Gas Flow Measurements

Objectives of Training
Describe the importance of flow sensing and its problems?
Describe principle of operation of different flow meters?
Describe constructional and measurement aspect of different
flow meters?

Contents
1. Over view
2. Process Significance
3. Air Flow measurement safety
4. Flow calculation parameters (Area, temp, Gas composition and density)
5. Gas Velocity-Sampling site
6. L type Standard Pitot
7. S type Pitot
8. Manometers (Digital/ Utube)
9. Anemometer
10. Pizo Rings

Flow Measurement Orientation

Basic Process Parameter for monitoring
Daniel Bernouli - 1783
How much amount?
Control of amount?
Mass or volumetric Flow Rate
Provides instantaneous value for quantity Integrate

Differential flow meters

Differential pressure across a restriction is measured in the line
of fluid flow which is proportional to the flow rate.
Orifice plate
Venturi tube
Dall tube
Pitot tube
Rota meter
Flow nozzle

Differential flow meters

Parts of a Differential flow meters
Primary element
Part of meter used to restrict the fluid flow in
pipe line to produce differential pressure
Secondary element
Measures the differential pressure produced by
primary elements and convert them to usable
forces or signals

Orific Plate
Orifice meter
Simple and inexpensive flow restriction to determine
flow rate.
Material of construction is stainless steel, glass nickel
and plastic and is applicable for cleaner fluids.
Orifice plate inserted between the flanges in the pipes
having flow of certain velocity and pressure.
Several types of orifice plates based on the shape and
position of hole present like concentric, eccentric and
segmental.

Differential Flow Meter

Differential Flow Meter

Venturi meter
Less pressure losses as compared to the orifice meter
The fluid is accelerated while passing through the converging
cone in its way where the pressure is reduced and then become
constant and in the diverging section the pressure is recovered
with very little loss. Usually made of cast iron or steel.
Venture tubes built in several form like long form, eccentric
form or rectangular form.

Differential Flow Meter

Differential Flow Meter

Flow nozzle
Combines the better features of both elements.
Capable of measuring greater flow of gases and liquids at high
temperatures.
They dont have sharp bending parts like orifice and venturi and thus are
not easily eroded.
Flow nozzle consist of convergent inlet and a cylindrical throat.
Differential pressure is measured at the one pipe diameter upstream and
one half diameter downstream from the inlet face of a nozzle.
Mostly manufactured from stainless steel or chrome molybdenum steel.

Differential Flow Meter

Differential Flow Meter

Differential Flow Meter

Dall tube
Modified form of the venturi tube with a low pressure drop
than a venturi meter.
Shorter then venturi tube and less expensive.
It have a short, flanged cylindrical body with an abrupt
decrease in diameter followed by a conical restriction and a
diverging outlet section.
They are mostly used in applications with high flow rates.

Differential Flow Meter

Differential Flow Meter

Pitot tube
Another simple pressure measuring element used to measure the fluid flow
by determining the stagnation pressure at the point of measurement and
comparing it with the static pressure.
The pitot tube units consists of a tube with one end bent at right angles
towards the flow direction. The impact unit end is opened while the static
end is closed.
Te tubes can be mounted separately in a pipe or combined in a single
casting.
Pitot tube cane be a single point or multiple point pitot tubes (averaging
pitot tubes) but most of pitot tubes are limited to single point measurement.

Differential Flow Meter

Differential Flow Meter

Differential Flow Meter

Rota meter
Size of restriction is adjusted such that the pressure differential remains
constant.
The amount of adjustment required is proportional to the flow rate.
It consist of a tapered conical sort of tube, typically made of a glass with a
float in the path of the fluid.
The float is acted upon mainly by the gravity pull and upward push by a
flowing fluid.
The area between the float and tube allows the fluid to flow.
The height of the float is directly proportional to the flow rate.
In liquids the float is moved by the combination effect of buoyancy and
velocity head while in the gases by velocity head only.

Positive displacement meters

Positive displacement meters

Entrapping fixed and known volume of fluid and then
displacing it repeatedly.
Common characteristics of the PD flow meters is that they
are driven by the liquid itself.
PD flow meters are preferred measuring clean liquids,
gases and viscous fluids.
They employ some of the rotating mechanical parts to
entrap and discharge the fluids.
Based upon these parts they are divided into several types.

