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Orifice Plates

Of all the pressure-based flow elements in existence, the most common is the orifice plate. This is simply a metal plate with a hole in the middle for fluid to flow through. Orifice plates are typically sandwiched between two flanges of a pipe joint, allowing for easy installation and removal:

 

The point where the fluid flow profile constricts to a minimum cross-sectional area after flowing through the orifice is called the vena contracta, and it is the area of minimum fluid pressure. The vena contracta corresponds to the narrow throat of a venturi tube. The precise location of the vena contracta for an orifice plate installation will vary with flow rate, and also with the beta ratio (β) of the orifice plate, defined as the ratio of bore diameter (d) to inside pipe diameter (D):

 

The simplest design of orifice plate is the square-edged, concentric orifice. This type of orifice plate is manufactured by machining a precise, straight hole in the middle of a thin metal plate. Looking at a side view of a square-edged concentric orifice plate reveals sharp edges (90o corners) at the hole:

 

 

Square-edged orifice plates may be installed in either direction, since the orifice plate “appears” exactly the same from either direction of fluid approach. In fact, this allows square-edged orifice plates to be used for measuring bidirectional flow rates (where the fluid flow direction reverses itself from time to time). A text label printed on the “paddle” of any orifice plate customarily identifies the upstream side of that plate, but in the case of the square-edged orifice plate it does not matter.

The purpose of having a square edge on the hole in an orifice plate is to minimize contact with the fast-moving moving fluid stream going through the hole. Ideally, this edge will be knife-sharp. If the orifice plate is relatively thick (1/8 or an inch or more), it may be necessary to bevel the downstream side of the hole to further minimize contact with the fluid stream:

 

 

Looking at the side-view of this orifice plate, the intended direction of flow is left-to-right, with the sharp edge facing the incoming fluid stream and the bevel providing a non-contact outlet for the fluid. Beveled orifice plates are obviously uni-directional, and must be installed with the paddle  text facing upstream.

Other square-edged orifice plates exist to address conditions where gas bubbles or solid particles may be present in liquid flows, or where liquid droplets or solid particles may be present in gas flows. The first of this type is called the eccentric orifice plate, where the hole is located off-center to allow the undesired portions of the fluid to pass through the orifice rather than build up on the upstream face:

 

 

For gas flows, the hole should be offset downward, so any liquid droplets or solid particles may easily pass through. For liquid flows, the hole should be offset upward to allow gas bubbles to pass through and offset downward to allow heavy solids to pass through.

The second off-center orifice plate type is called the segmental orifice plate, where the hole is not circular but rather just a segment of a concentric circle:

 

 

As with the eccentric orifice plate design, the segmental hole should be offset downward in gas flow applications and either upward or downward in liquid flow applications depending on the type of undesired material(s) in the flowstream.

An alternative to offsetting or re-shaping the bore hole of an orifice plate is to simply drill a small hole near the edge of the plate, flush with the inside diameter of the pipe, allowing undesired substances to pass through the plate rather than collect on the upstream side. If such a hole is oriented upward to pass vapor bubbles, it is called a vent hole. If the hole is oriented downward to pass liquid droplets or solids, it is called a drain hole. Vent and drain holes are useful when the concentration of these undesirable substances is not significant enough to warrant either an eccentric or segmental orifice:

 


The addition of a vent or drain hole should have negligible impact on the performance of an orifice plate due to its small size relative to the main bore. If the quantity of undesirable material in the flowstream (bubbles, droplets, or solids) is excessive, an eccentric or segmental orifice plate might be a better choice1.

Some orifice plates employ non-square-edged holes for the purpose of improving performance at low Reynolds number2 values, where the effects of fluid viscosity are more apparent. These orifice plate types employ rounded- or conical-entrance holes in an effort to minimize the effects of fluid viscosity. Experiments have shown that decreased Reynolds number causes the flowstream to not contract as much when traveling through an orifice, thus limiting fluid acceleration and decreasing the amount of differential pressure produced by the orifice plate. However, experiments have also shown that decreased Reynolds number in a venturi-type flow element causes an increase in differential pressure due to the effects of friction against the entrance cone walls. By manufacturing an orifice plate in such a way that the hole exhibits “venturi-like” properties (i.e. a dull edge where the fast-moving fluid stream has more contact with the plate), these two effects tend to cancel each other, resulting in an orifice plate that maintains consistent accuracy at lower flow rates and/or higher viscosities than the simple square-edged orifice.

Two common non-square-edge orifice plate designs are the quadrant-edge and conic-entrance orifices. The quadrant-edge is shown first:

 

 

The conical-entrance orifice plate looks like a beveled square-edge orifice plate installed backwards, with flow entering the conical side and exiting the square-edged side:

 

Here, is it vitally important to pay attention to the paddle’s text label. This is the only sure indication of which direction an orifice plate needs to be installed. One can easily imagine an instrument technician mistaking a conical-entrance orifice plate for a square-edged, beveled orifice plate and installing it backward!

Several standards exist for pressure tap locations. Ideally, the upstream pressure tap will detect fluid pressure at a point of minimum velocity, and the downstream tap will detect pressure at the vena contracta (maximum velocity). In reality, this ideal is never perfectly achieved. An overview of the most popular tap locations for orifice plates is shown in the following illustration:

 

 
 
 

Flange taps are the most popular tap location for orifice meter runs on large pipes in the United States. Flanges may be manufactured with tap holes pre-drilled and finished before the flange is even welded to the pipe, making this a very convenient pressure tap configuration. Most of the other tap configurations require drilling into the pipe after installation, which is not only labor-intensive, but may possibly weaken the pipe at the locations of the tap holes.

