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Overview of Vortex Flow Meters
Vortex flow meters are flow measurement instruments that utilize the Karman vortex street principle in their design. They measure the volume flow rate of gases, steam, or liquids, the volume flow rate under standard conditions, or the mass flow rate of fluids through relevant calculations.
The core working mechanism is as follows: when fluid flows through the vortex generator or collector rod inside the meter, it forms alternating vortices on both sides of the generator. The frequency of vortex shedding has a direct proportional relationship with the fluid flow velocity, enabling precise flow measurement.
Applicable Scenarios for Vortex Flow Meters
- Water-based Liquid Measurement
- Cooling Circuit Monitoring
- Small Pipe Diameter Systems
- Stable Operating Conditions and Low Vibration Environments
- Cost-sensitive Industrial Fields
Core Advantages of Vortex Flow Meters
Strong Versatility
Vortex flow meters can efficiently measure the flow of various media such as liquids, gases, and steam, and they do not restrict themselves to the conductivity of the measured fluid.
On the one hand, they suit deionized water systems that do not require the fluid to have specific conductivity, and they solve the problem that some flow meters depend on the conductivity of the medium.
On the other hand, they can stably adapt to steam in thermal power plants and various gases in industrial production, and they meet the measurement requirements of different industrial scenarios.
Excellent Durability and Low Maintenance Costs
Vortex flow meters have a simple structure with few moving parts, which fundamentally reduces the probability of mechanical failures.
Unlike traditional throttling differential pressure flowmeters, they do not require auxiliary components such as pressure guiding tubes and three-valve groups, thus avoiding leakage, freezing, and other problems that these components cause due to aging and clogging.
This design not only extends the instrument’s service life but also significantly reduces the maintenance workload and costs for enterprises.
Stable measurement with minimal external interference
Within a specific range, thermodynamic parameters such as fluid temperature, pressure, density, and viscosity do not affect the measurement results of the vortex flowmeter. Its instrument coefficient only relates to the shape and size of the vortex generator and the pipe.Therefore, even in dynamic working conditions where the temperature and pressure of the measured medium fluctuate, the vortex flowmeter can still provide stable and reliable data.
Except for special cases such as strong vibration, external environmental factors have minimal impact on the vortex flowmeter during its normal operation. This ensures the accuracy of the measurement results and makes it suitable for industrial production scenarios with relatively complex working conditions.
High measurement accuracy and wide measurement range
Vortex flowmeters typically achieve a measurement accuracy of ±(1% – 5)% R (relative accuracy) — ±1% – ±2% for gas measurement and ±2% – ±5% for liquid measurement. This accuracy fully meets the flow measurement requirements of most industrial scenarios, such as material proportioning in chemical production and steam statistics in energy measurement.
When you determine the appropriate diameter, the vortex flowmeter can reach a measurement range ratio of 20:1. It can adapt to significant changes in fluid flow during different production stages, eliminating the need to frequently replace the instrument due to flow fluctuations and improving production efficiency.
High cost-effectiveness
Vortex flowmeters have a relatively low initial installation cost. Especially for pipes with a diameter of less than 6 inches, compared with orifice plate flowmeters, they do not require additional pressure guiding tubes or special anti-freezing measures beyond the basic pipe protection — this significantly reduces enterprises’ initial investment.
Combined with their low-maintenance characteristics, from a life-cycle cost perspective, the total investment in vortex flowmeters is much lower than that in other similar instruments. This makes them highly attractive to small and medium-sized enterprises with limited budgets.
Low pressure loss
Vortex flowmeters have a pressure loss that is only 1/4 – 1/2 of that of throttling differential pressure flowmeters. This advantage is crucial for pressure-sensitive systems.
The smaller pressure loss can reduce the energy consumption of the fluid transportation system and prevent excessive pressure loss from affecting the normal operation of the production process. It is especially suitable for scenarios with tight energy supply or strict system pressure requirements, such as precision chemical reaction systems.
Main disadvantages of the vortex flowmeter
Poor anti-pollution ability and prone to clogging
Vortex flowmeters are not suitable for measuring media containing impurities: impurity particles and dirt in the measured fluid tend to adhere to the surface of the vortex generator, changing its geometric dimensions and interfering with the vortex shedding frequency. This significantly increases measurement error and may even make normal measurement impossible.
If the measured liquid has polymerization properties, polymer substances can clog the instrument’s sensor port and cause it to fail. Although some models are equipped with filters or use special anti-clogging sensor designs, they still have limitations in high-pollution environments.
Prone to vibration interference
Vortex flowmeters have weak anti-vibration ability: high-intensity vibrations in the system can make the instrument misinterpret vibration signals as increased flow, leading to distorted measurement results; in severe cases, vibrations can also damage the instrument’s internal structure and render it completely inoperable.The high-speed impact of fluid in the pipe on the cantilever structure of the vortex generator can cause additional vibration, further reducing measurement accuracy — this effect is more pronounced in large-diameter pipes.
Although some instruments have a “noise frequency band” adjustment function to filter out vibration interference, this function simultaneously reduces the instrument’s sensitivity and significantly increases the low-flow cut-off value, limiting its application in low-flow scenarios.
Limited in measuring high-viscosity and low-flow media
Vortex flowmeters cannot effectively measure high-viscosity media: When the fluid viscosity is too high, it struggles to form stable vortices (or fails to generate vortices at all) as it passes through the vortex generator, leaving the instrument unable to perform normal measurement. For such scenarios, we recommend using dedicated instruments such as Coriolis mass flowmeters or oval gear flowmeters.
