Δptc= Differential pressure=
154pascal; Ptc= Test meter pressure; = 999.988 mbar
;=999.988 × 100pascal
Y= 1-[{.351+ (.256× .707 ^4) + (0.93 ×707 ^8)}× {1-
(1-(154/(999.988×100))^(1/1.4)}]=.999479
Pv= {[(0.0853 × Tv³)-(1.46 × Tv²) + (100.7 × Tv)] +
227}× (RH/100) Pascal
Pv= Vapor Pressure
Tv=Ambient temperature; =25.484 °c
RH= Relative humidity=54.27 %
So, Pv= {[(0.0853 × 25.484³)-(1.46 × 25.484²) + (100.7
× 25.484)] + 227} × (54.27/100) Pascal
=1739.047 Pascal
Me= 28.966-{10.95× (Pv/Pb×100)} kg/mol k
Me= Molecular weight; Pv= Vapor pressure
=1739.047 Pascal
Pb= Ambient Pressure; =1000.125 mbar
= 100012.5 Pascal
Me=28.966-{10.95× (1739.047 /100012.5)} kg/mol k
=28.65283 kg/mol k
ρt= (Ptc x Me)/( R x Tt) kg/ m3; Ptc=999.988 Pascal
Me=28.65283 kg/mol k
R=Gas constant=8314.4
Tt=Test meter temperature in Kelvin; =25.210+273
=298.21 K
So, ρt= (999.988 x 28.65283) / (8314.4 x 298.21) kg/
m3 ;; =1.155604kg/ m3
ReD= (4×m) / (π×D×μ)
ReD= Reynolds number
M= Mass flow rate kg/sec; =117.229/3600=0.03256
kg/sec
D= Orifice diameter m=77.92/1000=0.07792 m
So, ReD = (4×0.03256) /
(π×0.07792×1.8363×10^-5) =28976.78
Cd = {qa× (1- β^4) ^ ½} /
(A×Y× (2Δptc/ ρt)^½)
Qa= Volumetric flow rate m3/sec
= 101.073/3600 m3/sec= 0.0280758 m3/sec
A= Area m= 2.3853 × 10^-³ m²; Y =.999479
Δptc=154pascal; ρt= 1.155604kg/ m3
So, Cd= {0.0280758 × (1-0.707^4) ^ ½} / (2.3853 ×
10^-³×.999479 ×
(2×154/1.155604)^½)
=0.62464
4. Results and Discussion
Air as the medium and the air sucked from blower.
In which calibration of 3 inch orifice meter is
done.Calibration of orifice meter at low pressure is
carried out in Secondary Air Flow Laboratory (SAFL)
for flow ranges up to 1018m3/h. with ambient is
maintained at a temperature of 25 +/- 1oC and at
relative humidity of 55 +/- 5% through an air
conditioning system operated continuously.The
required data of mass flow rate and volumetric flow
rate are, we got from DAS.The differential pressure
value is detected by DP transmitter. The ambient
condition and the sonic nozzle condition is shown on
DAS. The necessary expansion factor is used in
calculation for air as air is compressible.
Table 1: Experimental Values of straight pipe
coefficient of discharge Cd (Average Cd = 0.62123)
Table 2: Experimental Values of single bend
coefficient of discharge Cd (Average Cd = 0.61158)

Table 3: Experimental Values of two bend same
plane coefficient of discharge Cd (Average Cd =
0.6113662)
Table 4: Experimental Values of two bend
perpendicular plane coefficient of discharge Cd
(Average Cd = 0.6156)
Table 5: Cd values in different condition
Figure 5: Graphical comparison of different
condition Cd with Qa
These data’s are got from the system;Mass flow rate
and volumetric flow rate, Sonic Nozzle Condition,
Temperature and Pressure in the Test meter, ambient
temperature and Pressure and the DP value got from
Micro Manometer or a Transmitter.
From the experimental results prevent placing
perpendicular planes near to flow meter because this
increases the rotational flow.Same plane one bend or
two bends gave minor variation therefore placement of
bends in the same plane is recommended. Distance
between bends in same plane is not required since it
does not have a significant effect on Cd.
5. Conclusions
From this research experimental works concluded
that the straight pipe installation is better than other
installation due to the formation of swirl.
References
[1] Manish S. Shah , Jyeshtharaj B. Joshi 1, Avtar S.
Kalsi, C.S.R. Prasad, Daya S. Shukla. “Analysis
of flow through an orifice meter: CFD
simulation”, Chemical Engineering Science,
Volume 71, pp 300-309, 2012.
[2] Mohamed A, Siba Wan and MohdFaizal, “Wall
pressure due to turbulent flow through orifice
plate” International Journal of Mechanical and
Mechatronics Engineering, 15(2), pp. 36-41,
2015.
[3] Prajapati C B, Patel V K, Singh S N and Seshadri V,
“CFD analysis of permanent pressure loss for
different types of flow meters in industrial
applications”, Proceedings of the 37th National
and 4th International Conference on Fluid
Mechanics and Fluid Power, December 16-18, IIT
Madras, Chennai, India, 2010.
[4] J. Song, L. Lu, B. Teng, H. Park, G. Tang, and H.
Wu, “ Laboratory tests of vortex induced
vibration of along flexible riser pipe subjected to
uniform flow”, Ocean Engineering 38 (11-12),
1308-1322, 2011
[5] Aaron Xavier Fernandes “Computational Fluid
Dynamics Analysis for Wastewater Floc Breakage
in Orifice Flow” Chemical Engineering and
Applied Chemistry University of Toronto in 2012.
[6] Smith E, Ridluan A,Somravysin P and
Promvonge, “Numerical investigation of turbulent
flow through a circular orifice”, KMITL Science.
Journal, 8(1), 43-50.