How to Avoid

Flow Meter
Trouble
Countermeasures Learned
from Operating Principles

Types of Flow Meters and Flow Sensors &

Their Operating Principles

ULTR ASONIC WAVES METHOD

ELECTROMAGNETIC METHOD
Excitation coil

Ultrasonic element

Ultrasonic element

Velocity of
flow: V

Core

Electromagnetic
flow meter

Electromotive
force: E

Detector
V

Water flow

E
B

Excitation coil

The majority of ultrasonic flow meter products currently on the market are
"propagation time difference types."

Disadvantages

No pressure loss
With some types, flow can be detected outside of the
piping.

Advantages

Straight section of pipe is required

Excessive solids in fluid may cause malfunction
Measurement is impossible if the target fluid contains
lots of bubbles

CORIOLIS METHOD

Disadvantages

A'

Not strongly influenced by changes in fluid temperature,

pressure, density, or viscosity
Fluid containing solids or air bubbles can be
detected
Little pressure loss
No moving parts (good maintainability)
Gas or non-conductive fluids cannot be detected
Straight section of pipe is required

K ARMAN VORTEX METHOD

When the fluid is flowing

B

Magnetic field
(Magnetic field
strength: B)

Electromagnetic method flow meters, as their name implies, use Faraday's

law to detect flow. According to Faraday's law, when conductive fluid
flows through a magnetic field, electromotive force (voltage) is generated
in proportion to the the flow rate. The flow rate can be calculated by the
following equation:
"the inner.diameter of the pipe x the magnetic field strength x the average
flow velocity of the fluid"
In other words, the "velocity of flow" moving through a magnetic flux band
is converted to electricity.

[Propagation time difference type] (example of reflective model)

Ultrasonic waves are emitted in the upwards and downwards direction to
the direction of fluid progression by two ultrasonic elements. The ultrasonic
waves that are reflected back inside the piping are received by each of these
elements. The ultrasonic waves in the fluid are transmitted slowly if they
go against the flow and fast if they are carried by the flow. The difference
between these two propagation times is converted to velocity of flow.

Advantages

Fluid
Measuring pipe
Electrode

B'

Flow

When the fluid is not flowing

A

Resonance

A'

Vortex generator
Vortex sensing element

B'

Flow

Coriolis method flow meters use Coriolis' force, a physical phenomenon,

A'
inside theA meterB to detect flow.
When fluid flows through a vibrating U-pipe

as shown in the figure above, Coriolis' force in

the opposite direction acts
between inlet side A and exit side B, andB'causes the pipe to twist. Coriolis'
force is proportional to the mass and speed of an object, so the mass flow
can be known by measuring the torsional amount of the pipe.

Advantages

Disadvantages

High precision
Mass flow can be measured
Requires no straight section of pipe
High-speed response
Highly viscous fluids can be detected
Density can be measured
More expensive compared with other principles of detection
Large pressure drop
Susceptible to the influence of vibration

Karman vortex street

This type is broadly classified as vortex flow meters, which use a

law that was proved theoretically in 1912 by Karman. When there is
an obstacle (vortex generator) in a flowing fluid, mutual vortices are
generated downstream. The frequency at which the vortex is generated
is in proportion to the velocity of the flow. This means that flow can be
measured by detecting the number of vortices. Picking up the vibration of
the vortices by a piezo-electric device is the main detection method used
to detect the number of vortices. Another method is to detect vortices by
ultrasonic waves.

Advantages

Disadvantages

No mechanical moving parts

Gases, fluids and vapors can be detected
Some types have excellent chemical resistance due to the
absence of an electrode
Large sensing ranges, good accuracy
Pressure loss occurs since flow path is constricted
(Flow path cannot be constricted on some types.)
Elution of scale and fluids containing solids cause "clogging."
Unsuitable for highly viscous fluids
Sensitive to piping vibration
Straight section of pipe is required

THERMAL METHOD

DIAPHR AGM METHOD

Orifice

Heater
Temperature sensor

Temperature sensor
Water flow

Water flow

Diaphragm

When a fluid comes into contact with a hot object, the object loses heat
and the temperature of the fluid rises. Thermal type flow meters use this to
measure flow. Thermal type flow meters are divided into two types.
Temperature difference measurement method...
The fluid temperature is measured by a heater installed in the fluid at
two points, upstream and downstream. The flow is calculated from the
temperature difference between the two points. This type is mainly suited
for small flows.
Power consumption measurement method...
The fluid temperature is measured by a heater installed in the fluid at two
points, upstream and downstream. The heater is controlled so that the
temperature difference between the two points is constant at all times.

Advantages

Disadvantages

Gases can be detected

Basically no pressure loss
Mass flow can be measured
Error occurs when fluid temperature changes
Troublesome to determine specifications matched to fluid type
and composition

PADDLE WHEEL TYPE

This type is broadly classified as a differential pressure type flow meter.

Differential pressure type flow meters are currently one of the most
common mass-produced flow meters. These flow meters operate according
to Bernoulli's principle as follows. An orifice (throttle) is placed in the
path of the flow which intentionally generates pressure loss. The pressure
difference (differential pressure) before and after this orifice is calculated to
detect the flow. A diaphragm is placed upstream and downstream to detect
the pressure difference caused by pressure loss.

