Computational Investigation of Turbulent

Flow Through Fractal Plates by Using

COMSOL Multi-physics 5.2a

SHEIKH ADNAN ATTA SP15-BME-013

MUHAMMAD SAEED SP15-BME-029
M.SHAHID NAZEER SP15-BME-031
MUHAMMAD AHMAD SP15-BME-079

Supervisor

Hassan Raza
Lecturer

DEPARTMENT OF MECHANCIAL ENGINEERING

FACULTY OF ENGINEERING
COMSATS UNIVERSITY ISLAMABAD
SAHIWAL CAMPUS
December 2018
 Computational Investigation of Turbulent
Flow Through Fractal Plates by Using
COMSOL Multi-physics 5.2a

SHEIKH ADNAN ATTA SP15-BME-013

MUHAMMAD SAEED SP15-BME-029
M.SHAHID NAZEER SP15-BME-031
MUHAMMAD AHMAD SP15-BME-079

Supervisor

Hassan Raza
Lecturer

External Examiner 1 Signature: _________________________________________

External Examiner 2 Signature: _________________________________________

Thesis Supervisor Signature: __________________________________________

DEPARTMENT OF MECHANCIAL ENGINEERING

FACULTY OF ENGINEERING
COMSATS UNIVERSITY ISLAMABAD
SAHIWAL CAMPUS

December 2018

i
 ABSTRACT

This report related to the Computational Fluid Dynamics (CFD) analysis of a turbulence

loss in a pipe with different design of fractal plates using COMSOL Multi-physics 5.2a.

COMSOL Multi-physics 5.2a is a general-purpose finite element-modeling package for

numerically solving a wide variety of mechanical problems.

When, we used conventional orifice in a pipe for flow, then maximum pressure drop. To

overcome, pressure drop, we adopted a new method to reduce the pressure drop in a pipe.

We made different design of orifice called fractal plate. Fractal plates are S-1 Series, S-2

Series, S-3 Series and S-4 Series. Analysis performed on these series by using COMSOL

Multi-Physics 5.2a. We apply different pressure range on these series. We conclude from

these analyses, that S-4 Series is better as compared to other series. In this Series (S-4

Series), pressure drop is minimum, which is our requirement. By changing the design, we

reduced pressure drop of 28%.

ii
 ACKNOWLEDGEMENTS

First, I am grateful to ALMIGHTY ALLAH, The Merciful, The Beneficent,

whose bountiful blessings and exaltation flourished my thoughts and thrived my

ambitions.

Secondly, I would like to express my sincere gratitude to my Supervisor

Hassan Raza, who provided in valuable assistance in accomplishing this task. It was

under his supervision that I easily understood all the technicalities associated with this

activity. I am truly indebted for his advice and guidance.

I am also thankful to Hassan Raza and all my teachers for their guidance and help.

Sheikh Adnan Atta

Muhammad Saeed

M.Shahid Nazeer

Muhammad Ahmad

iii
 TABLE OF CONTENTS

Abstract ............................................................................................... ………...ii

Acknowledgement ..............................................................................................iii

List of Figures ....................................................................................................vii

List of Tables....................................................................................................... ix

Chapter I: Introduction ......................................................................................... 1

1.1 Statement of the Problem ........................................................................ 1

1.2 Objectives ................................................................................................ 1

1.3 Organization of the Thesis ...................................................................... 1

1.3.1 Orifice .............................................................................................. 1

1.3.2 Introduction of Orifice ..................................................................... 2

1.3.3 Principle of Orifice .......................................................................... 2

1.4 Types of orifice ........................................................................................ 3

1.4.1 Concentric Orifice Plate ................................................................... 4

1.4.2 Eccentric Orifice Plate ...................................................................... 5

1.4.3 Segmental Orifice Plate .................................................................... 5

1.4.4 Quadrant Radius Orifice Plate.......................................................... 6

1.4.5 Conical Entrance............................................................................... 7

1.5 Parameters of Orifice ............................................................................... 7

1.6 COMSOL Multi-Physics 5.2a ................................................................. 9

1.6.1 Modules ............................................................................................ 9

1.6.2 Simulation ....................................................................................... 11

1.6.3 COMSOL Features ......................................................................... 11

iv
 1.6.4 Applications .................................................................................... 12

1.6.5 Why COMSOL Used ..................................................................... 13

Chapter II: Literature Review ............................................................................ 14

2.1 Literature Review .................................................................................. 14

2.1.1 Fundamental of Orifice Metering ................................................... 14

2.1.2 Design Criteria to Assure Measurement Accuracy ....................... 14

2.1.3 Eccentricity ...................................................................................... 15

2.1.4 How does it works ........................................................................... 15

2.1.5 General Installation and Recommendation ..................................... 16

2.1.6 Construction of Orifice .................................................................... 17

2.1.7 Use of Orifice ................................................................................... 17

2.1.8 Fractal Orifice Plate ........................................................................ 19

2.1.9 Principal of Orifice Plate ................................................................ 22

Chapter III: Methodology .................................................................................. 23

3.1 3D Modeling of Pipe ............................................................................ 23

3.2 3D Modeling of Triangular Fractal plate .............................................. 24

3.3 Assembly Portion .................................................................................. 26

3.4 Other Fractal Plate Design .................................................................... 27

3.5 Experimental Setup OR Analysis ........................................................ 29

Chapter IV: Results ............................................................................................ 31

