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MAC0010.1177/0020294014551110Tech Talk: (6) Flow Measurement Basics (Part 1)Tech Talk: (6) Flow Measurement Basics (Part 1)

Contributed Paper

Tech Talk (6) Flow Measurement


Measurement and Control
2015, Vol. 48(1) 18­–25
© The Institute of Measurement

Basics (Part 1)
and Control 2015
Reprints and permissions:
sagepub.co.uk/journalsPermissions.nav
DOI: 10.1177/0020294014551110
mac.sagepub.com

John E Edwards
Institute of Measurement and Control, Billingham, UK
David W Otterson
Institute of Measurement and Control, Billingham, UK
davidotterson@ntlworld.com

I. Introduction B. Custody Transfer Standard Temperature and Pressure


(STP): 15.556 °C (60°F) and 1.01325 bar
The Tech Talk series of papers is Measurement to determine the costing of
(14.696 psia)
intended to provide a useful reference for material transfer between suppliers and
Some manufacturers apply other
designers and technicians. Further consumers, requiring high accuracy and
standard conditions depending on the
papers to augment the series are invited reproducibility as small errors can have
application.
from experienced engineers and major cost consequences.
manufacturing companies.
Flow metering has undergone major C. Process Control III. Flow through Circular Pipes
evolution over the last seven decades,
A. Nature of Flow
from the use of differential pressure (DP) Measurement to provide data acquisition
flow meters – at their simplest using an and stable process control. Fluid volumetric flow (V) through a circular
orifice plate or flow tube coupled to a pipe causes a pressure drop as a result
manometer – through to a wide variety of D. Equipment Monitoring and Safety of wall friction due to pipe roughness and
both insertion and in-line electronic flow Shutdown creates a mean velocity (v) determined by
meters/transmitters in today’s marketplace. the pipe cross sectional area (A)
There is not one meter that will meet every Measurement for the safe operation of
application, and every application needs to equipment and process. V W
v= =
be looked at individually. A Aρ
This paper looks at the basics of fluid E. Mass or Volume Flow
flow metering and the application to DP where W is the mass flow (kg/s) and ρ is
If the fluid properties are variable and the the fluid density (kg/m3).
metering methods. This Tech Talk series
application requires good reproducible All flow meters have maximum and
will continue with Part 2 of this paper
accuracy, mass flow metering should be minimum operating velocity limits beyond
devoted to understanding the various
considered. This can be achieved by which their stated accuracy limits will be
other types of flow meter available and
selecting proprietary mass flow meters or by exceeded. In some cases, the size of the
their practical application.
using volumetric flow meters provided with fluid pipeline may need to be changed
the appropriate compensation for through the metering position so as to
II. Application temperature, pressure and fluid composition enable an acceptable fluid velocity to be
changes in order to satisfy the relationship obtained.
Flow meters are used to satisfy a variety
There are three flow regimes – laminar,
of objectives which determine the Mass flow (W) = Volume flow (V)  transitional and turbulent – as shown in
measurement principle selection and × Density (ρ) Figure 1. They have different velocity
detailed specifications.
profiles which are determined by the
For gas flow, reference conditions must mean velocity, density and viscosity (µ), as
be specified to equate volume flow, shown in Figure 2. The flow regime can
A. Nature of Application
regardless of its temperature and pressure be predicted by means of a dimensionless
The nature of application include flow to what it would be if flowing at a specific quantity called the Reynolds Number (Re)
through circular pipes, non-circular or reference pressure and temperature. which is defined as
conduits, channels or unconstrained Typical reference conditions are as follows:
space. This paper is primarily concerned Normal Temperature and Pressure (NTP): vDρ
Re =
with flow through circular pipes. 0 °C and 760 mm Hg µ

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Tech Talk (6) Flow Measurement Basics (Part 1)

The continuity equation for


Figure 1.  Fluid flow conditions
incompressible flow provides the
following relationship for a change in pipe
cross sectional area between two points
1 and 2

