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Flow Sensor Technical Guide Book
Flow Sensor Technical Guide Book
TECHNICAL
GUIDE BOOK
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
INDEX
Chapter 1
P. 4
Chapter 2
P. 6
Chapter 3
P. 1 4
Chapter 4
PRESSURE LOSS
P. 1 6
Chapter 5
PIPING TECHNIQUES
P. 1 8
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 1
2. COOLING WATER
As mentioned above, "cooling water" is one of the most frequently used applications of water in Factory Automation. Additionally,
due to its role in the prevention of overheating during processing, "cutting water", often referred to as coolant, can be broadly
classified as "cooling water" as well. Opposite to cooling, water may also be used as "insulating water".
Tap water is not generally used because "cooling water" is not for human
consumption. Instead, industrial water is pumped from groundwater or directly
from rivers. Because all water is viewed as a limited and vital resource, it is
generally circulated repeatedly prior to being cleaned and discharged.
Cooling tower
Downstream section
Water flow
Upstream section
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
Pump
CHAPTER 1
80 miles
(=integrated flow "gallons")
The speedometer of the car is instant (instantaneous), and the trip meter and odometer is cumulative (integrated).
MEASURE
NORMAL FLOW
PERFORM ALARM
SETTINGS
1. Run the water and tighten the valve. Then create a pseudo lower limit alarm level.
2. Measure the water after accumulating it in a container. Then confirm if you have found the
instantaneous flow of the lower limit alarm.
3. Once done, perform settings for the flow meter so that it will emit real signals.
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 2
Under Faraday's law of induction, moving conductive liquids inside of a magnetic field
generates an electromotive force (voltage) in which the pipe inner diameter, magnetic field
strength, and average flow velocity are all proportional. In other words, the flow velocity of
liquid moving in a magnetic field is converted into electricity. (E is proportional to V B D)
Core
Exciting coil
Inside an electromagnetic flow meter,
Flow velocity: V
Electromagnetic
flow meter detector
Electromotive force:
E (Voltage)
Measurement pipe
Electrode
As the flow changes, the electromotive force (voltage) captured by the electrodes changes as follows.
Small flow
Large flow
t (time)
t (time)
The light becomes
brighter
Peddling slowly
Peddling quickly
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
PROS
CHAPTER 2
Besides H 2 O (water molecules), Ca 2+ (Calcium ions) and Mg2+ (Magnesium ions) exist
within water. The terms hard water and soft water are determined by the amount of ions
found within a given amount of water.
Because these ions conduct electricity within water, tap water, groundwater and other ion
rich waters possess a property that conducts electricity. Also, since pure water is only H 2 O
and does not contain any impurities, it cannot conduct electricity.
Q U I CK T ECH N I Q U E
When you would simply like to confirm the presence or absence of electrical conductivity,
a standard multi-meter can be used. Place the tester in a mode that measures resistance
values and place both probes into the liquid. If the needle of the tester moves even slightly
towards the zero side, it shows that electricity is flowing.* Conversely, if the needle does not
move from at all, then there is no electrical conductivity. It can be judged that detection
with an electromagnetic flow meter is not possilbe.
*As a precautionary measure, confirmation using an electrical conductivity meter is required.
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 2
Flow
Vortex
shedder
Karman vortex
Vortex
detection
element
CONS
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 2
CONS
Because the paddle wheel spins at high-speeds, periodic maintenance is needed to deal with axial wear
or the paddle wheel must be replaced
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 2
Float
Not suited for fluids that include solids (clogging will occur)
With the directly-read type, the float cannot be seen if the tapered pipe becomes dirty
Heater
Temperature
sensor
Temperature
sensor
Water flow
10
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 2
Small flow
Large flow
The difference in pressure between upstream and downstream is detected using a pressure diaphragm.
Orifice
Water
flow
CONS
Diaphragm
Sensor
Water
flow
CONS
Sensor
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
11
CHAPTER 2
PROS
High-accuracy
High-speed response
CONS
When flowing
Output voltage
Low-density liquid
Output voltage
Output voltage
High-density liquid
T: Mass flow
A: Entrance-side output
B: Exit-side output
T = Proportional to density
12
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 2
Consider cost
Density
Viscosity
Electrical conductivity
Contaminants
Flow range
Fluid temperature
Fluid pressure
Pressure loss
Measured as necessary
Next, clarify the purpose of measurement. At this point, determine a selectable detection system along with properties such as
accuracy and flow range.