4.1 S-1 Series (P=50pa, P=10pa) ................................................................ 31

4.2 S-2 Series (P=50pa, P=10pa) ................................................................ 32

4.3 S-3 Series (P=50pa, P=10pa)....................................................................... 33

v
4.4 S-4 Series (P=50pa, P=10pa)....................................................................... 34

4.5 Graph b/w Pressure and Time ..................................................................... 36

Chapter V: Discussion ....................................................................................... 37

5.1 Discussion .............................................................................................. 37

Chapter VI: Conclusion ..................................................................................... 41

6.1 Conclusion ............................................................................................. 41

References .................................................................................................... 42

Abbreviations ............................................................................................... 44

vi
 LIST OF FIGURES

Fig 1.1Concentric Orifice Plate .......................................................................4

Fig 1.2 Eccentric Orifice Plate .........................................................................5

Fig 1.3 Segmental Orifice Plate .......................................................................6

Fig 1.4 Quadrant Orifice Plate .........................................................................7

Fig 1.5 Concentric Orifice Plate. .....................................................................7

Fig 2.1 Orifice flow Meter .............................................................................14

Fig 2.2 Fractal Plates......................................................................................20

Fig2.3: SF1, SF2, SF3 and SF4......................................................................21

Fig2.4 Graph between change in Cd and Reynolds Number .........................22

Fig 3.1 Pipe ....................................................................................................24

Fig 3.2 Triangular Fractal Plate .....................................................................26

Fig 3.3 Final Assembly ..................................................................................27

Fig 3.4 Final Assembly ..................................................................................27

Fig 3.5 S-2 Series ...........................................................................................28

Fig 3.6 S-3 Series ...........................................................................................28

Fig 3.7 S-4 Series ...........................................................................................29

Fig 4.1 S-1 Series Results (Pa-=50pa). ..........................................................31

Fig 4.1.1 S-1 Series Results (Pa-=10pa). .......................................................32

Fig 4.2 S-2 Series Results (Pa-=50pa). ..........................................................32

Fig 4.2.1 S-2 Series Results (Pa-=10pa). .......................................................33

Fig 4.3 S-3 Series Results (Pa-=50pa). ..........................................................33

vii
Fig 4.3.1 S-3 Series Results (Pa-=10pa). .......................................................34

Fig 4.4 S-4 Series Results (Pa-=50pa). ..........................................................34

Fig 4.4.1 S-4 Series Results (Pa-=10pa). .......................................................35

Fig 5.1 S-4 Suppress Flow Behavior. ............................................................38

viii
 LIST OF TABLES

Table 1.1 Parameters ........................................................................................8

Table 3.1 Dimensions of Pipe ........................................................................23

Table 3.2 Dimensions of Triangular fractal plate ..........................................24

ix
 CHAPTER 1

Introduction

1.1 Problem Statement

Conventional orifice used in a pipe, retardation produce and pressure drop. By using

conventional orifice, maximum pressure drop. In Industrial point of view and daily life,

require maximum flow rate where minimum pressure drop. In Industrial point of view

and in daily life, this phenomenon is very important.

1.2 Objectives

The main objective of this computational study is to investigate the following parameters:

1. To construct the 3D model pipe and orifice on Solids Works and simulation

be carried out on COMSOL MULTI-physics 5.2a.

2. To investigate the effect of fractal plate on pressure drop and flow rate.

1.3 Organization of thesis

1.3.1 Orifice

An orifice plate is a device used for measuring flow rate, for reducing pressure or for

restricting flow. Either a volumetric or mass flow rate may be determined; depending on

the calculation associated with the orifice plate. The small hole on orifice plates restricts

flow, which causes the pressure to drop. The pressure can be measured using pressure

gauges before and after the orifice plates, which allows you to determine the flow rate

using the Bernoulli’s Equation. An orifice plate is installed between orifice flanges or a

metering unit.[1]

1
1.3.2 Introduction of Orifice

An orifice meter is a conduit and a restriction to create a pressure drop. An hour glass is a

form of orifice. A nozzle, venture or thin sharp edged orifice can be used as the flow

restriction. In order to use any of these devices for measurement it is necessary to

empirically calibrate them. [2]

That is, pass a known volume through the meter and note the reading in order to provide

a standard for measuring other quantities. Due to the ease of duplicating and the simple

construction, the thin sharp edged orifice has been adopted as a standard and extensive

calibration work has been done so that it is widely accepted as a standard means of

measuring fluids. Provided the standard mechanics of construction are followed, no

further calibration is required. An orifice in a pipeline is shown in figure 1 with a

manometer for measuring the drop in pressure (differential) as the fluid passes thru the

orifice. The minimum cross sectional area of the jet is known as the “vena contracta.” [3]

1.3.3 Principle of the Orifice

It is based on Bernoulli’s principle and is derived as follows;

Bernoulli’s Equation for Incompressible Fluids for a parcel of fluid moving through a

pipe with cross-sectional area “A”, the length of the parcel is d”x”, and the volume of the

parcel A dx. If mass density is 𝜌 the mass of the parcel is density multiplied by its

volume m =𝜌 A dx. The change in pressure over distance dx is “dp” and flow velocity v

