Monroe L.

Weber-Shirk
School of Civil and
Environmental Engineering
Flow Control Flow Control
Creativity without a trip
Variations on a drip
Giving head loss the slip

Overview

Why is constant flow desirable?

If you had electricity

Hypochlorinators in Honduras Hole in a Bucket

Constant head devices

Overflow tanks

Marriot bottle

Floats

Float valve

Orifices and surface tension

Flow Measurement

Applications of Constant Flow Applications of Constant Flow

POU treatment devices (Point of Use)

UV disinfection

clay pot filters

SSF (slow sand filters)

arsenic removal devices

Reagent addition for community treatment

processes

Alum for ____________

Calcium or sodium hypochlorite for ____________

Sodium carbonate for _____________

Could you make a flow control device that

increased the dose in proportion to the main flow?
coagulation
disinfection
pH control

Why is constant flow desirable for
POU treatment devices?
Why is constant flow desirable for
POU treatment devices?

Slow constant treatment can use a smaller

reactor than intermittent treatment

It isnt reasonable to expect to treat on

demand in a household

Flow variations are huge (max/average=_____)

System would be idle most of the time

Use a mini clearwell so that a ready supply

of treated water is always available
40

If you had electricity If you had electricity

Metering pumps (positive displacement)

Pistons

Gears

Peristaltic

Valves with feedback from flow sensors

So an alternative would be to raise the per capita

income and provide electrical service to everyone

But a simpler solution would be better!

Constant Head: Floats
(variation on hypochlorinator)
Constant Head: Floats
(variation on hypochlorinator)
orifice
VERY Flexible hose
Head can be
varied by
changing
buoyancy of
float
Supercritical
open channel
flow!
Unaffected by downstream conditions!
2
orifice orifice
Q K A g h
h

Floating Bowl Floating Bowl

Adjust the flow by changing the rocks

Need to make
adjustments (INSIDE)
the chemical tank

Rocks are submerged in

the chemical

Safety issues

Chemical Metering
(Hypochlorinator)
Chemical Metering
(Hypochlorinator)
Transparent
flexible tube
(0.5)
1.0 m
1.05 m
1.78 m
1.5 PVC
overflow tube
Float
PVC needle
valve 0.5 PVC tube
Water in the distribution tank
What is the simplest
representation that
captures the fluid
mechanics of this
system?

Hole in a Bucket Hole in a Bucket
Vena contracta
0.6
vc orifice
A A
Orifice
2
orifice orifice
Q K A g h
h
0.6
orifice
K

Transparent
flexible tube
(0.5)
1.0 m
1.05 m
1.78 m
1.5 PVC
overflow tube
Float
PVC needle
valve 0.5 PVC tube
Water in the distribution tank
Transparent
flexible tube
(0.5)
1.0 m
1.05 m
1.78 m
1.5 PVC
overflow tube
Float
PVC needle
valve 0.5 PVC tube
Water in the distribution tank
Use Control Volume Equation:
Conservation of Mass
h
0
or
cv
Q dV
t

2
or or or
Q K A gh
2 0
res or or
dh
A K A gh
dt
+
res
or
A dh dV
Q
dt dt

cs cv
dA dV
t
r r

=-

Vn
Orifice in the PVC valve
Integrate to get h as f(t)
volume
2 V gh

Finding the chlorine depth as f(t)
0
0
2
h t
res
h or or
A dh
dt
K A g h

( )
1/2 1/2
0
2
2
res
or or
A
h h t
K A g

0
2
2
or
or
res
A
h h tK g
A

Integrate
Solve for height
Separate variables

Finding Q as f(t) Finding Q as f(t)
2
or or
Q K A gh
0
2 2
2
or or
or or
res
tK A
Q K A g h g
A
| `


. ,
0
0
2
or
or
Q
A
K gh

Find A
or
as function of initial target flow rate
Set the valve to get desired dose initially
0
2
2
or
or
res
A
h h tK g
A


Surprise Q and chlorine dose
decrease linearly with time!
Surprise Q and chlorine dose
decrease linearly with time!
0 0
1
1
2
res
design
h Q t
Q t h

0
0
2
or
or
Q
A
K gh

0
2 2
2
or or
or or
res
tK A
Q K A g h g
A
| `


. ,
Relationship between Q
0
and A
res
?
Assume flow at Q
0
for time (t
design
) would empty reservoir
0 design res res
Qt A h
0 res
res design
Q h
A t