=
Q A=
1v1 A 2 v 2

substituting for diameter becomes

2 2
=
Q D=
1 v1 D2 v 2

element, the mean volumetric flow within D1 v2 d


Figure 2.  Fluid flow profile = =β=
the pipe obtained. D2 v1 D
However, if there is a disturbance to
the flow upstream of the measuring where d is the orifice diameter and β is
point, such as a bend, a valve or a the orifice diameter to pipe internal
change in pipe diameter, then the profile diameter ratio
will not be fully developed, and the The above relationships
installed flow meter result will not be demonstrate that when a fluid flows
predictable. through an orifice, the velocity
increases and the downstream
B. Theory pressure decreases and generates a
Manufacturers’ guides detail the Re limits Bernoulli’s theorem applies the law of DP to maintain the energy balance.
for their flow meters. conservation of energy to the flow of This is the basic principle on which all
Laminar flow (Re < 2000) occurs at low fluids in a conduit and states: differential flow meters are based. All
fluid velocity in which the fluid tends to Total energy at any point = Velocity practical formulae for the study of the
form parallel layers across the pipe Head + Elevation Head + Pressure Head flow of fluids are derived from these
diameter. This results in a parabolic relationships, thus.
velocity profile across the pipe. v2 p Rate of flow of any fluid through an
H= + +h
Transitional flow (Re > 2000 < 10,000) 2g ρg orifice or nozzle neglecting velocity of
occurs as the fluid velocity increases, approach is given by
causing mixing between the layers. The where v is the fluid velocity along the
profile may vary between the laminar and streamline (m/s); g is the acceleration Q = Cd A 2ghL
turbulent shapes. due to gravity on earth (9.81 m/s2); h is
Turbulent flow (Re > 10,000) occurs at the elevation above reference (m); p is Correcting for velocity of approach
higher fluid velocity. The laminar layers the pressure, Pascal (kg/m s2) and ρ is which can have a significant effect
break down and form eddies and the fluid density (kg/m3).
whorls, which results in a flatter velocity Check the following equation for Cd A
Q= 2ghL
profile and is the most favourable consistency of units 1 − β4
condition for predictable and accurate
flow metering. m2 s 2 kg m3 s2
m= 2 m
( = m) + ( = m) + m The flow coefficient C is defined to
The ideal installation for flow s ms2 kg m eliminate for calculation of the velocity of
measurement is one with a large length
approach
of smooth straight pipe preceding the If friction losses are neglected and no
measurement point to provide uniform energy is added (by pumps) or removed
2∆P
and predictable velocities across the pipe (by turbines), the equation will be CA 2ghL = CA
ρ
– termed a ‘Fully Developed’ condition. constant for any point in the fluid. This is
In the majority of installations, the flow is not the case in practice, so an energy
turbulent and the condition is referred to balance between two points 1 and 2, where Cd is the discharge coefficient; C
as ‘Fully Developed Turbulent Flow’, allowing for pipe friction (hL), becomes is the flow coefficient, discharge
which is well understood, having been coefficient corrected for velocity of
v12 p1 v2 p
documented following extensive test + + h1 = 2 + 2 + h2 + hL approach factor and hL the measured
work and by using a suitable flow 2g ρ1g 2g ρ2g differential

February 2015  Vol 48 No 1  l  Measurement and Control  19


Contributed Paper

Tech Talk (6) Flow Measurement Basics (Part 1)

IV. Types of DP Flow Meters


Figure 3.  Device head loss versus beta d/D
This group of flow meter includes orifice
plates, flow nozzles wedges and venturi
1
tubes, all of which are insertion devices
0.9
that create unrecovered pressure loss as
0.8
shown in Figure 3. 0.7