= dx/dt.[4] Apply Newton’s Second Law of Motion we have

𝑑𝑢
𝑚 =𝐹 (1.1)
𝑑𝑡

𝑑𝑢
𝜌𝐴𝑑𝑥 = −𝐴𝑑𝑝 (1.2)
𝑑𝑡

2
 𝑑𝑢 𝑑𝑝
𝜌 = − ⁄𝑑𝑥 (1.3)
𝑑𝑡

With density 𝜌 constant, the equation of motion can be written as

𝑑 𝑣2
(𝜌 + 𝑑𝑝) = 0 (1.4)
𝑑𝑥 2

By integrating equation (4) with respect to x

𝑣2 𝑃
+ =𝐶 (1.5)
2 𝜌

Where C is a constant, sometimes referred to as the Bernoulli constant. It is not a

universal constant, but rather a constant of a particular fluid system. Where the speed is

large, pressure is low and vice versa. In the above derivation, no external work-energy

principle is invoked. Rather, Bernoulli’s principle was inherently derived by a simple

manipulation of the momentum equation.[4]

1.4 Types of Orifices

• Plate types orifice

• Hemispherical orifice

• Conic shape orifice

• Concentric orifice

• Eccentric orifice

• Segmental orifice

3
 • Quadrant edge orifice
1.4.1 Concentric Orifice Plate

Second name of concentric orifice plate is square edge. This type of orifice plate is

manufacturing by a machine with precise state hole in the mid of thin metal plate. This is

the most used, low cost and commonly designs because of its proven reliability in a

variety of industrial applications. Used to measure a wide variety of single phase liquid

and gas products typically in conjunction with flange plate and tapes. This plate reveals

shard edge 90 degree corner at the hole. This hole in an orifice plate helps to minimize

contact with the fast moving fluid stream going through the hole.

These are most commonly used for flow measurement. This has special features such as

simple structures, high accuracy, and ease of installation & replacement. The orifice

plates are correctly finished to the dimensions, surface roughness, and flatness to the

applicable standard. These plates are recommended for clean liquids, gases & steam flow,

when the Reynolds number 7 ranges from 10000.[5]

Fig 1.1: Concentric Orifice plate [5]

4
1.4.2 Eccentric Orifice

That type of orifice plate has a hole that is located off-centered to allow the undesired

portion of the fluid to pass through the orifice rather than build up on the upstream phase.

These are generally used when the process material contain foreign matter may block the

orifice in the case of the concentric configuration. Eccentric orifice plate area used to

measure the flow of fluid that carry solids and are also used to measure gasses which

carry liquids. It should be noted that the eccentric orifice has higher degree of uncertainty

as compare to the concentric orifice. [5]

Fig 1.2: Eccentric Orifice plate [5]

1.4.3 Segmental Orifice Plate

The segmental orifice plate has a hole that is not circular but rather a segment of a

concentric circle. This plate is used to measure the flow of light slurries and fluid with

high concentration of solids. The design of this orifice plate eliminates the damming of

5
foreign matter and provides more complete drainage than the eccentric orifice plate. This

plate is most expensive and has more uncertainty as compare to others.[5]

Fig 1.3: Segmental Orifice plate [5]

1.4.4 Quadrant Radius Orifice Plate

They are recommended of measurement of viscous fluid which has pipe Reynolds’s

number below 10 thousands and increase in the viscosity of the fluid flowing through a

sharp edge orifice will increase the diameter of vena contracta, which results in a

decrease in differential pressure.[5]

6
 Fig 1.4: Quadrant Radius Orifice plate [5]

1.4.5 Conical Entrance

These conical entrance orifice plates are used for low Reynolds number in the range of 80

to 2000 and give more constant or predictable discharge coefficient. At lower Reynolds

numbers, the discharge coefficient of square edge orifice plate may change by as much as

30%. These are more usable for viscous service.[5]

Fig 1.5: Concentric Entrance [5]

1.5 Parameters of Orifice

In orifice plate different types of parameters are involved during the measurement of flow,

some of them are listed below:

7
 Table 1.1: Parameters

Sr.# Symbols Parameters

1 C Discharge Coefficient

2 A Area of orifice

3 Do Outer diameter of orifice

4 Di Inner diameter of orifice

5 Z Elevation

6 A Flow of coefficient

7 β Ratio of pipe diameter of orifice diameter

8 Ρ Density

9 Y Expansion Coefficient

10 H Fluids area

11 G Gravitational Acceleration

12 K Ratio of specific heats

13 P Pressure

There steps that are involve to design an orifice plate Identify the some physical attribute

of piping system [6]

• Pipe size

• Pipe schedule

• Flange rating

8
 • Orifice plate material[6]

Identify and accumulate data on process flow conditions

• Fluid to be measured

• Temperature

• Pressure

• Viscosity

• Flow rates[6]

Identify and accumulate information on other requirements of the flow meter

• Design

• Deferential pressure

• Target

• Beta ratio Maximum

• flow viscosity

• Acceptable permanent pressure drop[6]

1.6 COMSOL Multi-Physics 5.2a

COMSOL Multi-physics is a powerful interactive environment for modeling and solving

all kinds of scientific and engineering problems. The software provides a powerful

integrated desktop environment with a Model Builder where you get full overview of the

model and access to all functionality.[7]

1.6.1 Modules

• AC/DC Module

• Acoustics Module

9
• Batteries & Fuel Cells Module

• CFD Module (Computational Fluid Dynamics)

• Chemical Reaction Engineering Module

• Corrosion Module

• Geo-mechanics Module

• Heat Transfer Module

• MEMS Module

• Micro-fluidics Module

• Nonlinear Structural Materials Module

• Optimization Module

• Particle Tracing Module

• Pipe Flow Module

• Plasma Module

• RF Module

• Structural Mechanics Module

• Subsurface Flow Module

10
1.6.2 Simulation

• Process of reality mimicking through software analysis.