Once the detection method has been determined, make a decision while confirming detailed model specifications.
Finally, compare costs. Because removing a flow meter also takes time, you must make a decision that not only considers the
unit price of the product, but also considers maintenance time after installation as well as the cost of set-up or troubleshooting.
Generally when the product unit price is low, frequent maintenance or failure replacement may be required.
Paddle wheel
type
Floating element
type
Thermal type
Coriolis type
Liquid
Available
Available
Available
Available
N/A
Available
Available
Available
Gas
N/A
Available
N/A
Available
Available
Available
Available
Conditional
Vapor
N/A
Available
N/A
Available
N/A
Available
Conditional
N/A
Available
Available
Available
Available
Available
Available
Available
Available
Micro flow
Conditional
N/A
Available
N/A
Available
Conditional
N/A
Available
Medium flow
Available
Available
Conditional
Available
Available
Available
Conditional
Available
Large flow
Available
Available
Conditional
Available
Available
Available
Available
Conditional
Viscosity
Available
N/A
N/A
Conditional
N/A
N/A
Available
Conditional
Slurry
Available
Conditional
N/A
Conditional
N/A
Available
Available
Available
Oil
N/A
N/A
Available
Available
N/A
Available
Available
Available
Accuracy
Available
Available
Conditional
Conditional
Available
N/A
Available
Available
Maintainability
Available
Available
N/A
N/A
N/A
N/A
Available
Available
Pressure loss
Available
Conditional
N/A
Conditional
N/A
N/A
Available
N/A
Air bubbles
Conditional
Conditional
Conditional
Conditional
N/A
N/A
N/A
Available
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
13
CHAPTER 3
1. SCALING
This describes objects created by metallic ions contained in groundwater or tap water that have crystallized and attached to the innerwalls of the piping. They are composed of elements such as calcium, magnesium, and sodium. If buildup of too many layers occurs, the
flow path inside the piping narrows and restricts flow. There is also the possibility that scaling will attach to the inside of the flow meter and
negatively affect its operation. Additionally, for flow meters with mechanical components, it is possible that fragments will break off from
this buildup and result in clogging.
When using floating element and paddle wheel flow meters, the display may no longer be readable or the moving mechanisms may clog. There
are almost no problems with electromagnetic types, but if a thick layer of scaling attaches to the inside of the flow path, eventually the flow meter
could become unable to sense the voltage that has been generated and maintenance would be required.
2. SLUDGE
This is a generic term for foreign objects that exist within the fluid such as suspended matter and sediment. On a production line, this
generally includes chips and abrasive grain coming from a grinding machine. Sludge is constantly circulated along with the fluid and
causes clogging of the flow meter or acts as noise interference. With a flow meter that has mechanical components in the piping, axial
wear and abrasion may occur, and flow may be lowered. Though sludge can be removed using a strainer* or magnetic separator,
complete removal is difficult and maintenance is still required.
*STRAINER
A filter for the purpose of removing
large foreign particles (sludge) in
the fluid. As seen in the illustration
below, the fluid is filtered through
a metallic mesh. The filter can be
removed and cleaned.
With an electromagnetic type flow meter, the flow pipe has a free-flowing
structure, so accumulation and clogging does not occur. Sludge colliding with
the "wetted" electrodes can create interference. However, the effects can be
limited by utilizing an electromagnetic flow sensor with "non-wetted" electrodes.
Also, flow sensors that can adjust the response time and sampling frequency
are less vulnerable.
3. RUST
Different from scaling, this is when oxidation occurs within the pipes. Corrosion-inhibitors can be added
to the fluid to prevent rust, but if pipes that are not in use come into contact with air, rust will occur. Once
water flows through the pipes again, the rust turns into fragments, which flake off and become the cause
of clogging inside the flow meter or attach to the window sections of floating element flow meters.
