The Importance and Uses of Variable Area Flowmeters (Rotameters) in Industrial Applications

Variable area flowmeters, known as rotameters, have long been a staple in various industries, from chemical processing to water treatment. They offer a simple yet effective method for measuring the flow rate of liquids and gases. Understanding the importance and the vast array of applications they serve can underscore the reason behind their continued relevance in the industrial landscape.

How Does a Rotameter Work?

Before diving into its uses and importance, it's essential to grasp the basic operation of a rotameter. A rotameter consists of a tapered tube, typically made of glass or clear plastic, with a float inside. As fluid flows through the tube, it raises the float. The float's height corresponds to the flow rate, read from a scale marked on the tube.

The float's upward movement is due to the balance between the buoyant force exerted by the fluid and the gravitational force pulling the float downwards. When these forces reach equilibrium, the float stabilizes at a particular height, allowing for flow rate measurement.

Importance of Rotameters in Industrial Applications

Simplicity and Reliability: Rotameters have no moving parts other than the float itself, resulting in less wear and tear and ensuring a long service life. Their simple design means fewer points of failure, translating to increased reliability.

• Cost-Effective: Due to their uncomplicated design and construction, rotameters are generally more affordable than many other flowmeter types, making them a preferred choice for applications where cost is a significant concern.
• Direct Readout: Rotameters provide an immediate visual indication of the flow rate, eliminating the need for additional electronic devices or readout systems, particularly useful in environments where electronic instrumentation may be impractical or undesirable.
• Flexibility: Rotameters apply for both liquids and gases, provided the appropriate float material and tube size are selected.
• Low Maintenance: With few moving parts and no electronic components, rotameters require minimal maintenance, reducing operational downtime.
• No Power Requirement: Rotameters operate without external power sources, making them ideal for locations where power availability is a challenge.

Common Uses of Rotameters in Industry

• Chemical Processing: Rotameters are extensively used in chemical plants to monitor and regulate the flow of raw materials, intermediates, and finished products. Their ability to handle aggressive chemicals, assuming construction with compatible materials, makes them suitable.
• Water Treatment: In water treatment plants, rotameters help monitor and control the flow of water and treatment chemicals, ensuring effective treatment and efficient plant operation.
• Gas Distribution: Industries that utilize various gases, like nitrogen, oxygen, or carbon dioxide, use rotameters to monitor and regulate gas flow, ensuring optimal process conditions.
• Pharmaceuticals: Ensuring precise flow rates is crucial in the pharmaceutical industry. Rotameters help regulate the flow of solvents, active ingredients, and other fluids, maintaining the consistency and quality of drug products.
• Laboratories: Rotameters are commonly found in research and analytical labs, allowing scientists to control the flow of gases or liquids in experiments precisely.
• Food and Beverage: The food industry uses rotameters for tasks such as regulating the flow of ingredients in food processing or managing cleaning agents in CIP (Clean-In-Place) systems.
• HVAC Systems: In heating, ventilation, and air conditioning (HVAC) systems, rotameters help ensure the proper flow of refrigerants and other fluids, guaranteeing system efficiency.

In the vast landscape of industrial applications, rotameters stand out for their simplicity, reliability, and versatility. Whether dealing with chemical processing, water treatment, or any other industry, having a dependable flow measurement device cannot be overstated. With its proven track record, the variable area flowmeter continues to be a valuable tool in various sectors, underlining the time-tested principle that, sometimes, simplicity is the highest form of sophistication.

Miller Energy, Inc.

https://millerenergy.com

800-631-5454

Selecting Variable Area Flow Meters for Process Flow Measurement

Many industrial processes involve the movement of fluid product components, either liquid or gaseous, through pipes. Because processing is about control, an input to the facility's management, measurement, or data logging centers will answer the query, "How much is going through that pipe?" 