Vortex flowmeters have a “low-flow cut-off” characteristic: They require the fluid to be in a turbulent state to operate. When the flow rate is too low and the fluid transitions from turbulent to transitional or laminar flow, the instrument stops reading and cannot measure flow rates below the cut-off value.
Moreover, the low-flow cut-off value relates to fluid viscosity, which temperature and composition affect. This makes vortex flowmeters unsuitable for applications that require precise measurement of low flow rates.
Mass flow measurement depends on fluid density
The core function of vortex flowmeters is to measure volumetric flow. If mass flow needs to be calculated, it must be converted based on fluid density. However, fluid density is easily affected by changes in working conditions, such as temperature and pressure fluctuations. If the density changes cannot be monitored in real time and accurately, the calculated mass flow will have significant errors.
Strict requirements for straight pipe sections
Vortex flowmeters require sufficient straight pipe sections for normal operation: To ensure a stable fluid flow field and regular vortex generation, they typically need an upstream straight pipe section length of 15 – 40 times the pipe diameter (D) and a downstream section of 5 – 20 times D. Some manufacturers even specify that the upstream straight pipe section must be no less than 25D and the downstream section no less than 10D.
If the on-site pipeline layout fails to meet the straight pipe section requirements (such as elbows or valves near the instrument), it will distort the fluid flow field, disrupt the regularity of vortex generation, and lead to measurement errors. This requirement increases the difficulty of on-site installation, and some enterprises may need to modify existing pipelines, which incurs additional costs and labor.
| Category of Technical Parameters | Specific Indicators | Description |
| Measuring Principle | Karman Vortex Street Principle | When fluid flows through the vortex generator, alternating vortices are formed, and the frequency of vortex shedding is proportional to the fluid velocity. |
| Measured Media | Gases, steam, liquids (mainly water-based) | Not limited by the conductivity of the medium; not suitable for media containing impurities, easy to polymerize, or with high viscosity. |
| Measurement Accuracy | Relative accuracy ±(1%-5)% R | For gas measurement: ±1%-±2% R; For liquid measurement: ±2%-±5% R. |
| Measurement Range Ratio | 20:1 (requires matching appropriate pipe diameter) | Can adapt to significant changes in fluid flow during different production stages without frequent instrument replacement. |
| Temperature Resistance Range | Conventional ≤ 300°C | For high-temperature scenarios, dedicated high-temperature flow meters are required; long-term use near the upper limit of temperature resistance accelerates the aging of electronic components. |
| Pressure Loss | 1/4 – 1/2 of that of throttling differential pressure flow meters | Suitable for pressure-sensitive systems, reducing energy consumption of fluid transportation. |
| Straight Pipe Section Requirement | Upstream: 15-40D, Downstream: 5-20D | Some manufacturers require upstream ≥ 25D and downstream ≥ 10D to ensure a stable flow field. |
Limited temperature resistance
The temperature resistance range of vortex flowmeters is relatively narrow, typically only capable of measuring media with temperatures below 300°C. For high-temperature scenarios, dedicated high-temperature flowmeters must be used.
Additionally, long-term use near the upper limit of temperature resistance will accelerate the aging of electronic components inside the instrument’s transmitter, reducing its service life. Therefore, in high-temperature scenarios, remote transmission transmitter heads should be selected to prevent electronic components from being damaged by “high-temperature baking.”
Weakened economic advantage in large-diameter pipe scenarios
The cost advantage of vortex flowmeters is mainly reflected in pipes with diameters less than 6 inches. When the pipe diameter exceeds 6 inches, compared with other instruments such as orifice plate flowmeters, its cost advantage gradually disappears, and in some cases, it may even be more expensive.
This characteristic limits its application in large-diameter pipe flow measurement, such as large-scale water supply and drainage pipes and large-diameter gas transmission pipes.
Vortex Flowmeter Selection Guide
- Consider the contamination level of the measured medium
- Match the temperature and pressure range
- Pay attention to the requirements for straight pipe sections
- Determine whether additional functions are needed
- Adapt to the pipe diameter and flow range
- Evaluate the vibration environment
| Scenario Type | Specific Scenarios | Adaptability | Core Reason |
| Suitable Scenarios | Water-based liquid measurement (e.g., cooling water) | ★★★★★ | The medium cleanliness meets requirements, with no polymerization or high viscosity issues. |
| Suitable Scenarios | Small-diameter pipe systems (< 6 inches) | ★★★★★ | Low initial installation cost and significant economic advantages. |
| Suitable Scenarios | Stable and low-vibration environments (e.g., conventional chemical workshops) | ★★★★☆ | Avoids vibration interference with vortex generation and ensures measurement accuracy. |
| Suitable Scenarios | Cost-sensitive industrial fields (small and medium-sized enterprises) | ★★★★☆ | Low life-cycle cost and minimal maintenance workload. |
| Unsuitable Scenarios | Media containing impurities / easy to polymerize (e.g., slag-containing wastewater) | ★☆☆☆☆ | Impurities are easy to adhere to the vortex generator, and polymers are easy to block the sensor. |
| Unsuitable Scenarios | High-vibration environments (e.g., pipes near large compressors) | ★☆☆☆☆ | Vibration easily leads to signal misjudgment and even damages the internal structure of the instrument. |
| Unsuitable Scenarios | High-viscosity media (e.g., heavy oil) | ★☆☆☆☆ | Difficult to form stable vortices, making normal measurement impossible. |
| Unsuitable Scenarios | Large-diameter pipes (> 6 inches, e.g., municipal water supply pipes) | ★★☆☆☆ | The cost advantage disappears; in some cases, it is more expensive than orifice plate flow meters. |
