The post The Good, Bad and Ugly of Thermal Mass Flowmeters first appeared on the ISA Interchange blog site.
The following technical discussion is part of an occasional series showcasing the ISA Mentor Program, authored by Greg McMillan, industry consultant, author of numerous process control books, 2010 ISA Life Achievement Award recipient and retired Senior Fellow from Solutia Inc (now Eastman Chemicals). Greg will be posting occasional questions and responses from the ISA Mentor Program, with contributions from program participants.
Thermal mass flowmeters can be a relatively inexpensive flowmeter that can handle extremely small flows (e.g., inline 1/16 inch meters) and large flows (e.g., multipoint insertion type in 60 inch ducts). Thermal flowmeters introduce heat into the flow stream and measure how much heat is absorbed using one or more temperature sensors. However, the meter requires a fixed specific heat capacity, no heat loss or gain from ambient conditions, a fixed composition, predictable heat distribution, no change in phase and no change in heat transfer coefficient unrelated to velocity (e.g., surfaces must be clean and dry). Thermal mass flowmeters are most frequently used for gas flow since heat absorption in liquids and solids can be problematic. The greatest success is seen with properly installed inline meters measuring single component gas flows in a very controlled environment.
The flow measurement uses two temperature sensors, the upstream one being heated by an electrical current. Flow is inferred either from the temperature rise for a constant current or from the amount of current needed to maintain a constant temperature differential.
Total shipments of thermal mass flowmeters have been increasing by about $5 million per year to become about 2 percent of the total worldwide market for all types of flowmeters that was about $5 billion in 2009.
Questions from ISA Mentor Program Participant Adrian Taylor
Answers from ISA Mentor Program Participant Hunter Vegas
Rule #1 (and it is a huge one) – If you are trying to use a thermal flow meter on air/gas/vapors never install it in a service where it can ever see a gas/vapor approaching dew point. Even a tiny bit of liquid will create erratic flow readings.
Rule #2 – Most thermal flow meters do not promise high accuracy particularly if they are the insertion type. If you need highly accurate flow readings you should probably investigate a different meter type. However they do work well as a flow switch or a go/no go type of flow application like purges and the like.
Greg McMillan’s Comments
I have seen thermal mass flow meters extensively use in laboratories and pilot plants to measure air, oxygen and carbon dioxide flows for bioreactors. As you can imagine, the gas and ambient conditions are exceptionally controlled, which may explain their success.
For more on the physical principles and practical considerations as to selection and installation of thermal mass flowmeters and all other types of measurements see my 2010 ISA book Essentials of Modern Measurements and Final Elements in the Process Industry: A Guide to Design, Configuration, Installation, and Maintenance.