In the industrial process measurement and control industry, there are several ways for quantifying flow, each with unique characteristics that may be useful under certain operating situations. All flow measuring methods are indirect because the actual measurement is of a character influenced predictably by a change in the media flow. Flow measurement is a critical component that, when paired with other fluid properties, is used to calculate the total mass of a fluid passing through the measurement site. 

The variable area meter, commonly known as a rotameter and VA meter, is a tried and true flow measuring device that operates by creating an equilibrium between an upward force created by fluid motion and a downward force, gravity. A tapering glass or metal tube encases a specifically shaped float, also known as a shaped weight, in the device. VA meters must be positioned vertically, with the media flowing upward from the bottom, so that the gravity force required for functioning is correctly aligned with the flow direction. As fluid flows upward via the precisely tapered tube, drag is created on the float enclosed within the tube, pulling it upward. As the float rises, the open space between the float and the tube wall expands, causing the fluid velocity and drag force to decrease. The flow velocity within the tube will cause the weight to climb for any given flow volume until the drag force generated by the flow reaches equilibrium with the countervailing power of gravity on the float. The tube and float are well designed, allowing for an immediate indication of flow volume.

Variable area flowmeters have the following operating characteristics: 

• There is no need for external power or fuel for functioning. 
• Vertical installation is required, with flow arriving at the bottom. 
• Meters are calibrated to a given chemical and temperature. 
• The operation is stable and has a modest pressure drop. 
• For operation, constant gravity is required. 
• Flow rate can be read locally using a meter or a scale inscribed on the tube. 
• The visibility of the float through the medium is required for unit flow readings using glass tubes. 
• For industrial flow metering equipment, accuracy is relatively low. 
• Inexpensive upkeep, simple construction, and low comparative cost.

Brooks Instrument, a world-renowned maker of flow, pressure, and level measurement equipment, created a brief paper highlighting the parameters to consider when specifying a VA meter and how each aspect influences the unit's performance. The description is realistic and straightforward to grasp. It is suggested reading for all process stakeholders who want to improve their flow measuring skills.

For more information about variable area flow meters contact Miller Energy. Call 800-631-5454 or visit https://millerenergy.com.

GT1600 Industrial Glass Tube Variable Area Flowmeter (Rotameter) for Liquids & Gases

As one of the pioneering manufacturers in variable area (VA) flow meter (rotameter) technology, Brooks Instrument has created a diverse and proven portfolio of gas flow meters, installed and used across virtually every industry.

The NEW Brooks Instrument GT1600 Series industrial design is ideal for the toughest applications. 

GT1600 Features

• Configurable to retro-fit GT10xx, GT130x and Full-View
• 360 degrees rotatable viewing angle
• High quality materials for safety, in- and outdoor durability
• 316 stainless steel frame
• Polycarbonate safety shield
• 316/316L dual certified stainless steel process fittings
• Alarms for high- and low flow (optional for all flow ranges, either at time of
• order,or as add-on in the field)
• Flanged or threaded connections, available horizontal and vertical
• Panel- and wall mount options
• Easy in-situ maintenance: Clean or replace tube and float without removal from
• the process piping
• Adjust the scale to compensate for process variation
• Optional integral needle valve

For more information about the Brooks Instrument GT1600 contact Miller Energy, Inc. Call them at 800-631-5454 or visit their website at https://millerenergy.com.

Industrial Fluid Flow Measurement

Coriolis flow meters deliver a mass flow measurement
Image courtesy Yokogawa

Fluid flow measurement is commonly employed in many industrial process control operations. Accurate and useful flow measurement can be obtained with the proper application and installation of a flow meter as part of the fluid transfer system.

Industrial flow meters employ differing technologies to directly or indirectly measure gas and liquid flow rates. The selection of an appropriate measurement technology and instrument will be influenced by a number of factors related to the installation and application demands.

Among the many available technologies for fluid flow measurement, vortex flow meters, magnetic flow meters, Coriolis flow meters, and rotameters are among some of the most common found in industry.