Head Loss Fraction


Other meters using this basic principle 0.6
include wedge and target meters. Pitot 0.5
tubes and fan air inlet cones are also in 0.4
this category and create minimal 0.3
resistance to flow. Centrifugal force is 0.2
used for the pipe elbow meter. 0.1
All of these primary devices, with the 0
0.1 0.2 0.3 0.4 0.5 0.6 0.7
exception of the target meter, are
Beta Ratio d/D
connected to the measuring Orifice Flange Flow Nozzle Wedge Short Venturi Long Venturi
instrumentation using impulse tubing
which is subject to blockages when
applied to difficult fluids that may form or
contain solids. To overcome this, the
A. Square Edge Orifice Plate
transmitter can be close coupled to the Figure 4. 
element as shown in Figure 4 or fitted The most common form is the concentric
with remote seals that isolate the process orifice which can be supplied with a drain
fluid from the transmitter without affecting hole near the bottom of the plate when
accuracy, provided the connecting handling wet gases, or a vent hole near
capillaries are of the same length and the top of the plate for liquids with
experience the same ambient entrained gas (Figure 5). Eccentric orifice
temperature. plate construction can provide for full
In this type of application, segmental drainage or venting. Integral orifice
orifices may be considered but are not assemblies, supplied within a ‘metering
generally recommended as more suitable pipe section’, are available for the
methods are now available which will be measurement of flow through small
discussed in Tech Talk 6 Part 2. In diameter pipes.
general, these devices should only be The orifice plate (primary element) is
considered for use on clean single-phase available in a variety of materials of
fluids. construction and is a relatively
Valve manifolds are available in inexpensive device. However, the total
3-valve (Figure 4) and 5-valve installation involving primary isolation
configurations and are suitable for most valves, impulse tubing and valve
applications, providing an ideal low-cost manifolds adds considerable cost to the Figure 5.  Square edge orifice plate
solution for connecting a transmitter to design, installation and maintenance
its impulse lines. The 3-valve activities.
configuration provides span and zero The maximum flow rangeability ratio is
calibration, with additional ports in the region of 3:1 with moderate
available to connect test instruments. accuracies of 2%–4% of full-scale
The 5-valve configuration provides the reading. This can be improved by flow
additional ports for draining or purging meter calibration. In some applications,
of the impulse lines. such as wet steam, the sharp edge and
The basics of flow metering using bore may degrade over time.
square edged, concentric orifice plates orifice plate. For a given diameter and DP,
are described below. ISO 5167-2:2003 they will pass almost 65% more flow.
B. Flow Nozzle
and other equivalent National or They can be used on non-homogeneous
International Standards should be Flow nozzles (Figure 6) have an inlet with fluids, provided large percentages of
consulted with respect to the design and a streamlined contour making them solids are not present. For pipe sizes
installation of the other types of metering suitable for use at high fluid velocities and 150–300 mm and Re > 33000 with β
elements listed above. are more resistant to erosion than the ratios in the range 0.3–0.7, test data

20  Measurement and Control  l  February 2015  Vol 48  No 1


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Tech Talk (6) Flow Measurement Basics (Part 1)

Figure 6.  Flow nozzle Figure 8.  Wedge flow tube

Figure 7.  Venturi tube


has no critical surface dimensions, or
Figure 9.  Target meter
sharp edges, that will affect measurement
accuracy as the result of wear.
Although more expensive than an
orifice plate. This device can handle dirty
fluids and is generally suitable for most
liquids, gas and steam. It can be used to
measure bi-directional flow and handles
show standard deviation is ±0.475%. For fluids with a Re as low as 500. The
applications requiring precision, flow slanted faces of the wedge provide self-
nozzles for pipe sizes less than 150 mm scouring action and minimise damage
should be flow calibrated. from impact with entrained material. Its
Flow nozzles come in three types: ISA Figure 10.  Pipe elbow meter
rangeability of 8:1 is relatively high for a
1932 nozzle, the long radius nozzle and DP element, and accuracies are possible
the venturi nozzle, which combines up to ±0.5% of full-scale reading.
aspects of the other two.
E. Target Meter
C. Venturi Tube
The target flow meter (Figure 9) is
The classical venturi tube (Figure 7) is suitable for difficult-to-meter fluids. The
streamlined at both entrance and exit. primary element is a supported circular
Variations in the outlet cone dimensions disc that forms an annular orifice to the
have little effect on the discharge coefficient flowing fluid and is directly connected to
and may be truncated considerably on the transmitter. β ratios are in the range of flow meters and provide a reproducible,
applications having low β ratios. Pressure 0.5–0.8 depending on fluid velocity and if not accurate result. This method can
loss is minimal, making it a good choice properties. At β ratios around 0.8, measure bi-directional flow and is used
when little pressure head is available. viscosity correction variations are extensively on dyeing machinery.
Rangeability is less than 6:1, with accuracy considerably less than for orifice plates.
of ±1%–2% of full-scale reading. Viscosity Repeatability is good, and high accuracy G. Pitot Tube
effects on accuracy are high. Flow must be is obtainable using flow calibration
turbulent (Re > 10,000). This element is Pitot tube (Figure 11) is a low-cost
considerably more expensive than orifice element used to measure fluid flow,
F. Pipe Elbow Meter
plates but is used extensively in water and especially air flow in ventilation and
wastewater applications, being able to When fluid flows through a pipe elbow, the heating, ventilation and air conditioning
handle dirty fluids. centrifugal force generated creates a (HVAC) systems and also used to
pressure differential between the inner and measure the speed of aero planes. This
outer radii of the elbow. Pressure taps in element works by comparing the
D. Wedge Flow Tube
the elbow measure this differential, which is pressure created by the kinetic energy of
This element consists of a V-shaped proportional to the elbow’s radius. Elbow the fluid flow with the static pressure. It is
restriction formed into the meter body taps located at 22.5° from the inlet (Figure not suitable for dirty fluids and has limited
(Figure 8). The wedge provides a 10) result in a more stable and reliable rangeability. As an insertion meter, the
segmental orifice plate profile to the reading than if placed at 45° and are less pitot tube makes a measurement at a
incoming fluid. This restriction creates a affected by approach conditions. Pipe single point within the pipeline or duct,
DP in proportion to the square of the elbow meters (Figure 10) are used where so positioning is sensitive to the velocity
volumetric flow rate. The wedge restriction lack of space prohibits use of other types profile. Positioning problems can be