Positive displacement meters

Nutating disc meter
When the liquid flows through the meter it
causes the disc into nutating motion.
This nutation or rocking motion is caused by the
pressure drop form the inlet to the outlet of the
meter.
For each nutation a specific volume of the fluid
passes through the meter.

Positive displacement meters

Rotary vanes
Rotor turns and a known volume of the fluid is
trapped between the two vanes and the outer
wall.
The flow rate is based upon volume per
revolution.

Positive displacement meters

Oscillating piston meters
A slotted cylinder oscillates about a dividing bridge separation
the inlet and outlet ports. Fluid enters through the inlet port
and forces the piston to the left causing it to roll downward
and then discharges through outlet port.

Positive displacement meters

Lobed and Gear impeller
Used two lobbed impellers or oval shaped teethed gears in
fluid flow path.
Both are mounted in different axis that is one is horizontally
and one vertically and upon fluid flow they moves oppositely.
In this way the fluid enters and pass by both gears or lobes
separately one by one.
A known volume of fluid is transferred for each revolution
and counts of revolution thus gives the flow rate.

Open Channel Flow (Just For

Info)

Velocity flow meters

Velocity flow meters

Turbine Flow Meter
It employs a set of rotating blades mounted at right angle to
the flow of the fluid.
When the fluid flows through the axially place blades in its
path it imparts a force and causes the rotor to run.
Speed of rotation is proportional to the volumetric flow rate.
Generally output is transmitted by electronic means.

Velocity flow meters

Target Flow Meter
It measures flow by measuring the force on a target.
Fluid develops a force on the target which is proportional to
the square of the flow. Q = K (F)1/2
The target is placed perpendicular to the fluid stream.
The force bar transmits the force to force transducer to
measure the force.

Velocity flow meters

Magnetic flow meter
Its operation based upon the Faradays Law of electromagnetic
induction and can measure the flow of conductive fluids only.
Magnetic flow meter consists of the non conducting pipe with a pair
of electrodes mounted opposite to each other with the inside walls of
the pipe.
A magnetic coil is mounted around the pipe so that it generate the
magnetic field in a plane perpendicular to the plane of the electrodes.
The amplitude of the induced voltage is proportional to the velocity
of the flowing liquid.

Velocity flow meters

Ultrasonic
The measurement of flow rate is determined by the variation
in the parameters of ultrasonic.

Doppler flow meter:

An ultrasonic wave is projected at an angle through the pipe
wall into liquid parts reflected from bubbles.

Velocity flow meters

Thermal flow meter
Measuring the rise in the temperature of the fluid after the
addition of known heat to the fluid.
Based upon the specific heat equation.
m = q/ Cp (T2-T1)
Hot wire Anemometers
Rate of cooling is proportional to mass flow rate.
Mostly used for gases

Flow Measurement Method

Air Flow Measurement - Equipment

PITOT Tube
S Tube
Manometer
Anemometer
PIEZO ring
Isokenitic measurement

Air Flow - Anemometer

The anemometer give the velocity
across the measured area.
move it at constant speed.
Instrument very fragile if vanes
bent you need to repair and
re calibrate it.
Air direction shown on anemometer
side

Air Flow - Anemometer

Air Flow - Anemometer

Used in the wrong direction the wheel will pulled off !

Air Flow - Anemometer

Flow in m3/s = velocity reading from anemometer in m/s *
Area m2
The area chosen for the calculation is very important and can
modified a lot the results
Precision is not good

Air Flow - Piezometer Ring

The PIEZO ring measure the pressure in a pipe
(i.e. inlet of a fan). With a calibration the
pressure can be related to the flow.
Reliable if the ring is kept clean
Q = k P

Air Flow - Piezometer Ring

Air flow Pierzo ring

Calibration Piezometer - Flow in Nm3/h
80000

Flow in Nm3/h

70000
60000
50000
40000
30000
20000
10000
0
0.00

0.20

0.40

0.60

0.80

Square root (Piezom eter pressure)

1.00

Air flow - Estimation from fan curves

NOT AS A PRIMARY MEASUREMENT DUE TO SYSTEM
EFFECTS
Fan Curve (Clinker Cooler Fan)

18

36

16
15
14
13
12
11

Power (B H P)

Static Pressure (inWG)

17

40

28
24
20
16
12

10

9
8

32

Volume (acfm x 1000)