Advantages

Disadvantages

Gases, fluids and vapors can be detected

Generally, low-priced
No moving parts
Large pressure loss occurs since there are orifices
Not suited to fluids that contain solids
Long straight section of pipe required since they are
sensitive to turbulence

FLOATING ELEMENT TYPE

Magnetic Sensing Element

Float
Visual scale
Magnet on tip of paddle wheel

This type is broadly classified as turbine flow meters. These are classified
into two types due to their structure, "tangential flow impeller-type"
designed in a waterwheel structure and "axial flow impeller-type"
designed in a windmill structure, respectively.
Rotation of the impellers is proportional to flow at all times. Accordingly,
the impellers are rotated by the force that causes the fluid to flow, and flow
can be measured by the rotation speed of the impellers. To obtain a rotation
speed count, a magnet is embedded in the tip of the impeller or rotating
shaft so that a pulse can be extracted as a signal, which is then converted to
flow.

Advantages

Disadvantages

Excellent reproducibility (repeatability) and responsiveness

Simple structure, cheap
Small but capable of measuring large capacities
Sensitive to foreign particles (Can cause clogging)
Periodically requires maintenance due to shaft wear, etc.
since the paddle wheel rotates at high speed

This type is broadly classified as variable area flow meters. The main
method used is to suspend a float inside a taper tube (tube that gradually
expands in diameter towards the upper side). When a fluid passes in
between the taper tube and the float, a differential pressure is generated.
At this time, the float comes to a stop when "upward force caused by the
differential pressure" and "downward force caused by the float weight"
balance each other out, which means that instantaneous flow is indicated.
Generally, the "floating element type flow meters" that are commonly
seen use a taper pipe made of transparent material which has a flow scale
attached so that flow can be directly read. Sometimes, the float also has a
built-in magnet so flow can be detected by a magnetic sensor.

Advantages

Disadvantages

Gases, fluids and vapors can be detected

Generally, low-priced
Relatively little pressure loss
Accuracy not very high
Not suited to fluids that contain solids
Flow not visible if taper pipe is dirty on direct readout types

Trouble
Causes of Trouble on Flow Meters and Flow Sensors

SCALE

Disassemble and perform maintenance

RUST

Smooth operation is
sometimes lost by shaft
wear or clogging with dirt.

Overview

The indication on the pipe cannot be seen at all due to scale contained in
cooling water.

Rust is different from scale in that rust occurs due to

oxidation on the inside of iron pipes. Although a corrosion
inhibitor can be added to the fluid to prevent rust from
forming, if plastic formed parts are left unused for some
time, the inside of the water flow pipe is exposed to air which
may cause rusting. When water is again passed through the
pipe, fragments of rust break off the inside of the pipe.

Overview

Scale is the result of metal ions contained in ground water or tap water
crystallizing and sticking to the inside wall of piping. Typical main components
of scale are calcium, magnesium and sodium. When layers of scale build up, it
results in narrowing of the cross-sectional area of the flow path inside piping,
which causes flow to drop.
Influence on flow meters/flow sensors

Scale might also stick to the inside of flow meters, and scale fragments that
break off might cause clogging. On floating element type or paddle wheel type
flow sensors, scale sometimes prevents the indication from being seen or causes
clogging of rotating mechanisms.

Influence on flow meters/flow sensors

Fragments of rust that have broken off the inside of the pipe
cause clogging inside the flow sensor. This also can impair
the ability to read the flow on transparent meters, such as
floating element type flow meters. Additionally, with flow
sensors such as paddle wheel type, that have resistance
inside the piping, these fragments might cause shaft wear
and cause flow to drop.

SLIME
SLUDGE
Overview
*Strainer
This is a filter for removing large
refuse or foreign matter (i.e. sludge).
Fluid is filtered by being passed
through a metal filter as shown in the
figure on the right. The filter can be
removed for cleaning.

This refers to products caused by algae, microorganisms

and other living creatures in water. Slime is of a sticky and
muddy consistency.
Influence on flow meters/flow sensors

Slime might clog mechanical type flow meters.

Overview

This is a generic term for floating matter, sediment or other fine foreign matter in
fluids. On product lines, this generally refers to very fine chips or abrasive grain
refuse, for example, that is generated by grinders or other machine tools. In the
broader sense of the word, mud or earth and sand mixed into water also are types
of sludge. Sludge is circulated together with the fluid, causing clogging causing
and disturbance as a noise component. A strainer*, magnet separator or other
separation device is used to remove sludge from fluid. However, it is difficult to
completely remove it all.
Influence on flow meters/flow sensors

With flow meters that have an electrode built into the sensor, sludge becomes
a noise component when it collides with the electrode. Also, with flow sensors
such as paddle wheel types, these fragments might cause shaft wear and cause
flow to drop.

Slurry
Overview

Slurry is a generic term for fluid containing a uniform

concentration of solid particles, such as fluids
containing abrasive compounds.
Influence on flow meters/flow sensors

On flow meters that have pipe resistance, wear inside the

flow meter or clogging due to solidification sometimes
occurs.