4. SLIME
This involves living matter such as algae and microorganisms in the water. It is sticky, and mud-like. Similar to scaling, clogging and
obstructions will occur in paddle-wheel types, along with limiting the visible portion of the floating element type meters.
With an electromagnetic type flow meter, the flow pipe has a free-flowing structure, so accumulation
and clogging does not occur. Also, because the slime itself possesses electrical conductivity,
detection remains possible.
14
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 3
For flow meters that obstruct flow (i.e. karman vortex models), the slurry
may cause axial wear and clogging. With an electromagnetic type flow
meter, wear and clogging are minimal due to the free-flowing structure of
the unit. Slurry detection is also possible using Coriolis type flow meters.
6. AIR BUBBLES
When dealing with an open system, it is possible for air to be introduced into the system during liquid intake. Air or impurities that have
blended into the liquid cause bubbles. For a vortex flow meter, these bubbles disturb the creation of Karman vortices. For an ultrasonic
flow meter, they inhibit the propagation of ultrasonic waves. Both cases result in malfunctions.
Air bubbles
Since Coriolis type flow meters measure mass flow, they are unaffected by air bubbles. For
electromagnetic type flow meters, bubbles can cause unstable flow readings. This is due to the
fact that detection is based on volume and the bubbles are mistaken for fluid.
Water
Flow
Drifting flow
away from the center of the pipe. Swirl flow occurs when the fluid
rotates around a center axis, parallel to the direction of flow. Both
swirling and drifting cause irregular distributions of flow velocity.
Performing flow measurements in these conditions may lead to large
measurement errors.
8. PULSATING FLOW
If the pulsations are large, the instantaneous flow may temporarily exceed
the rated flow range of the flow meter. In this situation, the flow displayed
on the flow meter is smaller than the actual flow. Volume type reciprocating
9. PIPING VIBRATION
Piping vibration is commonly caused by machine
vibration, opening and closing of valves, and even the
transmission of the fluid itself.
With Coriolis and Karman vortex type flow meters, the flow may not be properly
measured due to vibration. With electromagnetic and ultrasonic type flow meters,
there are essentially no problems caused by vibration. (With ultrasonic type flow
meters, there is such a large difference between the frequencies of the ultrasonic
waves, piping vibrations can be ignored.)
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
15
CHAPTER 4
PRESSURE LOSS
1. WHAT IS PRESSURE LOSS?
As an example, if part of the flow path is restricted, the downstream pressure will reduce starting from the restricted area.
This is called pressure loss. Pressure loss is energy loss and not only is downstream pressure lowered, but flow, and flow velocity
are reduced as well.
When pressure loss occurs on a production line, the flow of circulating cooling water is lowered, causing a variety of quality
and production problems. To correct this, it is best to remove the part that is creating the pressure loss. However, in most cases
pressure loss is reactively handled by raising the pressure generated by the circulation pump and/or raising the power of the
pump itself. This measure results in a waste of energy and unecessary cost.
Diaphragm type
Electromagnetic type
Free-flowing
16
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 4
PRESSURE LOSS
2. FACTORS THAT CAUSE PRESSURE LOSS
[1] NARROWING THE PIPE DIAMETER
Restricting the flow path means that piping joints with different diameters will result in pressure loss.
Globe valve
Closed
Water Flow
Open
Open
Water Flow
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
17
CHAPTER 5
90 bent pipe
Expanding pipe
Flow meter
T-pipe
Flow meter
Flow meter
Be sure to install a straight pipe section equivalent to 5 times the bore diameter upstream from the flow meter. This section limits turbulence in the
liquid and creates uniform flow. * Regarding the irregular distribution of flow velocity, refer to Chapter 3, Section 7.
Air bubbles
Flow sensors best measure flow when the flow path is in a full volume state. Water accumulates in lower sections due to gravity. When water
flows in piping like the illustrations above and below, a full volume state is maintained.
18
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
CHAPTER 5
Air bubbles
Open
Closed
Closed
Flange
Valve
Open
Closed
FLOW S EN S O R T E C H N I C A L G U I D E B O O K
19
3/8" RC/NPT
1" RC/NPT
3/4" RC/NPT
2" RC
Electrical conductivity
: 5 S/cm or more
Wetted materials
Withstanding pressure
[2 MPa]*
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