EXECUTIVE SUMMARY
Aerofoil is specially designed to measure flow through square/rectangular duct, where other
flow meters like Orifice, Flow Nozzle, Venturi etc. cannot be used.
The name itself explains that, the flow meter uses the Aircraft wing shaped foil obstruction
which creates pressure drop. Aerofoil is constructed with at least 02 numbers of foils. The
piezometric ring arrangement is connected inside the foil, which gives averaged pressure
readings for both HP & LP side. The difference between these two readings will give the DP
& in turn the flow reading.
Application
• Steel Plant
• Power plant
• Sugar industry
Features
• Specially designed for rectangular ducts
• It can be used for the fluid having dust particles
• Short upstream and downstream requirement
• Less maintenance
• Low permanent pressure loss
Table of Contents
1. Definition
1.1. Technical review
1.2.Design requirements
2. Design Description
2.1. Overview
2.2.Flow rate measurement
3. Evaluation
3.1. Overview
3.2. Prototype
3.3. Testing
3.4. Assessment
4. References
1. Definition
Aerofoil development is very important hence the enquires receiving for the same is
quietly high and the response getting from vendors are poor. This in-house
development will be reducing the dependency to our sub vendor (competitors) and it
has huge potential in cement plant and thermal power plants.
1.1. Technical review
Aerofoil is normally to measure the flow rate in rectangular ducts and the flow are
shall be rectangular in shape. The existing products which we are manufacturing are
for measuring he flow rate in circular pipes. So the beta calculation for aerofoil shall
be bit complex.
And also for aerofoil, there is no written standard for calculation and manufacturing.
1.2. Design Requirements
Hence the measurement technology is similar to our existing product range, our
engineering experience and knowledge will be use for the development of the
instrument. Also from the earlier calculations and drawings provided by our sub
vendor shall be use for reverse engineering.
Solidworks simulation software and calibration shall be use for the validation of the
aerofoil.
The calculation of aerofoil has to be in-line with the simulation calibration results.
Our aim to achieve the calculation results shall be within ±10% of simulation results
and ±5% of calibration results.
2. Design Description
2.1. Overview
The basic principle of aerofoil to measure flow rate is Bernoulli’s principle.
Bernoulli's principle states that an increase in the speed of a fluid occurs
simultaneously with a decrease in pressure or a decrease in the fluid's potential energy
Bernoulli's principle can be derived from the principle of conservation of energy. This
states that, in a steady flow, the sum of all forms of energy in a fluid along
a streamline is the same at all points on that streamline. This requires that the sum
of kinetic energy, potential energy and internal energy remains constant. Thus an
increase in the speed of the fluid – implying an increase in both its dynamic
pressure and kinetic energy – occurs with a simultaneous decrease in (the sum of)
its static pressure, potential energy and internal energy. If the fluid is flowing out of a
reservoir, the sum of all forms of energy is the same on all streamlines because in a
reservoir the energy per unit volume (the sum of pressure and gravitational
potential ρ g h) is the same everywhere.
2.2. Flow Rate Measurement
After derived from Bernoulli's equation and mass conservation, the flow rate shall be,
𝜋𝐷 2 𝛽 2
Qm = 𝐶𝑑 . ɛ. √2𝛥𝑃𝜌
4√1−𝛽 4
Cd = Discharge Coefficient
ɛ = Expansion factor
D = Pipe Internal Diameter
ΔP = Differential Pressure
ρ = Mixture density
β = Beta Ratio
3. Evaluation
3.1. Overview
The strength of the aerofoil shall be evaluated by hydrostatic test after all welding,
and the performance evaluation shall be by to methods
1. By 3D model simulation
2. By Wet calibration
3.2. Prototype
The 3D model of aerofoil has prepared in solidworks. All the manufacturing prospects
shall be considered in the 3D model.
The prototype of the same dimensions has been manufactured, and the quality
department shall be check with the 3D model dimensions.
3.3. Testing
The CFD analysis of the 3D model has been carried out and attached the results as
Annexure-2
The calibration of the prototype shall be carried out at FCRI, Palakkad
Assessment
The results from simulation has come in-line with requirement of design, so the
design calculation as per above design description is acceptable for Aerofoil.
The calibration is pending, it will reduce the uncertainty in our calculation results.
4. References:
1. ISO, Measurement of fluid flow by means of pressure differential devices inserted in
circular-cross section conduits running full – Part 1-5: ISO 5167-1 2003.
APPENDIX-1
Rev 00
Aerofoil Customer __
Offer No Sample
Tag No: AF Sample
Service Air Rev
Duct Size [W x H] 1000 1000 mm
Pipe Material / Thermal Exp Co-ef IS 2062 0.000012 mm/°C
Element Material / Thermal Exp Co-ef IS 2062 0.000012 mm/°C
Beta β 0.5737
Throat Height h 164.551 mm
Throat Width w 1000.000 mm
Throat Length l 1128.265 mm
Fluid Air Base
Temperature T 25 0 °C
Inlet Pressure p1 1.500 1.0332 Kg/cm2
Density ρ 1.719 __ Kg/m3
Specific Heat Ratio ƙ 1.40
Expansion Factor ε 0.9958
Viscosity η 0.018000 cP
Co-efficent of discharge Cd 0.895886
Velocity of Approach 1.0590
Flow Coeffient 0.9488
TMCR BMCR Design
Flow Rate Kg/hr Q 32500.00 52000.00 65000.00
Inlet Velocity m/s V1 5.25 8.40 10.50
Differential Pressure mmwc dP 25.00 64.00 100.00
Permanent Pressure Loss mmwc PPL 2.55 6.54 10.22
Volume Flow Rate m3/s Qa 5.2518 8.4028 10.5035
Reynolds No (duct) ReD 565873 905398 1131747
Reynolds No (Throat) Red 400166 640266 800332
Uncertainty Uncertainty in Flow Rate : ±5% (uncalibrated)
in Discharge Coefficient : ±5% (uncalibrated)
Prepared By: VP Checked & Approved BY:
Date: 07/04/2015 Date:
APPENDIX-2
FULL REPORT
Document1 Page 1 of 4 11.09.2015