• Suitable Environment.

• High Speed Calculations.

• Boundary Conditions.

• To see what expensive experiments will give as a result.

• To understand thing beyond experimental laboratory conditions.

• To check the performance of a system and develop new ideas quickly.

1.6.3 COMSOL Features

• Material library Multi-physics in single simulation process

• Practical physics extending various features from heat treatment to optics

• Model library

• Link to various software like AUTO CAD ,Solid works, MS excel ,MATLAB and
many other

• Online webinar

• Multi-plot features

• Curves and geometries.

11
1.6.4 Applications

• Acoustics

• Bioscience

• Chemical reactions

• Corrosion and corrosion protection

• Diffusion

• Electrochemistry

• Electro-magnetic

• Fluid dynamics

• Fuel cells and electrochemistry

• Geophysics

• Heat transfer

• Micro-electromechanical systems (MEMS)

• Micro-fluidics

• Microwave engineering

• Optics

• Particle tracing

• Photonics

• Plasma physics

• Porous media flow

• Quantum mechanics

12
 • Radio-frequency components

• Semiconductor devices

• Structural mechanics

• Transport phenomena

• Wave propagation

1.6.5 Why COMSOL used

• Scientifically trust worthy environment

• Recommended by experts in engineering and physics

• Relatively fast calculations

• Open excess features

• Use of finite element method in calculations

• Attraction of new research areas such as photonics, plasmonics, electronics and

material engineering.

13
 CHAPTER 2

Literature Review

2.1 Literature Review

2.1.1 Fundamentals of Orifice Metering

Throughout the oil and gas industry, there stems the need for accurate and economical

measurement of process fluids and natural gas. Orifice Meters, sometimes referred to as

Orifice Fittings, satisfy most flow measurement applications and are the most common

flow meter type in use today. The Orifice Meter, sometimes also called a head loss flow

meter, is chosen most frequently because of its long history of use in many applications,

versatility, and low cost, as compared to other available flow meter types. [8]

Fig 2.1: Orifice Flow Meter [8]

2.1.2 Design Criteria to Assure Measurement Accuracy

Most flow meters require flow calibration to verify accuracy. However, an Orifice Fitting

will not require flow calibration if designed and manufactured in accordance with

14
acceptable design practices. Since the beginning of orifice flow measurement, numerous

research studies have been conducted to determine what physical changes take place in a

pipeline when flowing liquid or gas passes through an orifice plate. Conclusions of all

this work have determined that when an orifice plate is properly installed and maintained

and the Orifice Fitting is properly designed and manufactured, the Orifice Fitting can

produce a measurement accuracy on the order of +/-0.5 to 1.0% of reading. However,

orifice flow measurement is sensitive to the flowing conditions, the adjacent piping

installation configuration, the precision machining of the fitting and its attachment to the

adjacent straight run of pipe, plus the cumulative error of the secondary instrumentation.

Overall accuracy of the metering installation under average operating conditions could be

in the range of +/-2 to 5% of reading. If not properly maintained and inspected

periodically, the Orifice Fitting could produce measurement accuracy only about +/-10 to

25% of reading. [8]

2.1.3 Eccentricity

The orifice plate bore must be concentric with the bore of the fitting. The eccentricity

maximum tolerance is line size and β (beta ratio) dependent. When measured in a plane

parallel to the tap holes both upstream and downstream of the orifice plate, for a 0.75 β

design and 2” size the maximum tolerance is 0.006” for 3” it is 0.009”. When measured

perpendicular to the tap hole axis the allowable tolerance may be 4 times greater e.g. 2” is

0.024” and 3” is 0.036”. [8]

2.1.4 How does it work?

As the fluid approaches the orifice the pressure increases slightly and then drops

suddenly as the orifice is passed. It continues to drop until the “vena contracta” is reached

15
and then gradually increases until at approximately 5 to 8 diameters downstream a

maximum pressure point is reached that will be lower than the pressure upstream of the

orifice. The decrease in pressure as the fluid passes through the orifice is a result of the

increased velocity of the gas passing thru the reduced area of the orifice. When the

velocity decreases as the fluid leaves the orifice the pressure increases and tends to return

to its original level. All of the pressure loss is not recovered because of friction and

turbulence losses in the stream. The pressure drop across the orifice increases when the

rate of flow increases. When there is no flow there is no differential. The differential

pressure is proportional to the square of the velocity, it therefore follows that if all other

factors remain constant, then the differential is proportional to the square of the rate of

flow. [9]

2.1.5 General Installation Recommendation

1. Meter manifold piping should always be installed to enable calibration as well as to

protect the differential element against overage. [9]

2. The meter should be installed as close as possible to the orifice fitting. [9]

3. Always slope the manifold lines gently from the orifice fitting to the meter to eliminate

any high or low points in the manifold lines. [9]