Solution
Technique for Avoiding Trouble

Selection-related point

Example of ultrasonic waves method ... Detection from outside piping

Selection of an "ultrasonic waves method" sensor

that can detect flow in a non-contact manner or
"electromagnetic method" sensor that can adopt
a through structure, helps prevent trouble from
occurring. This is because the sensor itself never
causes clogging.

Ultrasonic element

Ultrasonic element

Water flow

Also, if a digital type sensor is used, there is no

worry about visibility or "not being able to read the
flow meter's scale because of foreign matter or dirt
adhering to it".
With "electromagnetic method" sensors, if a sensor
has non-immersion type electrodes, the influence
of sludge or other noise elements can further be
alleviated.

Example of electromagnetic method

Less likely to clog

No moving parts

Piping remedy
Equipment downtime can be minimized by installing a bypass line in advance, such as that in the figure below. This helps in
case of any unexpected clogging or maintenance needs to be performed inside the flow meter.

Open

Open

Flange

Closed

Closed

Closed

Maintenance is easy!

Valve

Open

Trouble

Solution

Causes of Trouble on Flow Meters and Flow Sensors 2

Technique for Avoiding Trouble 2

Air bubbles

Selection-related point
With the "Coriolis Method," there is never malfunction
due to air bubbles and net flow excluding air bubbles
can be detected because mass flow is measured.

Air bubbles

Water flow

Piping remedy
1. By adjusting a valve on the secondary side of the
flow sensor, internal pressure is applied to the
fluid, which sometimes causes air bubbles to
dissipate and alleviate the problem.
2. Air bubbles gather at the top of water. Mixing in
of air bubbles can be prevented by venting piping
as shown in the figure below.

Overview

Air bubbles are generated in a fluid by being taken in together when

a fluid is introduced from an intake port or by air or impurities
dissolved in a fluid forming and gathering due to changes in
pressure or temperature and other factors.

Air bubbles

Influence on flow meters/flow sensors

With vortex type flow meters, generation of Karman vortex causes

air bubbles, and with ultrasonic waves method flow meters, air
bubbles obstruct the propagation of ultrasonic waves and causes
malfunction. With the electromagnetic method, flow sometimes
becomes unstable.

Air bubbles

L
L

Trouble

Solution

Causes of Trouble on Flow Meters and Flow Sensors 3

Technique for Avoiding Trouble 3

Nonuniform velocity of flow

Selection-related point
The degree of measurement error is the degree
of nonuniformity of the velocity flow distribution.
Install a straight section of pipe at the upstream or at
both the upstream and downstream to make velocity
flow distribution uniform, and then measure flow.
(A rough guide is 5x the piping inner diameter)

Water flow

Swirl flow

Water flow

Uniform

Drift

Piping remedy
L=5 diameter or more

Overview

The velocity flow distribution inside circular piping becomes uniform

after the fluid has sufficiently passed through the straight section of
pipe. However, bends in the pipe or changes in pipe diameter cause
velocity flow distribution to become nonuniform. Drift is where
the velocity of the flow distribution shifts from the center of the
piping. Swirl flow is where the fluid flows while rotating around a
shaft parallel to the direction of flow. Drift and swirl are examples of
nonuniform velocity flow distribution.

90 vent

L is the length of the straight section of pipe,

and D is the nominal diameter of the body.

Expander
Flow meter

Tee

Flow meter

Flow meter

Gate valve fully open

Influence on flow meters/flow sensors

When flow is measured in this state, a measurement error might

appear whichever sensor is used.

Flow meter

Trouble

Solution
Technique for Avoiding Trouble 4

Causes of Trouble on Flow Meters and Flow Sensors 4

Vibr ation on piping

Selection-related point
With the electromagnetic method or ultrasonic
waves method, vibration is basically not a problem.
With the ultrasonic waves method, the influence of
vibration can be ignored since the frequencies of the
ultrasonic waves and pipe vibration are considerably
different.

Ultrasonic element

Ultrasonic element

Water flow

Overview

The piping itself vibrates when fluids are allowed to pass or the
valve is opened or closed. Also, vibration from ancillary facilities
and equipment also may be transmitted to the piping.

Influence on flow meters/flow sensors

Piping remedy
Pipe vibration applied to the sensor itself is
alleviated by securing the piping immediately
before and after the flow meter to the equipment,
etc.

Secure piping to
equipment, etc.

With the Coriolis method and Karman vortex method, vibration

sometimes prevents flow from being measured correctly.

Also, with the Coriolis method, the influence of

vibration might be alleviated by installing the flow
sensor between vibration-proof rubber.

Example of vibration-proof mounting bracket for a KEYENCE Coriolis method flow sensor

Ultrasonic Waves Method

Clamp-on Flow Sensor FD-Q Series

Pipe is not cut

Flow sensor

www.keyence.com

www.keyence.com

Copyright
Copyright (c)
(c) 2015
2015 KEYENCE
KEYENCE CORPORATION.
CORPORATION. All
All rights
rights reserved.
reserved.

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