Each of the separate technologies have attributes which can make them more suitable to certain applications. Selecting the most appropriate flow measurement technology for an application is one of the initial and crucial steps to designing a well functioning flow measurement system.
Selection criteria, such as fluid temperature, pressure, and velocity will be part of the selection process. Additional considerations include whether the fluid may be abrasive, corrosive, clean or dirty. The state of the fluid, liquid or gas, must also be considered. The desired output, whether volumetric or mass flow, will certainly be an integral part of the criteria.

Selecting the right measurement technology and instrument is not always an easy task, especially since it may be something that you do infrequently. Share your flow measurement challenges and requirements with process instrumentation specialists, leveraging your own knowledge and experience with their product application expertise to save time and develop an effective solution.

Sometimes the Simple Solution Is the Best

This metal tube variable area flow meter is reliable,
accurate, and requires little maintenance
Photo courtesy Brooks Instrument

For process control and commercial or industrial applications, there are numerous methods of flow measurement from which to choose. Technologies range from very simple applications of physical principles to deployment of very specialized electronics and sensors. The available range of accuracy, response, and cost is quite broad, with a general expectation that higher cost will deliver better performance and accuracy.

Making the best instrument selection for a flow measurement application should include an assessment of what the operators really need in order to safely and effectively run the process or perform the task related to the measurement of fluid flow. Installing instrumentation with capabilities far beyond what is required is almost certainly a waste of financial resources, but may also have an unexpected impact on operators. Through the generation of data that, while accurate, does not provide any actionable information about process condition, operators can be misled, similar to the occurrence of a false or nuisance alarm. Some applications call for high accuracy, some do not. Define your informational needs and select instruments that will meet those needs.

There is a large array of applications that can be satisfied with simpler, less costly measurement technology. These devices often employ turbines or vanes to produce an indication of flow rate. Incorporated into some of the instruments is a means to visually observe the flowing liquid to verify color and clarity. Simple devices sometimes are intended only to indicate the presence of fluid flow, and whether the flow rate is high or low. Configurations are available that allow insertion into lines under pressure (hot tap) through a full port ball valve. Other variants with combinations of features and capabilities abound.

The selection range is enormous, so define your minimum needs first, then search for a compatible product. Your search can be enhanced by contacting an instrumentation specialist. Combining your process expertise with their broad product knowledge will produce effective solutions.

Metal Tube Variable Area Flow Meter from Miller Energy, Inc.

Level Measurement Using Isolating Air Flow

Bubbler method of liquid level
measurement is simple and reliable
Courtesy Yokogawa

Remotely utilized measurements of tank liquid level are common throughout the fluid processing industries. Various means of inferential or direct measurement are available, each with its own set of performance, maintenance, and cost attributes that may make it the preferred choice for a particular application.

Inferring liquid level using a hydrostatic pressure measurement is a simple, easy to implement strategy for delivering a continuous level signal to the process operating and control system. There can be situations where mounting the measuring gear near the bottom of a tank or other vessel may be impractical or undesirable. A pressure transmitter mounted low on a tank may expose it to damage from plant traffic or other physical hazards. It is also possible that the tank may not have a suitable fitting located low enough to provide the needed measuring range. Having a potential leakage point at a fitting low on the tank may also be undesirable. Another, and certainly not final, scenario would be an application involving a corrosive liquid which must not come in contact with the pressure sensor.

The bubbler method of liquid level measurement employs an arrangement that overcomes all of the previously mentioned impediments. It can utilize connections at the top of the tank, above the liquid level. The way in which the method works will keep the pressure sensor out of contact with the process liquid, providing isolation from potential corrosive effects.

