Orifice Flow Meter
Charm Industrial
During the pyrolysis process, the biomass is heated in reactors to release the carbon. The oxygen level is greatly reduced and replaced with Nitrogen as to not ignite the material. All four reactors in the system needed flow meters to indicate the N2 was flowing into the reactors and at what rate.
My task was to procure the components for, fabricate, test, and calibrate the N2 orifice flow meters. I also verified the flow meters did not interfere with other hardware, structural components, or electrical boxes in the CAD models while the system was stationed in Kansas. The flow rate was calculated buy measuring the temperature and pressure difference across an orifice of a known diameter. I procured very thin laser-cut stainless steel orifice plates to be welded into the end of a long sanitary spool. Four weld bungs were also welded near the interface for the temperature sensors and differential pressure transducer to be installed.
To test the device, I installed a valve, two pressure indicators, a regulator, and relief valves upstream of the four spools. They were attached in series to be able to test all at once to save time. An air compressor was used instead of N2 source and a rotameter was installed at the end to compare the reading with the calculated results. The initial tests displayed odd behavior, the rotameter indicator oscillated when the air began to flow through the line of spools. After a few tests, I concluded that the four orifices (all aligned at the same distances) were creating a standing wave. My manager suggested I put my hand over the outlet or use a regulator valve at the end to restrict the airflow and stabilize the indicator. After installing a regulator, the rotameter indicator stabilized at a value and the data from the sensors were consistent. The flow meters were installed in the system and returned the flow rate data during the next Hot flow system test.
