What is a mass flow meter and how does it work?

A thermal mass flow meter measures the flow rate of gas mass based on the convective heat transfer of a heated surface to the flowing fluid. The components of a basic thermal mass flow meter include two temperature sensors with an electric heater between them. The heater can protrude into the fluid stream or can be external to the pipe.

In the past, mass flow was often calculated from the outputs of a volumetric flow meter and a densitometer. Density was either directly measured, or was calculated using the outputs of process temperature and pressure transmitters.

These mass flow measurements were not very accurate, because the relationship between process pressure or temperature and density are not always precisely known, each sensor adds its own separate error to the overall measurement error, and the speed of response of such calculations is usually not sufficient to detect step changes in flow.

How does a mass flow meter work?

Mass flow meters operate either by introducing a known amount of heat into the flowing stream and measuring an associated temperature change or by maintaining a probe at a constant temperature and measuring the energy required to do so.

Thermal flow meters provide high rangeability (10:1 to 100:1) if they are operated at a constant - temperature-difference mode. Alternatively, if heat input is constant, the ability to detect very small temperature differences is limited and both precision and rangeability drop off. At normal flow, measurement errors are usually in the 1-2% full scale range.

Common mass flow meter applications

Thermal mass flow meters are used frequently in monitoring or controlling mass-related processes such as chemical reactions that depend on the relative masses of unreacted ingredients, such as recipe formulations, material balance determinations, and billing and custody transfer operations.

As these are the most critical flow measurements in a processing plant, the reliability and accuracy of mass flow measurement is very important.

In detecting the mass flow of compressible vapors and gases, the measurement is unaffected by changes in pressure and/or temperature. One of the capabilities of thermal mass flow meters is to accurately measure low gas flow rates or low gas velocities (under 25 ft. per minute)--much lower than can be detected with any other device.

Thermal flowmeters provide high rangeability if they are operated in constant-temperature-difference mode. On the other hand, if heat input is constant, the ability to detect very small temperature differences is limited and both precision and rangeability drop off. At normal flows, measurement errors are usually in the 1-2% full scale range.

This sensor is available in high pressure and high temperature designs, and in special materials including glass, Monel, and PFA. Flow-through designs are used to measure small flows of pure substances (heat capacity is constant if a gas is pure), while bypass and probe-type designs can detect large flows in ducts, flare stacks, and dryers.

Mass flow meter principles

Thermal mass flow meters are most often used for the regulation of low gas flows. They operate either by introducing a known amount of heat into the flowing stream and measuring an associated temperature change, or by maintaining a probe at a constant temperature and measuring the energy required to do so. The components of a basic thermal mass flow meter include two temperature sensors and an electric heater between them. The heater can protrude into the fluid stream or can be external to the pipe.

The power required to maintain a temperature differential is directly proportional to the mass flow rate. The mass flow (m) is calculated on the basis of the measured temperature difference (T1 – T2), the meter coefficient (k), the electric heat rate (q), and the specific heat of the fluid (Cp).

Here is the formula:

M=Kq/(Cp(T1 – T2))

What are the limitations of a mass flow meter?

Thermal mass flow meters can have very high rangeability and reasonable accuracy, but they also have serious limitations. Potential problems include the condensation of moisture (in saturated gases) on the temperature detector. Such condensation will cause the thermometer to read low and can lead to corrosion. Coating or material build-up on the sensor also will inhibit heat transfer and cause the meter to read low. Additional potential sources of error include variations in the specific heat caused by changes in the gas's composition.

Some common gas-flow applications for thermal mass flowmeters include combustion air measurement in large boilers, semiconductor process gas measurement, air sampling in nuclear power plants, process gas measurements in the chemical and petrochemical industries, research and development applications, gas chromatography, and filter and leak testing. While hot-wire anemometers are best suited for clean gases at low velocities, venturi meters can also be considered for some liquid (including slurry) flow applications. Thermal mass flow meters are well suited for high rangeability measurements of very low flows, but also can be used in measuring large flows such as combustion air, natural gas, or the distribution of compressed air.

► SHOW FLOWMETERS