The apparatus for level measurement using the bubbler method employs a simple dip tube that extends from the pressure sensor or transmitter to nearly the bottom of the tank or vessel. A small amount of purge air or gas continually flows through the dip tube and will bubble out the bottom of the tube. This dip tube arrangement essentially transfers the hydrostatic pressure at the bottom opening of the tube to the pressure transmitter, while the purge gas keeps the liquid from advancing up into the pipe. The bubbler can be used on atmospheric or pressurized tanks with a properly configured pressure or differential pressure transmitter.

Probably the most significant application point of the bubbler method that will distinguish its use from many other level measurement methods is the importance of maintaining air or gas flow in the dip tube. The flow provides isolation of the sensor, but the flow must also be set to a level that will not impact the pressure measurement in the tube itself. If the flow is excessive, backpressure in the tube can be offset from the level imparted by the tank contents, with the result being an incorrect measurement.

Below is an application note from Yokogawa, showing how their pressure transmitters and rotameters can be used to create the setup. Share your process measurement challenges and requirements with instrumentation experts, combining your own process knowledge with their product application expertise to produce effective solutions.

Liquid Level Measurement Using the Bubbler Method from Miller Energy, Inc.

Yokogawa Differential Pressure Transmitter from Miller Energy, Inc.

Yokogawa Rotameter Flowmeters for Industrial Applications from Miller Energy, Inc.

Factors For Selecting a Variable Area Flow Meter (Rotameter)

Three of many configurations of
variable area flow meters.
Courtesy Brooks Instrument

Industrial processes have many instances where fluid product components, liquid or gaseous, are moving within pipes. Processing is about control, so it follows that an input to the control, measurement, or data logging centers of the facility will answer the question, "How much is flowing through that pipe?".

There are numerous methods employed for quantifying flow in the industrial process measurement and control field, each with particular attributes that may be considered advantageous under  certain operating conditions. All flow measurement methods are indirect, as their actual measurement is of a property that is impacted in a predictable manner by a change in the flow. Flow measurement is an essential element that, combined with other fluid attributes, is used to calculate the total mass of a fluid that has traversed the measurement point.

One time tested method of measuring flow is the variable area meter, also called a rotameter.

Operation of the variable area meter (also referred to as a VA meter) is based upon creating an equilibrium between an upward force, produced by the fluid motion, and a downward force, gravity. The device includes a tapered glass or metal tube that encases a specially shaped float, often referred to as a shaped weight. VA meters must be installed vertically, with the media flowing from the bottom upward, so that the gravitational force necessary for operation is properly aligned with the flow direction. As fluid flows upward through the specially tapered tube, it creates drag on the float contained within the tube, lifting it upward. As the float rises, the free area between the float and the tube wall increases, causing a reduction in the fluid velocity and drag force. For any given flow volume, the flow velocity within the tube will cause the weight to rise until the drag force created by the flow reaches equilibrium with the countervailing force of gravity on the float. Proper design of the tube and the float allow for direct indication of flow volume.

Some of the attributes of variable area meters include:

• No external power or fuel required for operation
• Must be installed vertically, with flow entering bottom
• Meters are characterized to a specific substance, at a specific temperature
• Operation is stable, with low pressure drop
• Requires constant gravity for operation
• Direct local readout of flow rate with meter or scale imprinted on tube
• Glass tube based unit flow readings require visibility of float through the medium
• Accuracy is comparatively low for an industrial flow measurement device
• Generally low maintenance, simple construction, low comparative cost

Brooks Instrument, a world renowned manufacturer of flow, pressure, and level measurement instruments, has produced a concise and compact white paper that summarizes the factors to consider when specifying a VA meter, as well as how each factor impacts operation of the unit. The description is practical and easily understood. It is recommended reading for all process stakeholders to build their flow measurement knowledge.

I have included the paper below. Browse the paper. Contact the flow instrumentation specialists to discuss your application requirements and challenges. Combining your process know-how with their product application knowledge will produce a good solution.

Selecting Variable Area Flow Meters for Process Measurement from Miller Energy, Inc.