Vena contracta taps offer the greatest differential pressure for any given flow rate, but require precise calculations to properly locate the downstream tap position. Radius taps are an approximation of vena contracta taps for large pipe sizes (one-half pipe diameter downstream for the low-pressure tap location). An unfortunate characteristic of both these taps is the requirement of drilling through the pipe wall. Not only does this weaken the pipe, but the practical necessity of drilling the tap holes in the installed location rather than in a controlled manufacturing environment means there is considerable room for installation error3.

Corner taps must be used on small pipe diameters where the vena contracta is so close to the downstream face of the orifice plate that a downstream flange tap would sense pressure in the highly turbulent region (too far downstream). Corner taps obviously require special (i.e. expensive) flange fittings, which is why they tend to be used only when necessary.

Care should be taken to avoid measuring downstream pressure in the highly turbulent region following the vena contracta. This is why the pipe tap (also known as full-flow tap) standard calls for a downstream tap location eight pipe diameters away from the orifice: to give the flow stream room to stabilize for more consistent pressure readings4.

Wherever the taps are located, it is vitally important that the tap holes be completely flush with the inside wall of the pipe or flange. Even the smallest recess or burr left from drilling will cause measurement errors, which is why tap holes are best drilled in a controlled manufacturing environment rather that at the installation site where the task will likely be performed by nonexperts.

For relatively low flow rates, an alternative arrangement is the integral orifice plate. This is where a small orifice plate directly attaches to the differential pressure-sensing element, eliminating the need for impulse lines. A photograph of an integral orifice plate and transmitter is shown here:

 

The task of properly sizing an orifice plate for any given application is complex enough to recommend the use of special orifice sizing computer software provided by orifice plate manufacturers. There are a number of factors to consider in orifice plate sizing, and these software packages account for all of them. Best of all, the software provided by manufacturers is often linked to data for that manufacturer’s product line, helping to assure installed results in close agreement with predictions.

In the days before ubiquitous personal computers and the internet, some orifice plate manufacturers provided customers with paper “slide rule” calculators to help them select appropriate orifice plate sizes from known process parameters. The following photographs show the front and back sides of one such slide rule:

 

 
 

 

1L.K. Spink, in his book Principles and Practice of Flow Meter Engineering, notes that drain holes intended to pass solid objects may be useless in small pipe sizes, where the hole is so small it will probably become plugged with solid debris and cease to provide benefit. In such installations he recommends re-orienting the pipe vertically instead of horizontally. This allows solids to pass through the main bore of the orifice without “damming” on the upstream side of the orifice plate. I would add the suggestion to consider a different primary element entirely, such as a venture tube. The small size of the line will limit the cost of such an element, and the performance is likely to be far better than an orifice plate anyway.

2To read more about the concept of Reynolds number, refer to Viscous Flow, Reynolds Number article.

3One significant source of error for customer-drilled tap holes is the interior finish of the holes. Even a small “burr” of metal left where the hole penetrates the inner surface of the pipe wall will cause substantial flow measurement errors!

4What this means is that a “pipe tap” installation is actually measuring permanent pressure loss, which also happens to scale with the square of flow rate because the primary mechanism for energy loss in turbulent flow conditions is the translation of linear velocity to angular (swirling) velocity in the form of eddies. This kinetic energy is eventually dissipated in the form of heat as the eddies eventually succumb to viscosity.

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Comments (6)Add Comment
0
Orifice plate Sizing
written by Kristopher Manasco, May 29, 2012
I have been working on orifice plate experiments and ran into a wall. I used the Crane TP 410 for theoretical flow rate with a given orifice plate, the diameter is < 0.5 inch which is a parameter for using Crane I am getting faster flow rate than anticipated by over 20-30%, so for such problems what suggestions could you give to either find relevant equations or data from somewhere else. The orifice plate is square edged with a downstream bevel.
0
orifice plate detail
written by v.uppliyappan, February 03, 2013
what is the inside diameter for 4inch dia orifice plate to measure air flow.
0
..air lock issues...
written by jeevah, February 21, 2013
I m working solve a airlock issue at a 12" PVC pipeline for a wave pool at a theme park....the wave water that is being sucked in by the suction pump causes a water hammer/ air pocket....after studying this article... I was wondering if a orifice & a check valve could solve my issue where the wave water shall be calmed by the orifice initially & sending in calm water into the suction pipeline...terminating the root of air lock contribution...
0
Staff Engineer
written by Sean Kelly, April 13, 2015
I have a question as to the production of an 8” orifice plate for a water distribution system. Currently, we have a project with a design engineer who has specified an 8” orifice to be installed with a flow coefficient value equal to 500 (Cv=500). Can an orifice be manufactured based off this sole requirement?
Thank you for your time and I look forward to hearing from you,
0
Orifice Plate installed reverse direction what symptom will be effect
written by Alex, April 06, 2016
sir
FIC Control puenmatic loop (spill back) frac. Pump 108A/B flow valve (FTO) ATO but commissioned this loop when we put the puenmatic controller in Auto mode the PV goes in too 0 zero and valve start to open 100% Actually it is designed for that flow decrease according to setpoint 12 bpd the valve open to a desire setpoint to manipulated it. What I feel and took a decision the line in too height I told that required scraffolding to confirm the orifice flow direction. Or others any reasons it send me urs positive comment to my above mail mentioned.
0
...
written by Iñaki, January 20, 2018
If you are interested in this subject I wrote an article two years ago. Please, read it here:

http://instrumentationandcontr...ientation/

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