10

Can be used to validate flow measurement by another method

Air Flow Measurement - Safety

Only measuring points with safe access and platforms (safety standard of
working at height)
Possible high temperature and take care of possible variations of pressure
Lock out and empty air blasters
Be careful when opening measuring points, particularly if positive pressure
: do not stay inline with an open socket
Make sure that there is no risk that the inserted equipment can get caught
in any fan blades
If measuring point close to ESPs, the equipment should be earthed to avoid
static electric shock
Personnel Protective Equipment

Air Flow Measurement

Prerequisites : when the system is stable :
Check with CCR
During the operation, observe the evolution of the readings.
A drift can be an indication of non-stable conditions

Parameters to be determined :
Cross section area (check it with a steel rod)
Temperature
Gas density
Gas Velocity

Flow Rate

 Dry bulb temperature

The dry bulb temperature is the gas stream temperature (check
the direction)
Get the thermocouple junction upstream of the port to avoid
cooling from leak air (take care of the direction)
Plug the port hole if possible to reduce effect of leak air
In large duct do a (or two) traverse temperature as you do the
flow

Gas Flow

162 oC

Leak air

 Parameters to be determined :
Area
Temperature
Gas composition and density

The composition of the gas has to be determined to

calculate the gas density :
Moisture

content
Wet gas density calculation

Gas analysis (dry basis, % vol.)

Gas Velocity
Flow Rate

Air Flow Measurement

Parameters to be determined:
Area
Temperature
Gas density
Gas Velocity

A sampling site and the number and location of

sampling (traverse points) are determined to
optimize the extraction of a representative sample.

Flow rate

Gas Velocity Sampling Site

Applicability
The method is applicable to gas streams in stacks or
ducts
The method is not applicable if

Cyclonic flow
Reverse flow
Diameter less than 0.3 m
Non circular or non rectangular stacks or ducts
Sampling site less than 2 diameters from a downstream
disturbance or less than 0.5 diameter from upstream
flow disturbance

 Location of Sampling Site

Ideal location for circular and rectangular ducts :
In a straight section, 8 diameters downstream and 2 diameter
upstream of any flow disturbance (damper, bend, fan, stack exit).

8D

2D

Rectangular ducts : De (equivalent diameter) = 2LW/(L+W).

based on : Diameter = 4 * Surface / Perimeter for a circle

Number of ports determined by the number of traverse point

Circular duct : Two ports at 90
If conditions are not ideal, the number of traverse points has to be
increased

Gas Velocity Traverse Points

Traverse points location :
For circular cross section, the points are located
on two perpendicular diameters and at
the centroid of equal areas of the cross section.
For rectangular cross section, the area is divided into as many
equal rectangular sections as there are sampling points. The
points are located at the centroid of the rectangular section.
The location are marked on the tube.

Gas Velocity Traverse points

Minimum number of sampling points for sampling sites that meet the 8
and 2 diameter criteria
Minimum number of measuring points
duct diameter minimum nb of point mini / axis
(central point excluded)
0.3 0.7 m
4
0.7 1 m
8
1 2 m 12
> 2 m 16
The minimum distance between a duct wall and traverse points shall be
2,5 cm for diam. > 0,6
1,5 cm for 0,3 > diam. > 0,6

Gas Velocity Traverse points

Gas Velocity Traverse Points

Traverse points location on the tube

Gas Velocity
Principle
The average gas velocity in the duct is determined from the velocity
measure at each of the traverse points with a Pitot or an S-tube
(Strauscheib) and a manometer.
Applicability
The method is not applicable if the following conditions exist
Cyclonic or reverse flow
Velocity pressures fluctuate more than 20% of the average at each
traverse point.
Data is good when
75% of velocity pressure measurements are greater than 10% of the
maximum velocity pressure measured

Gas Velocity - S-Tube

S-tube
Requires calibration Cv. The S type must be corrected because it
gives a higher velocity pressure than the PITOT tube for the same
gas stream.
Calibrate against PITOT tube if necessary or by outside company
Mark flow direction on S tube
Use in gas stream too dusty for PITOT. If the gas stream is very
dusty (mill air sweep, kiln riser,) the tube may need to be clean
in between each point.