4. Use condensate chambers or air traps to remove either liquid from a gas system or gas

from a liquid system if lows or highs in the manifold piping cannot be avoided. [9]

It is important when pressurizing or depressurizing differential measuring devices to

apply or release pressure to or from the high and low meter chambers uniformly, so as

not to impose excessive overange. [9]

16
2.1.6 Construction of Orifice

Although the construction of the orifice plate looks very simple, the behaviour of the

flow through the orifice plate is very complex. There are some essential assumptions that

should be justified to get an acceptable accuracy in measuring flow rate. One of the

important assumptions that are made is that the flow approaching the orifice plate must

be fully developed and turbulent without any asymmetry and swirl. The overall accuracy

of the standard orifice plate, which is supplied with a fully developed flow or standard

velocity profile, is between 0.5% and 1%. [11]

In practical applications, it is very difficult to obtain this standard velocity profile

approaching the orifice plate. This is because swirl and distortion in the flow can be

generated by valves, joints, branches, bends, heat exchangers, compressors and other pipe

fittings. So, the velocity profile for actual applications is in most cases far away from the

standard fully developed flow and will provide some detrimental effects on the accuracy

of the flow measurement. In practical applications, two approaches can be used to

counter measure that problems. [11]

2.1.7 Use of Orifice Plate

The use of the orifice plate for flow metering has been around since the end of nineteenth

century. But the modern orifice plate was invented by John G. Pew and H.C. Cooper as a

quick and light replacement of pitot-tube in 1911. Since then numerous pieces of work

have been done, either to understand how the flow behaves in the presence of an orifice

plate or how the efficiency of an orifice plate could be increased by varying the plate

geometry. [10]

17
The first successful orifice plate visualization experiment was reported by Johansen. He

investigated the flow transition from steady to turbulent and found that the flow transition

was a function of the Reynolds number and at a moderately low Reynolds number, a two

dimensional flow free of vortices occurred. As the Reynolds number increased, a rise to

Karman vortex streets was noticed having identical airflow structures features as they

past a bluff body. Agarwal conducted experimental study of turbulent flow owing to the

presence of an orifice plate. He categorized the flow around an orifice plate in a pipe into

five flow zones and found that the mean separation and reattachment of turbulent pipe

flow was a strong function of the orifice to tunnel area ratio and the Reynolds number.

Investigated orifice plate induced pressure vibration and fluctuations on the pipe wall.

They observed the peak pressure fluctuation appeared at 1.7 diameters downstream of the

orifice in the axial direction but the power spectral density and the root mean square of

the pressure fluctuations do not show significant difference in the radial direction.

Morrison et al. Studied the upstream velocity profile effects on the performance of the

orifice plate. They observed the change in discharge coefficient with the decrease of

orifice to pipe diameter ratios. Studied the pressure loss through a square orifice plate in a

square duct for a range of Reynolds number and compared their results against a

perforated plate under the same initial and boundary conditions. Their results showed that

across the orifice plate pressure losses was substantially low. [10]

Aside from understanding the flow physics, many pieces of work have also been

conducted on how the geometrical variation could lead to a better efficiency of the orifice

plate. Hayward attached a spring loaded disk with an orifice plate and let the disk move

in an annular expansion. Thus the differential pressure he obtained was found to be

18
directly proportional to the flow rate. Ho and Leung tested the performance

characteristics of conical entrance orifice plates at low Reynolds number in a pipe with

small diameter. [10]They concluded that although the eccentricity of the plates had no

major role on the flow discharge coefficients and these coefficients increased with

increasing diameter ratio. However, the conical entrance was not deemed efficient from a

manufacturing point of view. [10]

McFadding et al. set a bundle of in-line tubes at 7, 12, 17 and 27 pipe diameters upstream

of the orifice plate and examined the overall performance of the orifice plate. They

observed that at 17 pipe diameters downstream of the orifice plate, the statistical flow

characteristics remained same and were not influenced by the orifice plate to pipe

diameter ratios. [10] Hobbs and Humphreys investigated the effect of the orifice plate

entrance geometry on the flow. He suggested that the edge sharpness at the upstream face

deemed much more significant than the downstream face to sustain the discharged

coefficient. Today we see, there are mainly three types of classical circular orifice plates,

concentric, eccentric and segmental, of which, one can view the latter two types,

eccentric and segmental, are the variant of the concentric one (In fact, in this paper, we

use the term “classical” to refer to the concentric type only). Nevertheless, all the existing

orifice plates have similar pressure disadvantages and therefore a need of new type of

orifice plate to tackle the pressure problem deemed very significant. [10]

2.1.8 Fractal Orifice Plate

Fractal geometry, defined as, it is a derivative of classical Euclidean geometry

characterized by infinite details where the edge smoothness is absent. Mandelbrot defined

19
the fractal property to be the self similar infinite repetition of the whole object from

macro to micro scale. [10]

One can view the fractal object as repetitive smaller replications of the whole. Take a

cauliflower for a fractal example in nature. Each segmented part of it resembles the

whole. A tree is another example of fractal object found in nature. The vertically erected

trunk of a tree bifurcates into two or more branches and these branches further bifurcates

into many self-similar smaller branches. [10]

Fig 2.2: Fractal Plates [10]