2
2
0
0
1
1
2
Cl
res
Cl design
C
h t
C t h
| `



. ,
0
0 0
1
2
res
tQ Q
Q A h

Linear decrease in flow

Effect of tank height above valve Effect of tank height above valve
2
0
2
0
Q
h h
Q

0 2 4 6 8
0
0.2
0.4
0.6
0.8
0
0.2
0.4
0.6
0.8
Qratio t t
design
, h
res
, h
0
,
( )
h t t
design
, h
res
, h
0
,
( )
h
0
h
res

( )

h
res
t
day
Depth in
reservoir
Case 1, h
0
=50 m,
h
res
= 1 m,
t
design
=4 days
0 2 4 6 8
0
0.2
0.4
0.6
0.8
0
0.2
0.4
0.6
0.8
Qratio t t
design
, h
res
, h
0
,
( )
h t t
design
, h
res
, h
0
,
( )
h
0
h
res

( )

h
res
t
day
Case 1, h
0
=1 m,
h
res
= 1 m,
t
design
=4 days

Constant Head: Overflow Tanks Constant Head: Overflow Tanks
Surface tension
effects here
What controls
the flow?
2
orifice orifice
Q K A g h
h
orifice
A

Constant Head:
Marriot bottle
Constant Head:
Marriot bottle

A simple constant head device

Why is pressure at the top of

the filter independent of water
level in the Marriot bottle?

What is the head loss for this

filter?

Disadvantage? ___________
2 2
2 2
in in out out
in in P out out T L
p V p V
z h z h h
g g


+ + + + + + +
L
h
batch system

Constant Head: Float Valve Constant Head: Float Valve
Float adjusts opening
to maintain relatively
constant water level in
lower tank
(independent of upper
tank level)
NOT Flow Control!
?
Describe sequence of events after filling

Flow Control Valve (FCV)

Limits the ____ ___

through the valve to a
specified value, in a
specified direction

Calculate the sizes of

the openings and the
corresponding
pressures for the
flows of interest
flow rate

Expensive

Work best with large

Q and large head loss

Raw water reservoir and SSF
Flow control device
Clean water reservoir
Small diameter tubing
Float valve and small
tube
Float valve and small
tube

Floating Ball Valve Floating Ball Valve
Float valve
Small
diameter
tube

Float valve with IV drip Float valve with IV drip
. cm 83
. cm 110
. cm 05
. cm 44
. cm 65
mm 2
. cm 23
. cm 91
mm 2
. cm 56
. cm 15
cm 2
. cm 52 Housing Dimensions:
ID = . cm 785
OD = . cm 88
Float
mass:
grams 6
IV roller
clamp
Rubber tip
Barb tubing
adapter
PVC
stem
IV tubing
(~ drops/ 10 mL)
. cm 83
. cm 110
. cm 05
. cm 44
. cm 65
mm 2
. cm 23
. cm 91
mm 2
. cm 56
. cm 15
cm 2
. cm 52 Housing Dimensions:
ID = . cm 785
OD = . cm 88
Float
mass:
grams 6
IV roller
clamp
Rubber tip
Barb tubing
adapter
PVC
stem
IV tubing
(~ drops/ 10 mL)

Floating Bowl with Orifice Floating Bowl with Orifice

S
a
n
d

c
o
l
u
m
n
HJR
Holding container
(bucket or glass
column)
Pong pipe
Sealing pipe
Driving pressure for sand column
Upflow prevents trapped air
(keyword: prevent)!

Flow Control Competition Results
from CEE 454 in 2004
Flow Control Competition Results
from CEE 454 in 2004

What are the two essential elements of

gravity powered flow control?

Constant head (float valve wins!)

Head loss elements

____________________________________

____________________________

____________________________

Can use flexible tube to facilitate adjusting the

head
Orifice i.e.. small hole or restriction
Long small diameter tube
Porous media

Flow control device
Small diameter tubing
Float valve and small tube
(Gravity dosing system)
Float valve and small tube
(Gravity dosing system)
h
l
f
2 4
32 128 LV LQ
h
gD g D



