HRL assists client with design and testing of venturi flow meters
Challenge
HRL was approached by our client to design and calibrate two venturi flow meters for their boiler air system. Our client was undertaking a transition from coal to natural gas firing for which the current air flow meter was not adequate. The client required an in-line flow meter to have adequate sensitivity to the typical range of flow rate, with reasonable pressure loss, and could fit into the compact space available for installation. The challenge was to evaluate different venturi designs and arrive at the final design geometry that would meet the client's requirements.
Solution
Front-end engineering design combining CFD and Finite Element Analysis
HRL employed Computational Fluid Dynamics (CFD) simulations to investigate different venturi designs and optimise the final design geometry. After determining the optimal design, further simulations were run to obtain a performance curve over a range of flow rates.
Finally, HRL performed a finite element analysis (FEA) on the venturi geometry determined from CFD modelling to aid mechanical design, such as the requirement of stiffeners.
Results
The CFD simulations allowed HRL to screen different venturi designs and arrive at the final design geometry that met the client's requirements. The final design balanced measurement sensitivity (venturi pressure drop), pressure loss, installation length, and geometric complexity.
After the client installed the first two venturi flow meters, HRL engineers completed gas velocity measurements at the client site to calibrate the actual performance curve of the venturi flow meters. The performance of the venturi flow meters was found to closely match the CFD model prediction in the range of typical flow rates.
This work highlights HRL's capability of integrating flow design (CFD), mechanical design (FEA) and plant performance measurements. HRL’s onsite testing capability can bridge the gap between computer modelling and actual equipment performance. These services have provided valuable insights and confidence to our client as they undergo a transition to alternative fuel utilisation.
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