Gas Velocity - S-Tube

S-tube Probe K factor (S.I. Units)
The K factor of the probe must be taken into account to ensure an
accurate reading.
The standard formula for calculating the airflow velocity from the
measured velocity pressure is :
From supplier Operating Instructions
V = 1.291 x ( Pv / K )0,5 or 0,84 x ( 2 Pv / Rh )0,5
Where V = velocity (m/s) ; K = 1,422
Pv = S type Pitot differential pressure (Pa)
This formula is only correct for :
Rh air = 1,2 kg/m3 ; Std Pressure 1000 mbar ; air TC =
16C

Gas Velocity - S-Tube

S-tube Probe K factor (Metrics Units)
The standard formula for calculating the airflow velocity from the
measured velocity pressure is :
From supplier Operating Instructions
V = 4,05 x ( Pv / K )0,5 or 0,84 x ( 2 x 9,8065 x Pv / Rh )0,5
Where V = velocity (m/s) ; K = 1,422
Pv = S type Pitot differential pressure (mmwg)
This formula is only correct for :
Rh air = 1,2 kg/m3 ; Std Pressure 762 mmHg ; air TC =
20C

To correct for non-standard conditions, this equation

becomes

Gas Velocity - S-Tube

S-tube Probe K factor (Metrics Units)

To correct for non-standard conditions :

From supplier Operating Instructions
V = 4,05 x ( 762/B x T/293 x 10363/(10363+Ps) x Pv / K )0,5
Where B = barometric Pressure (mmHg)
T = tC + 273C
Ps= duct static pressure (mmwg)

Gas Velocity - S-Tube

S-tube Probe K factor
To correct by a calibration on site :

Varies T / P / bar P
K = 0,79
Initial K = 0,84
Calculated by comparison with Pitot tube

Ps

Pt

90 rotation

Pt

+ : Pt

- : Ps

Gas Velocity - Manometers

U-tube manometer and digital manometer

Gas Velocity - Procedure

Procedure

Leak check the pitot tube and lines

Level and zero the manometer
Measure barometric pressure Pbar

Measure the static pressure Ps

unplug +
Measure velocity pressure Pv = Pt-Ps at each traverse points.
Ensure that the face opening planes of the tube are maintained
perpendicular to the longitudinal axis of the duct.
Measure the temperature
Normally you have to measure all those at each traverse point but
in the field most of the time you measure only the velocity at each
point and the rest is measure only once

Gas Velocity Static Pressure PS

Static pressure reading
Taken as the same location as the velocity pressure.
With a PITOT and S-tube, unplug the velocity pressure
pipe to do the reading of the static pressure.
Reference all static pressure to the same atmospheric
pressure.
Trouble may occur closely downstream of dampers where
the pressure profile may not be stabilized.

Absolute gas pressure Pabs

Pabs = Pbar + Ps
Pbar : Barometric pressure at sampling site, kPa

Gas Velocity Static Pressure PS

Data required :

Pitot Tube - Cv
Duct Dimension
Gas Density
(Gas Composition - Temperature - Pbar)
Velocity Pressure
Derived from Bernoulli :
P + 1/2 U2 = Constant

Remember : U = Cv * (2 Pd /

U = Gas Velocity
Pv = Velocity Pressure
Cv = Pitot tube factor
= Gas Density

Average Gas Velocity

To Average the velocity pressure use the Root
Mean square because U Pd
Measured Velocity pressure
0.2
0.8
Pv
1.6
1.9
0.7
0.4

Average = 0.933

Do Not Do this

SQ Root Velocity Pressure

0.4472
0.8944
1.2649 Pd
1.3784
0.8367
0.6325

Average = 0.826

Do this

Flow Rate - Q
Convert velocity U into Flow rate Q
Units :
If metric : U is in m/s
Q can be in m3/s, Nm3/s or kg/s :
only Nm3/s or kg/s : suitable for Mass Balance

Check if dry or wet flow is required

Useful to specify the Temperature, the Barometric
Pressure and the Gas Composition (%O2, %H2O)
when you report Flow Rates

Flow Rate - Q
Velocity to Flow rate Conversions
From m/s to m3/s:
only a multiplication by duct area is required :
Q [m3/s] = As [m2] * U [m/s]
From m3/s to kg/s:
Q [kg/s] = [kg/m3] Q [m3/s]
2 = 1 T1/T2 * P2/P1 , T in K and P in Pa
From m3/s to Nm3/s :
Q [Nm3/s] = 273 /( T+273).(Pbar + Pstat )/101325 * Q
[m3/s] T in C , Pbar and Pstat in Pa
Conversions are derived from Gas Law PV=nRT

Thank You