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Analysis of new forms of orifice plates using computational fluid dynamics

In many technologies, such as process industry or water supply, there is a
 need to measure fluid flowrates. Orifice plates are the most common
 instruments for measuring the fluid flowrate through pipelines due to their
 many advantages. On the other side, their use increases operating costs of
 industrial plants and pipelines. In this work, three new forms of orifice
 plates were designed and tested. These new forms and one standard, which
 served as a reference, were designed by using the SolidWorks software
 package. The aim of the new designs was energy savings, and consequently
 reduction of operating costs. Energy savings can be achieved by such a
 design, which decreases the orifice plate resistance an element of the
 pipeline. This was achieved by increasing the open part of the orifice plate
 permitting the fluid flow. CAD models of orifice plates were transferred to
 STL files that were further used for CFD simulation as well as 3D printing
 of experimental replicas. According to the proposed algorithm, the new
 designs were tested by CFD simulation performed in the COMSOL Multiphysics
 software package, by using a finite-difference method. Equations used were
 based on the Reynolds form of Navier-Stokes equations (RANS,
 Reynolds-averaged Navier-Stokes), and the continuity equation for
 incompressible fluids. Next, as we have proposed in our algorithm of
 development of new orifice plate designs, experimental orifice plates were
 made by using 3D printing technology and FDM (Fused Deposition Modeling)
 procedure and tested at laboratory conditions. The results of laboratory
 tests were compared with the results of CFD simulation. A considerable
 amount of energy saving was indicated, which was achieved already by the
 first of the three new orifice plate forms (V1) as compared to the reference
 (V0). For the other two proposed forms, the effect of energy savings was
 considerably lower. By using CFD simulation, data can be obtained based on
 which a decision can be made whether the new shape of the measuring device
 should be corrected or is appropriate for further laboratory tests. Based on
 the presented results it can be concluded that the proposed testing
 algorithm proved useful in designing new forms of orifice plates.