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Annular Flow Meter: Segmented Wedge Differential Pressure Processing Sensors
Quick Answer: Segmented wedge differential pressure flow meters from Silver Instruments measure difficult process fluids such as slurries, heavy oil, wastewater sludge, and wet steam. These annular flow meters reduce plugging and hold a stable signal on pipe sizes from DN15 to DN200. Send your pressure in bar, temperature in °C, pipe size in DN, and flow range to get a quote and model selection.
Here is the thing about process flow measurement. Most standard differential pressure meters fail when the fluid contains solids, wax, or polymer. The annular flow meter design uses a segmented wedge restriction that sits away from the pipe wall. Because the wedge shape is not symmetrical, solids do not pack in front of the sensor. This is a practical choice for process lines that run 24 hours a day.
What Is a Segmented Wedge Differential Pressure Flow Meter
A segmented wedge DP flow meter has a V shaped restriction that creates a pressure drop. The annular body holds a wedge segment in the lower part of the pipe. Upstream and downstream pressure taps send a differential pressure signal to a transmitter. Silver Instruments builds these meters with an integrated DP transmitter and optional PT100 temperature sensor.
The annular flow meter version is often used for viscous or dirty fluids. In practice, this means slurries, sludge, heavy ends, and fluids with Reynolds numbers below 5000. A standard orifice plate would need straight run and may clog in these services. The wedge element handles a wider range of velocities without losing signal.
How the Annular Flow Meter Works on Process Sensing Lines
The sensor measures the pressure difference between the high side and low side of the wedge. The transmitter converts this differential to flow rate. For liquid service the output can be kg/h, m³/h, or l/min. For gas service the output is often Nm³/h or kg/h. The 4-20 mA HART signal drops into most PLC and DCS systems without extra converters.
Silver Instruments annular wedge meters work with remote diaphragm seals on slurry lines. The seals isolate the transmitter from solids and crystals. A PT100 sensor can be installed in the downstream tap for temperature compensation. This keeps the signal stable on heat jackets and steam traced lines.
Key Specifications for Process Sensors and Transmitters
Most orders from Southeast Asia and the Middle East fall in the following range. Sizes run from DN15 to DN200 as standard. Larger sizes up to DN300 are available on request. The wetted material can be 316L stainless steel, Hastelloy C, or duplex steel. Pressure ratings cover PN16 to PN100 and ANSI 150 to 600. Process temperature can go from -40 °C to 260 °C with the right seals.
Accuracy is ±0.5 percent of rate for liquids above 15 percent of full scale. The minimum measurable flow depends on density and viscosity. For water at 1 bar and 20 °C a DN50 unit measures from about 0.6 m³/h. The transmitter output includes 4-20 mA HART and RS485 Modbus. ATEX Zone 1 and IECEx versions are available for gas and chemical plants.
Typical Applications and Fluid Conditions
We have seen these meters run on many different process lines. A paint manufacturer in Vietnam used a DN80 annular wedge meter on solvent and resin blends at 12 bar and 150 °C. The unit ran for 14 months without cleaning. Another customer in Saudi Arabia measured heavy fu
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Water and wastewater plants in the Gulf region use these meters on thickened sludge with 3 to 5 percent solids. The annular design prevents rags and grit from blocking the tapping points. Food and beverage users often install a DN25 or DN40 meter on molasses, syrup, or chocolate mass. For these fluids the viscosity can cross 1 000 cP and still produce a repeatable DP signal.
Why Process Engineers Choose Wedge DP Over Orifice Plates
Orifice plates are cheap but they have a sharp edge. That edge wears down in slurry service. It also catches fibers and wax. The wedge has a sloped face and a wider flow gap. Debris passes under the restriction instead of collecting in front of it. Because of this shape, a wedge meter does not need the same long straight pipe run as an orifice plate. In compact skids this saves space and reduces piping cost.
Another reason is low Reynolds number performance. Many chemicals and heavy oils run in laminar or transitional flow. A wedge DP meter keeps a usable differential at low velocity. That is important for batch charging and start up conditions. Most engineers skip the complex viscosity correction for this reason unless the process is very sensitive.
Model Selection Guide and Sizing Inputs
Silver Instruments uses model code SI-WG-A for the annular segmented wedge flow meter. For clean liquid service the standard version works with a direct mounted transmitter. For dirty or crystallizing fluid select the remote diaphragm seal version with PT100. For gas or steam add the pressure transmitter input and flange rating to match your pipe spec.
To get a firm quote we need these process data: fluid name, flow range, operating pressure in bar, temperature in °C, pipe size in DN, and required output. The flow range can be in kg/h, m³/h, or Nm³/h. Viscosity in cP helps for heavy oil and molasses. Conductivity in µS/cm is not needed for wedge DP because this is not a magnetic flow meter.
Frequently Asked Questions
What is the minimum pipe size for a segmented wedge DP meter?
Standard sizes start at DN15. Smaller sizes are possible but they require clean process fluid and a lower flow turndown.
Can this meter handle viscous fluids above 100 cP?
Yes. Wedge DP meters are often used from 100 cP to over 3 000 cP. The exact range depends on density, pipe size, and differential pressure.
What output signals are available?
The transmitter gives 4-20 mA HART as standard. RS485 Modbus is optional. Pulse output is available when a flow totalizer is required.
Is the meter suitable for ATEX Zone 1?
Flameproof and intrinsically safe versions are available for ATEX Zone 1 and IECEx. You must specify the gas group and temperature class with your order.
How do I send sizing data to Silver Instruments?
Send your fluid, pressure in bar, temperature in °C, pipe size in DN, and flow range to our sales team. We reply with a model recommendation, accuracy estimate, and price.
Contact Silver Automation Instruments
Tel: +86-135-1213-1526
Whatsapp: 86-135-12131526
WeChat: +86 13512131526
Send us your pressure in bar, temperature in °C, pipe size in DN, and flow range. We will confirm the segmented wedge DP model and lead time within one working day.
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