February 2015  Vol 48 No 1  l  Measurement and Control  21


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Tech Talk (6) Flow Measurement Basics (Part 1)

Figure 11.  Pitot tube Figure 13.  Orifice plate taps and pressure profile

Figure 12.  Fan inlet cone

(C) depends partly on the tap positions. equal to the unrecoverable pressure
The permanent pressure loss depends loss caused by the orifice; this may
on the β ratio and varies from 62% to be used to verify the performance of
90% of total pressure drop for β ratios in flow restriction orifices;
the range 0.6–0.3. •• Vena contracta taps placed one pipe
There are three standard positions diameter upstream and 0.3–0.9
covered by ISO 5167-2:2003 and other diameters downstream, depending
avoided by using the averaging pitot major standards as follows: on the orifice plate type and its size
tube, which contains multiple orifices. relative to the pipe in the plane of
•• Corner taps placed immediately minimum fluid pressure.
H. Fan Inlet Cone upstream and downstream of the
Measuring variable air flow accurately on plate, convenient when the plate is The flow coefficient C is influenced by the
fan discharges requires long straight provided with an orifice plate; fluid flow Reynolds number and the orifice
lengths, which are frequently impractical, •• Orifice plate carrier assembly plate β ratio selected during sizing as
or flow straighteners, which are incorporating the taps; shown by the curves in Figures 14 and 15.
expensive, to give a reproducible and •• D and D/2 taps or radius taps placed This indicates that acceptable β ratios
stable velocity profile (Figure 12). A one pipe diameter upstream and half for fully turbulent flow are in the range
recognised method, to ISO5801:1997, a pipe diameter downstream of the 0.2–0.6. For β > 0.6, the viscosity effects
measures the air flow at the fan inlet orifice plate; these can be installed by are magnified combined with upstream
using a calibrated cone with the welding bosses to the pipe and are sensitivity to piping configurations. The
configuration shown in Figure 12. This generally used on large bore pipes measured meter DP (hF) is proportional
method is particularly useful on where the cost of an orifice plate to the actual flow rate (QF) squared as
combustion air installations which are carrier would be prohibitive; per the relationship
often space limited. •• Flange taps placed 1 in (25.4 mm)
QF hF
upstream and downstream of the =
V. Concentric Sharp Edge QMAX hMAX
orifice plate, normally incorporated
Orifice Plate Flow Meter within specialised pipe flanges.
Figure 13 shows the fluid pressure profile Compressible gas flows can be
through a concentric orifice where the Other types include the following: corrected to give mass rate (WF) from the
point of maximum velocity occurs flowing pressure (PF) and temperature
downstream at the ‘vena contracta’. It •• Pipe taps 2½D and 8D taps placed (TF) by using the following
can be seen that the measured DP is 2.5 pipe diameters upstream and 8
dependent on the selection of pressure diameters downstream, at which hFPF
WF ∝
tap position, and so the flow coefficient point the measured differential is TF

22  Measurement and Control  l  February 2015  Vol 48  No 1


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Tech Talk (6) Flow Measurement Basics (Part 1)