From a practical point of view, there are two main parameters to consider: the Reynolds

number and the porosity. The shape of the orifice can lead to very different pressure

drops and flow patterns and a fractal approach might be a systematic way to classify

those shapes. [10]

The experiment is performed which consists a pipe (4 m long, 140 mm internal diameter)

in which different iterations of a fractal grid are inserted. In which used hot-wire

anemometry to record the velocity after the fractal grid. In which use a fractal pattern

based on von Koch's flake, the different iterations we used the Reynolds number used for

this work is 86 300. Fractal grids used in this study, corresponding to different iteration

20
of the same fractal pattern. Prom left to right SF1, SF2, SF3 and SF4 A time series of the

velocity is recorded from the hot-wire every 35 mm (1/4 of a pipe diameter) from the

fractal from 70 mm to 315 mm. At each position, a velocity profile is obtained. The time

sampling frequency used was 10 kHz. [12]

Fig 2.3: SF1, SF2, SF3 and SF4 [12]

Fig. 2.4 the disturbances are created using two elbows in the same plane and two elbows

out of plane. Once again, the orifice plate combined with the fractal flow conditioner

provides better results than the standard orifice plate. Thus, the use of a fractal flow

conditioner upstream of the orifice plate successfully damped the disturbed flow due to

the two elbows in the same plane and the two elbows out of plane. Therefore, it could be

concluded that the fractal flow conditioner with 51.85% porosity is a good geometry for

the fractal flow conditioner, and this plate will achieve less than a 1% variation in the

metering when faced with a standard flow. This compares well with the standard orifice

plate without any disturbances, which can also obtain 1% accuracy. [11]

21
 Fig 2.4: graph b/w change in Cd and Reynolds Number [11]

2.1.9 Principles of Orifice Plate

As the fluid approaches the orifice the pressure increases slightly and then drops

suddenly as the orifice is passed. It continues to drop until the “vena contracta” is reached

and then gradually increases until at approximately 5 to 8 diameters downstream a

maximum pressure point is reached that will be lower than the pressure upstream of the

orifice. The decrease in pressure as the fluid passes thru the orifice is a result of the

increased velocity of the gas passing thru the reduced area of the orifice. When the

velocity decreases as the fluid leaves the orifice the pressure increases and tends to return

to its original level. All of the pressure loss is not recovered because of friction and

turbulence losses in the stream. The pressure drop across the orifice plate increases when

the rate of flow increases. When there is no flow there is no differential. The differential

pressure is proportional to the square of the velocity, it therefore follows that if all other

factors remain constant, then the differential is proportional to the square of the rate of

flow. [13]

22
 CHAPTER 3

Methodology

3.1 3D Modeling of pipe

With the help of Solids Works 2016, we create a model of this project. Different steps are

involved during modeled designing on Solids Works 2016.

Following these steps are involved to create this model are given as:-

• First, we design a pipe according to our required dimensions.

Table 3.1: Dimensions of pipe

Sr. # Name Dimension

1 Length 6000 mm

2 Thickness 5 mm

3 Inner Dia 100.8 mm

4 Outer Dia 110.8mm

List of using commands:

• Select Plane

• Circle Command

• Extrude Command

1. We go to software (Solids Works 2016) and firstly we select a plane.

2. After that, we choose a circle command and draw a circle according to given
dimensions.

23
 3. We draw two circles (inner circle and outer circle) of given dimensions.

4. After drawing circles, then we select extrude command to draw a pipe of our
required dimensions (length=6000 mm).

Fig 3.1: Pipe

3.2 3D Modeling of Triangular Fractal Plate

After designing a pipe, we design a fractal plate according to our required dimensions.

Table 3.2: Dimensions of Triangular Fractal Plate

Sr. # Name Dimensions

1 Dia of fractal plate 100 mm

2 Thickness of fractal plate 20 mm

3 Center Triangle on fractal plate 20 mm

4 Equilateral Triangle each side length 24 mm

24
 ➢ List of using Commands for design of triangular fractal plate:

• Circle command

• Extrude

• Equilateral triangle

• Circular pattern

• Extrude cut

Now steps are involved

• For designing a fractal plate, first of all we use circle command according

to our requirements.

• Then extrude this circle according to given thickness.

• We draw an equilateral triangle on the fractal plate.

• After drawing equilateral triangle, we use circular pattern command and

draw 6 equilateral triangles in a circle.

• Then, we used extrude cut command to create a hole in triangles.

• We used circle command to create a small circle on the center of the

fractal plate.

• Then, we used again extrude cut command for create hole in this plate.

25
 Fig 3.2: Triangular Fractal Plate (S-1 Series)

3.3 Assembly portion

Then, we further move on assembly portion in solids works 2016. We assembled the

triangular fractal plate into the pipe. We used different commands in this step.

List of using Commands:

• Insert Component into the assembly

• Concentric mate command

• Distance Mate

➢ Now steps are involved

• First, we insert components (pipe and fractal plate) into the assembly.

• We select the concentric mate command to center axis.

• Then, we used the distance mate command to fix the fractal plate into the

pipe according to our required dimensions (2200 mm).

• Save this model.

26
 • Now finally our model is ready.

Fig 3.3: Final Assembly

Fig 3.4: Final Assembly

3.4 Other Fractal Plate Design

We also made some other design of fractal plates for analysis to compute our results.