4
l
128
h g D
Q
L

chemical stock tank

If laminar flow!
2 2
2 2
in in out out
in in P out out T L
p V p V
z h z h h
g g


+ + + + + + +
L in out
h z z Neglecting minor losses

Long small tube head loss Long small tube head loss

Laminar flow

Turbulent Flow
f
2 4
32 128 LV LQ
h
gD g D



2
f
2 5
8
f
LQ
h
g D

2
0.9
0.25
f
5.74
log
3.7 Re D

] | `
+

]
. , ]
D
Q 4
Re
Flow proportional to h
f

Orifice flow Orifice flow
2
4
2
8
v
Q
D K
g h

2
or
Q K A gh
2
2 2 4
1 8
or
Q
h
K g D

2
1
or
K
K

Solve for h and substitute

area of a circle to obtain same
form as minor loss equation
K
or
= 0.63 therefore K=2.5
2.5 d 8 d
d
h
D

Porous Media Head Loss: Kozeny
equation
Porous Media Head Loss: Kozeny
equation
f
2
32
pore
pore
LV
h
gd

a
pore
V
V

Velocity of fluid above the porous media

Laminar flow assumption
( )
2
f
3 2
1
36
a
sand
V h
k
L gd

k = Kozeny constant
Approximately 5 for
most filtration conditions

Tube vs. Orifice Tube vs. Orifice

Clogging

Adjustability
0 50 100 150 200
0
1
2
3
D
tube
Q 20cm , 1m , , ( )
mm
D
orifice
2.5 Q , 20cm , ( )
mm
Q
mL
min
D
tube
Q h
f
, L , ,
( )
128 L Q
g h
f

.
`

,
1
4
:
D
orifice
K Q , h
e
,
( )
K
8 Q
2

g
2
h
e

.
`

,
1
4
:
Minor losses Major losses

Surface Tension Surface Tension
h
Is the force of gravity stronger than surface tension?
3
4
3 2
g
r
F g

2 r
F

=
F
p
=
( )
3
2
4
2 r
3 2
r
g g h r

( )
2
g h r
Will the droplet drop?

Surface Tension can prevent flow! Surface Tension can prevent flow!
0.050
0.055
0.060
0.065
0.070
0.075
0.080
0 20 40 60 80 100
Temperature (C)
S
u
r
f
a
c
e

t
e
n
s
i
o
n

(
N
/
m
)
( )
3
2
4
2 r
3 2
r
g g h r

( )
3
2
4
2 r
3 2
r
g
h
g r

Solve for height of water
required to form droplet
2 2
3
r
h
gr

Design constraint for flow control
devices: Surface Tension
Design constraint for flow control
devices: Surface Tension
0.1 1 10
1
10
100
h r ( )
mm
r
mm
2 2
3
r
h
gr

Delineates the
boundary between
stable and unstable
No droplets form to left of line
Flow control devices
need to be designed
to operate to the
right of the red line!

Hypochorinator Fix Hypochorinator Fix
http://web.mit.edu/d-lab/honduras.htm
What is good?
How could you improve this system?
What might fail?
Safety hazards?

Modular Flow
Control
Modular Flow
Control

Identify the Flow Controller Failure
Modes
Identify the Flow Controller Failure
Modes

Moving parts

Wear

Corrosion (especially with corrosive chemicals)

Precipitation (e.g. calcium carbonate)

Incompatible materials

Dont forget sunlight has UV rays!

Clogging

Design errors

Flow Measurement Devices Flow Measurement Devices

Orifice in the side of a pipe

Pipe vented through water

surface

Jet of water must free fall

inside the pipe
K
orifice
is due to the vena
contracta and has a value
of approximately 0.6.
h g A K Q
orifice orifice
2
h

Free Surface with Orifice limitations Free Surface with Orifice limitations

The head loss from making the

measurement is wasted (likely on the
order of 20 cm)

Ability to include this type of flow

measurement depends on availability of
excess potential energy

The useable measurement range doesnt

include the range where the orifice is
only partially submerged

Thus large diameter orifices arent ideal

because they limit the measurement
range

For reasonably small head loss the flow

per orifice cant be much greater than
100 Lpm

Use multiple orifices for larger flow

rates
Q
plant
d h , ( ) K
orifice
d
2

4
2 g h :
40 60 80 100 120 140
0
5
10
15
20
25
h
cm
Q
plant
d h , ( )
L
min

Alternative Flow Measurements Alternative Flow Measurements
Block the effluent port from a small tank and measure
the rate of depth increase
The grit chamber at the head of a water treatment plant could
be used for this purpose
But this causes a major flow disturbance for the plant
open channel weirs for very large flow rate
measurements
Orifice plates in a pipe (use manometer to measure
pressure drop)
If you have access to electricity, then there are a large
number of measurement techniques available