A. Impulse Pipe Installation


Figure 14.  Flow coefficient C square edge orifices (Reference Crane 410M)
Arrangements

1.3
Standard ISO 5167-2:2003 gives
detailed guidelines for the installation of
1.2
impulse pipes between the orifice plate
1.1
Flow Coefficient (C)

pressure taps and a DP indicator or


1
transmitter. In summary,
0.9
0.8 •• Keep impulse lines as short as is
0.7 practical and both of the same pipe
0.6 bore;
0.5 •• Install primary isolation valves at the
10 100 1000 10000 pressure tap points; this will facilitate
Reynolds Number (Re) maintenance;
Beta 0.4 Beta 0.6 Beta 0.8 •• Where impulse pipes must slope up
or down to the instrument, the
minimum slope should be 1 in 12.

Figure 15.  Flow coefficient C square edge orifices (Reference Crane 410M)
B. For Liquids

0.72
•• Install pressure taps either on the
horizontal centre line of the pipe or at
0.7
60° upwards slope from the centre
Flow Coefficient (C)

0.68 line.
0.66 •• For instruments above or below the
0.64 pipeline level, slope the impulse pipes
0.62
to the instrument ensuring that the
same static head will occur on both
0.6
impulse lines.
0.58 •• Consider the installation of vent
1.0E+03 1.0E+04 1.0E+05 1.0E+06
valves to purge gas bubbles at the
Reynolds Number (Re)
highest point of the impulse lines
Beta 0.2 Beta 0.4 Beta 0.6 Beta 0.7
and drain valves at the lowest point.
Purging for several minutes on
process start up is recommended
to eliminate gas bubbles from the
Conventional meter full-scale flow sizing calculation software based on one lines.
calibrations are set in the range 2500– of the several available International
5000 mm wg for liquids and 750– Standards which has been derived using
C. For Gases
1250 mm wg for gases and are adjusted experimental data.
to provide an acceptable β ratio. Historically, orifice plates were used to •• For dry gas, the orientation of
Due to the square root relationship, the measure difficult non-homogeneous pressure taps is usually not critical;
rangeability ratios are limited to the 3:1 to fluids exhibiting two-phase flow or having however, if condensation is possible,
4:1 region. This can be extended by varying physical conditions such as the pressure taps should be located
applying wide range flow metering viscosity, because no other methods on the top centre line of the pipe and
techniques using differently ranged and were available. Various design impulse lines arranged with a
switched DP transmitters. Correctly adaptations and techniques were minimum slope of 1 in 12 such that
designed and installed, the flow rate can developed by varying the orifice bore any condensate flows back to the
often be derived with an acceptably low location and shape and the purging of pipe.
uncertainty (typically ±3% of reading) by impulse lines with process compatible
taking the square root of the DP across clean fluids. Now, the generally preferred
D. For Steam
the orifice plate installation pressure taps practice is to use orifice plates on clean
and applying an appropriate constant. single-phase fluids or those only •• Install pressure taps on the side of
Most manufacturers of orifice plates, containing small quantities of a differing the pipe. Cooling chambers are
plate carriers and metering pipe units use phase. required so that vapour can

February 2015  Vol 48 No 1  l  Measurement and Control  23


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Tech Talk (6) Flow Measurement Basics (Part 1)

condense and form a constant head


Table 1.  Reasonable velocities for flow of fluids through pipes (Reference Crane 410M)
cold barrier between the pipe and the
instrument. Mounting of the cooling Service conditions Fluid Reasonable velocities Pressure drop
chambers is critical in order to ensure
  m/s ft/s kPa/m
an equal head in each impulse line.
Cooling chambers and impulse lines Boiler feed Water 2.4–4.6 8–15  
must not be lagged; however,
thermal protection in the form of a Pump suction and drain Water 1.2–2.1 4–7  
mechanical guard is essential. General service Liquids pumped; non- 1.0–3.0 3.2–10 0.05
Calibration of the transmitter should, viscous
if practical, be carried out under ‘hot’
conditions to minimise low scale Heating short lines Saturated steam; 20–30 65–100  
0–1.7 bar
offset error.
Process piping Saturated steam; >1.7 bar 30–60 100–200  
VI. Pipe Line Design Boiler and turbine leads Superheated steam; 14 30–100 100–325  
Considerations and up
The Instrumentation Engineer must be Process piping Gases and vapours 15–30 50–100 0.02%line
involved when pipelines incorporating pressure
flow meters are being designed to ensure
Process piping Liquids – gravity flow 0.05
that adequate pressure is provided and
that the pipe is sized to give an
acceptable fluid velocity through the
Figure 16.  Orifice plate approach conditions (Reference LK Spink)
meter. Accessibility for cabling and
maintenance purposes also requires
consideration. Industry practice for initial 35
design is based on economic velocity or 30
Straight Pipe Diameters