Some Designs are:

27
Fig 3.5: S-2 Series

Fig 3.6: S-3 Series

28
 Fig 3.7: S-4 Series

3.5 Experimental setup Or Analysis

• First, open the COMSOL MULTI-PHYSICS 5.2a software in laptop. Then select

the study phase where we select flow analysis option. Here we select the option of

single-phase flow. Then we select the turbulent flow to our requirement. We add

these selections in the study phase. We select whether the experiment is time

dependent or not. Then, we select the option of time dependent. After this, we go

to the main bar where we select the live link and live link of SOLID WORKS.

• By live link, solids works attached to COMSOL MULTI-Physics. Where we

synchronized our design in COMSOL Multi-Physics 5.2a and we go to fluid

properties where we put the density and dynamic viscosity of water.

• Then we apply the boundary conditions. Select the no slip condition, inlet and

outlet of the pipe in our given design. We select the normal flow and suppress

29
 flow on inlet point. Apply the pressure of 10 Pa at inlet and 1atmospheric pressure

at outlet.

• We went to the meshing option for meshing process. We select the element size

and the meshing type. Apply the fine meshing. Then, start the meshing process.

After taking sometime meshing process completed. After meshing completion, we

compute our study. After sometimes computations results occurred.

• We have performed above analysis on different design of fractal plates.

30
 CHAPTER 4

Results

4.1 S-1 Series (P=50 pa , P=10 pa)

Fig 4.1: S-1 Series result (P=50pa)

Both sides of pipe are opened. We applied 50 Pa at inlet point and at outlet point,

pressure is one atmospheric. Plate thickness 3 mm. Then, we compute our results through

COMSOL MULTI-physics. We obtained pressure drop is 2.50 pa.

31
 Fig 4.1.1: S-1 Series result (P=10pa)

Both sides of pipe are opened. We applied 10 Pa at inlet point and at outlet point pressure

is 1 atmospheric. Plate Thickness 20 mm. Then, we compute our results through

COMSOL MULTI-physics. We obtained pressure drop is 0.25 pa.

4.2 S-2 Series (P=50 pa, P=10 pa)

Fig 4.2: S-2 Series result (P=50pa)

32
Both sides of pipe are opened. We applied 50 Pa at inlet point and at outlet point pressure

is 1 atmospheric. Plate Thickness 3 mm. Then, we compute our results through

COMSOL MULTI-physics. We obtained pressure drop is 2.51 pa.

Fig 4.2.1: S-2 Series result (P=10pa)

Both sides of pipe are opened. We applied 10 Pa at inlet point and at outlet point pressure

is 1 atmospheric. Plate thickness 20mm. Then, we compute our results through COMSOL

MULTI-physics. We obtained pressure drop is 0.24 pa.

4.3 S-3 Series (P=50 pa, P=10pa

Fig 4.3: S-3 Series result (P=50pa)

33
Both sides of pipe are opened. We applied 50 Pa at inlet point and at outlet point pressure

is 1 atmospheric. Plate thickness 3 mm. Then, we compute our results through COMSOL

MULTI-physics. We obtained pressure drop is 2.50 pa.

Fig 4.3.1: S-3 Series result (P=10pa)

Both sides of pipe are opened. We applied 10 Pa at inlet point and at outlet point pressure

is 1 atmospheric. Plate thickness 20 mm. Then, we compute our results through

COMSOL MULTI-physics. We obtained pressure drop is 0.25 pa.

4.4 S-4 Series (P=50 pa , P=10 pa)

Fig 4.4: S-4 Series result (P=50pa)

34
Both sides of pipe are opened. We applied 50 Pa at inlet point and at outlet point pressure

is 1 atmospheric. Plate thickness 3 mm. Then, we compute our results through COMSOL

MULTI-physics. We obtained pressure drop is 2.48 Pa.

Fig 4.4.1: S-4 Series result (P=10pa)

Both sides of pipe are opened. We applied 10 Pa at inlet point and at outlet point pressure

is 1 atmospheric. Plate thickness 20mm. Then, we compute our results through COMSOL

MULTI-physics. We obtained pressure drop is 0.18 Pa.

35
4.5 Graph b/w Pressure & Time

0.26
Pressure Drop(Pa) 0.24

0.22
series 1
0.2
series 2
0.18
series 3
0.16 series 4
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Time (sec)
Pressure 10 Pa, Time 1 sec,(Series 1 and 3 result same)

Fig 4.5: Graph b/w Pressure and Time

2.515
2.51
2.505
Pressure Drop (Pa)

2.5
2.495
2.49 series 1
2.485 series 2
2.48 series 3
2.475
series 4
2.47
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Time(sec)
Pressure 50Pa,Time 1 sec,(Series 1 and 3 result same)

Fig 4.6: Graph b/w Pressure and Time

36
 CHAPTER 5

Discussion

5.1 Discussion

When, we use orifice plate in the pipe, flow area decrease due to this reason velocity

increase and pressure drop. Other reason of pressure drop is due to retardation of flow

along the wall of the pipe and orifice plate. To overcome the pressure drop, we made

different designs of fractal plates. Names of fractal plates represented by S-1 Series, S-2

Series, S-3 Series and S-4 Series.

