Flow Control and Measurement

Fluid mechanics is the branch of physics concerned with the mechanics of fluids (liquids, gases, and plasmas). Fluid mechanics has various applications in mechanical and chemical engineering, biological systems, and astrophysics. Fluid mechanics is a branch of continuous mechanics that deals with the relationship between forces, motions, and statical conditions in a constant material. The fluid mechanics can also distinguish between a single-phase and multiphase flow, i.e., flow made more than one phase or single distinguishable material.

In general, fluid mechanics is the study of fluids either in motion, fluid dynamics, or at rest, fluid statics. Both liquids and gases are classified as fluids.

Fluid dynamics

Fluid dynamics deals with the fluid mechanics where the fluids are in motion. Fluid dynamics has many applications, including calculating forces and moments on aircraft, determining the mass flow rate of petroleum through pipelines, predicting weather patterns, and many more.

Fluid statics

Fluid statics deals with the fluid mechanics where the fluids are at rest. Applications of fluid statics include pressure measurement with hydrostatics, water dams and gates, liquid storage tanks, and many more.

Flow is the movement of pressurized fluids between volumes of varying pressures. Pressurized fluid always moves from higher pressure to lower pressure. Without a pressure differential, the fluid is stagnant, and the system lacks flow. Uncontrolled fluid in motion can physically destroy pumps, piping, valves, meters, and other fluid flow control system components.

Fluid flow control is an advancing field of fluid dynamics that describes the flow of liquids, gases, and plasmas. Flow control of fluids can be accomplished by passive, which requires no energy, or active devices, which require energy. Controlling and measuring the fluid flow is increasingly incorporated in many applications, from aviation and defense to the pharmaceutical industry.

Passive flow control

Passive flow techniques include geometric shaping, vortex generators, and the placement of grooves or riblets on airfoil surfaces.

Active flow control

Active flow techniques include steady and unsteady suction or blowing and synthetic jets.

Controlling the fluid flow is essential for optimizing and protecting complex systems. Using various technologies to control fluids like air and liquid, fluid control systems and products last longer in demanding environments.

Managing fluid flow systems can be difficult; controlling and managing these systems can be done via multiple techniques and methods.

• Hydrostatic pressure: The idea is to put the inlet reservoir higher than the outlet reservoir to let the gravity force move the fluid from the inlet to the outlet, just like a water tower,
• Pressure pump or regulator: The working principle is to pressurize the sample reservoirs to control the pressure drop between the inlet and the outlet of the microfluidic system,
• Syringe pump: Widely used in standard laboratories, syringe pumps are based on a mechanical system usually actuated by an electric motor that pushes a syringe,
• Peristaltic pump: The liquid is contained in a flexible tube, and alternative compressions and relaxations will draw in the liquid and result in flow,
• Integrated micropump: They are mainly based on a peristaltic principle with flexible membranes.

Within a fluid control system, types of controls can be divided into two main categories: fluid conditioning controls and physical fluid controls. Fluid conditioning controls impact a fluid’s chemistry or chemical condition. Fluid conditioning controls include:

• Suspension control
• Viscosity control
• Contaminant control

Fluid physical controls are those controls that impact a fluid’s movement through the system. Physical controls include:

• Flow control
• Pressure control

Liquid flow controllers are most commonly used in applications that require a constant flow rate and can compensate for varying pressure changes. Because of this functionality, liquid flow controllers will cost more when compared to a liquid flow meter. Liquid flow controllers are utilized for applications requiring micro to low flow rate measurements and control and are used in cases where there is a constant flow rate.

Contamination within the system that controls flow fluid can originate when unwanted water, oil, or other fluid mixes with a fluid or materials in a fluid control system. Contamination most often occurs due to a system that is not flushed correctly.

The flow control industry performance has plateaued in recent years. Given the increasing demand and technological advancements, the flow control industry will rise in innovations.

The most recent flow control innovations include improvements in the steam measurement industry. In recent years, an ultrasonic steam meter got introduced that is both portable and permanent. This steam meter offers a quick installation, built-in data logger, increased accuracy.

In addition to the innovations in the steam measurement industry, the thermal energy industry has also introduced a new meter that offers accurate measuring of fluid velocity and energy consumption. This is one of the few flow sensors that used electromagnetic technology where a conductive liquid moves through a magnetic field to produce a current.

Fluid flow measurements are necessary for a wide range of applications, from the control of fuel flow in engine management systems to the regulation of drug delivery in ventilators. Fluid flow measurements involve the determination of the flow velocity, the mass flow rate, or volumetric flow rate. Fluid flow measurement is divided into several types since each type requires specific consideration of such factors as accuracy requirements, cost considerations, and the use of the flow information to obtain the necessary results.

When deciding on the best type of meter to measure a given flow, the nature of the fluid to be measured needs to be considered. Flow characteristics are also important. In custody transfer metering, the best flow measurement is required.

Whether a liquid or gas, measurement of flow is commonly a critical parameter in many processes, it is essential to know that the proper fluid is at the right place at the right time in most operations. Some critical applications require the ability to conduct accurate flow measurements to ensure product quality.

Direct mass flow measurement is an essential development across the industry as it eliminates inaccuracies caused by the physical properties of the fluid, not least being the difference between mass flow and volumetric flow. Mass is not affected by changing temperature and pressure, which alone makes it an essential method of fluid flow measurement.

A flow meter is an instrument used to measure a liquid or gas’s linear, nonlinear, volumetric, or mass flow rate. Flow meters are referred to by many names, such as flow gauge, flow indicator, liquid meter, flow rate sensor, etc., depending on the particular industry. However, they all measure flow. Like rivers or streams, open channels may be measured with flow meters. Or, more frequently, the most utility from a flow meter and the widest variety of flow meters focus on measuring gasses and liquids in a pipe. Improving fluid measurement precision, accuracy, and resolution are the most significant benefits of the best flow meters.

How do flow meters work?

A flow meter is meant to measure the amount of gas, steam, or liquid passing around or through it. Although there are many kinds of flow meter sensors that work in different ways, they all have one set goal: to give the most accurate flow rate report based on the application. The data could either be for general research, process control, or processing. Flow meters are either used to measure volume or mass.

Types of flow meters

The different categories of flow meters are as follows:

• Positive displacement: (or a volumetric flow meter or PD flow meter): These kinds of meters directly measure the volume – Many volumetric flow meters measure the speed of the flow rather than directly measure the volumetric flow rate
• Mass: Also known as an inertial flow meter. The output signal is directly related to the mass passing through the meter.
• Velocity: The output signal is directly related to the velocity passing through the meter.
  – Electromagnetic
  – Ultrasonic
  – Turbine, Propeller, and Paddle Wheel
  – Vortex Shedding