allowable pressure drops as shown in


25
Table 1.
The geometry upstream and 20
downstream of the flow meter can,
15
depending on the type of meter chosen,
have a marked effect on the metering 10
accuracy. Disturbance of the fluid flow
5
profile can be caused by upstream 0.1 0.2 0.3 0.4 0.5 0.6 0.7
obstructions such as a thermowell, Beta Ratio d/D
gasket protrusion, badly dressed Size Change 90 Elbow 3x90(2 planes) Valve
pressure tapping welds or in-line valves.
Swirl can cause very large metering
errors which are caused by one or more
bends in the pipeline, the worst cases to flow straightening and/or flow measurement compensation, the
being where changes in the pipeline conditioning in-line equipment. Such pressure instrument connection should
plane exist. Figure 16 shows typical devices, which include tube bundles be teed from the upstream DP
upstream straight pipe diameter and perforated plates, can reduce swirl measurement tapping and the
requirements, depending on the and in some cases improve the flow temperature thermowell installed at
disturbance, for concentric orifice plates. profile. Specialist advice should be between 5 and 15 pipe internal
For detailed application guidance, sought in the application of these diameters downstream of the metering
reference should be made to data devices. position.
contained within Standard ISO 5167- DP flow meters (orifice plates, venturi
2:2003. tubes, flow nozzles, wedge meters and
VII. Specifying Flow Meters
Ideally, manufacturers’ pitot tubes) are especially vulnerable to
recommendations regarding upstream inaccuracy resulting from poor pipeline The use of the manufacturer’s data sheet
and downstream straight pipe lengths design. In cases where temperature and or an equivalent is strongly
should be followed. If this is not pressure compensation instruments are recommended in order to transmit all
practical, consideration should be given to be installed for mass flow information relative to the process

24  Measurement and Control  l  February 2015  Vol 48  No 1


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Tech Talk (6) Flow Measurement Basics (Part 1)

conditions, reference conditions and B. Liquids Acknowledgements


pipeline design, required for the sizing The authors wish to thank Mr Greg Livelli of
•• Specific gravity, solids in suspension ABB Instrumentation, USA, for permission
calculation. An understanding of the
(nature and percent of flow), to use material from his paper ‘Flow
nature and dynamics of the fluid flow to
conductivity, corrosion and erosion metering theory and practice’.
be measured is essential in selecting a
properties;
flow meter. Below are some of the main Funding
•• Single- or two-phase flow.
considerations. This research received no specific grant
from any funding agency in the public,
A. All Fluids C. Gases commercial or not-for-profit sectors.

•• Flow rate – maximum, normal and •• Gas mixture composition, moisture References
minimum (to determine the turn- content, molecular weight; 1. ISO 5167-2:2003. Measurement of fluid flow by means
of pressure differential devices inserted in circular-
down ratio); •• Density, absolute pressure and cross section conduits running full.
•• Volume or mass flow measurement; absolute temperature; 2. Miller RW. Flow Measurement Engineering
•• Viscosity at flowing conditions; •• Flow rate reference conditions. Handbook. New York: McGraw Hill, 1996.
3. Crane 410M. Flow of Fluids through Valves,
•• Laminar, transitional or turbulent flow; Fittings, and Pipe. Ipswich: Crane, 1988.
•• Temperature and pressure – 4. Spink LK. Principles and Practice of Flow Meter
D. Steam Engineering. 9th ed. Foxborough, MA: Foxboro
maximum, normal and minimum;
Company, 1967.
•• Material of construction; •• Saturation temperature or °Kelvin of 5. Perry RH, Green DW. Perry’s Chemical Engineers’
•• Design pressure and temperature. superheat Handbook. 7th ed. New York: McGraw Hill, 1984.

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