We have gone through analysis by using software COMSOL Multi-Physics 5.2a. During

Process of analysis some parameters are considered, such as Turbulent flow, Normal

flow, suppress flow, No slip condition, viscosity of water, inlet condition, outlet

condition and atmospheric pressure, time dependent, contour pressure. We selected the

pipe dimension, plate length and plate thickness according to ASME/ANSI standard B-

36.10M. We selected the No slip condition because fluid viscosity effects on the flow

around the solid body. The flow velocity near the solid body is very low and in the center

of pipe, fluid velocity is maximum. Due to no slip, condition turbulence generates.

Turbulent flow, type of fluid flow in which the fluid undergoes irregular fluctuations. In

turbulent flow, the speed of fluid at a point is continuously undergoing changes in both

magnitude and direction. Turbulence is commonly observed in everyday phenomena such

as fast flowing rivers, billowing storm clouds, or smoke form a chimney, and most fluid

flows occurring in nature and created in engineering applications are turbulent.

37
Contour pressure define that, there is friction between layers of fluid, which is viscous

stress due to viscosity of fluids. Therefore, pressure drop by viscous stress also which is

called contour pressure. Contour pressure divides into equal height and this effect also

show in the color scheme with results.

The mixture model and bubbly flow interfaces have been updated with a new outlet

pressure condition, which includes options for suppress back flow and normal flow.

When, suppress back flow is selected, we also compute the results of back flow on the

entire boundary.

Fig 5.1: Suppress flow behavior

When, we import the 3D model of our design in COMSOL Multi-Physics 5.2a, analysis

performed in software. Software process of analysis performed on the base of Navier

Stokes Equation. Navier Stokes Equation governs the motion of fluid.

Navier stokes equation is:

𝜕𝑢 2
𝜌 ( + 𝑢. ∇𝑢) = −∇𝑝 + ∇. (𝜇 (∇𝑢 + (∇𝑢)𝑇 ) − 𝜇(∇. 𝑢)𝐼) + 𝐹 (5.1)
𝜕𝑡 3

Where u is the fluid velocity, p is the fluid pressure and ρ is the fluid density.

This equation consists of four different terms.

38
 1. Inertial Forces

2. Pressure Forces

3. Viscous Forces

4. External Forces applied to the fluid

These equations are at the heart of the fluid flow modeling. Solving them, for a particular

set of boundary conditions (such as inlets, outlets, and walls), predicts the fluid velocity

and pressure in a given geometry.

Firstly, we did the experiment on simple orifice (S-1 Series), at boundary conditions

(Inlet=50 pa, Outlet=1 atm (101325pa), No slip Condition, Normal Flow, Suppress Flow,

Viscosity of water=997 kg/m^3, Dynamic Viscosity of water= 8.90 × 10−4 pa.s, Time=1

sec, Time Dependent). We compute the result.

Then, we change the designs of fractal plate (S-2 Series, S-3 Series, and S-4 Series) and

analysis performed on it above boundary conditions of S-1 Series. We compute the

results on these different designs of fractal plates. S-4 Series result is very efficient as

compared to other series. We reduce the turbulence losses in pipe.

After performing at pressure=50pa, change the design of fractal plates (increase the plate

thickness). We did the experiment on simple orifice (S-1 Series), at boundary conditions

(Inlet=10 pa, Outlet=1 atm (101325pa), No slip Condition, Normal Flow, Suppress Flow,

Viscosity of water=997 kg/m^3, Dynamic Viscosity of water= 8.90 × 10−4 pa.s, Time=1

sec, Time Dependent). We compute the result.

Then, we again change the designs of fractal plate (S-2 Series, S-3 Series, and S-4 Series)

and analysis performed on it above boundary conditions of S-1 Series. We compute the

39
results on these different designs of fractal plates. S-4 Series result is very efficient as

compared to other series. We reduce the turbulence losses in pipe.

We noted that after analysis, plate thickness affect on pressure drop. If, we do not show

clear affect of plate on pressure drop in software during analysis, then increase the plate

thickness.

40
 CHAPTER 6

Conclusion

6.1 Conclusion

In this research, pressure drop in pipe through various design of fractal plates have been

investigated with the help of COMSOL Multi-Physics 5.2a.

6.1.1 Following Conclusions are made

➢ When, we applied pressure 50 pa and 10 pa on different designs of fractal plates,

S-4 Series is our best design. Because, in this design pressure drop is minimum as

compared to other design of fractal plates series.

➢ In S-4 Series, pressure drop is drop because retardation of fluid flow produced
minimum as compared to other. Retardation reduced because we give the

maximum area for passes to fluid flow in a pipe. Due to this reason, retardation

minimum and pressure drop become minimum.

➢ We noted that, thickness of plate is effect on results during analysis. If, we want
more accurate and precise results, then increased the thickness of plate.

➢ By increasing thickness of plate, we get more accurate and precise results during
analysis in COMSOL Multi-Physics 5.2a.

41
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[9] Fundamentals of Orifice Meter Measurement

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42
[11] The fractal flow conditioner for orifice plate flow meters B. Manshoor ∗, F.C.G.A.

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Nicolleau‡ SFMG, Department of Mechanical Engineering, The University of

Sheffield,28 june 2017.

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Shanmugan S and4Ganapathy Srinivasan R

43
 ABBREVIATIONS
ASME (American Society of Mechanical Engineers)

ANSI (American National Standards Institute)

Atm (Atmospheric Pressure)

Pa (Unit of Pressure Pascal)

MEMS (Micro-electromechanical systems)

44