Flow Measurement Typical Applications (gases)

“I do not see to many badly manufactured flow meters. I

know a few badly calibrated flow meters, but I have seen
loads and loads of badly applied flow meters in the world”

Flow Measurement Technologies

Measurement by Volume
1.Direct Measurement
- Displacement meter
2. Indirect measurement
- Variable area meter
- Turbine
- Sonic
- Vortex
Metering of Gas Flow is difficult because… - Magnetic induction

Gas is compressible. The volume of a given quantity of 1.Direct Measurement

molecules of gas is strongly depended of the pressure and A. Displacement meter
temperature. -Directly measures the total volume flow. The mechanical
99% of the applications are not related to volume, but to the movement is transferred directly to a counting mechanism or
number of molecules. Examples: pulse generator.
-This category includes rotary pistons, gear wheels, vanes,
Chemical: the molecules do the work! ring pistons.
Flame: the molecules do the work!
Advantages:
Pneumatics: the molecules to the work!
1. Suitable for liquids and gases
Respiration: the molecules do the work!
2. Simple, robust construction
We want to measure the number of molecules, not the 3. High dynamics
distance between the molecules. We want to measure Mass! 4. Independent of interferences in the flow profile
5. Independent of gas type
Metering of Gas Flow 6. High precision
Disadvantages:
Flow, as we use it, can be expressed in: 1. Susceptible to wear
- Volume
2. Risk of soiling
- Standardized or Normalized flow
3. Gas measurements with additional measurement of
- Real Mass flow
P and T
Volume and Real Mass are easy, but what about 4. Pulsations
Standardized or Normalized? 5. Pressure shocks lead to overload
Standardized or Normalized means “Referred to predefined 6. Limited operating pressure and temperature
conditions”. In case of gas it means predefined Pressure and 7. Leaks through mechanical tolerances
Temperature, because those are variables that relate Mass to
Volume. 2. Indirect Measurement
The relation between Volume, Pressure and Temperature for A. Variable area meter
gasses is defined in the Law of Boyle/Gay-Lussac -Vertical measuring glass with conical internal shape, in which
a defined body is made to float by the flow acting from
So what are the pre-defined reference conditions for below.
Standardized or Normalized volume or flow?
B. Orifice meters (Pressure differential principle)
Standardized: 70°F (21.1°C or 20°C) and 1013.25 mBar -Orifice meters are the most common equipment used in the
Normalized: 0°C and 1013.25 mBar natural gas industry for measurement of natural gas flow rate
However not everybody uses this!!
Natural Gas Industry: 15°C and 1013.25 mBar -The typical orifice meter consists primarily of a thin stainless
other manufactures: 20°C and 1013.25 mBar steel plate about 3/16-in thick, with a hole in the center that
“Standardized and Normalized are often reversed!” is placed in the flow line. Placing an orifice in a pipe in which
there is a gas flow causes a pressure difference across the
orifice. This pressure difference and the absolute pressure in
the line at a specified "tap" location are recorded Measurement by Mass
continuously and are later translated into rate of flow. 1. Direct Measurement
- Coriolis
Pressure differential principle 2. Indirect measurement
Advantages: - Thermal
1. Suitable for liquids and gases
2. Simple, robust construction 1. Coriolis principle
3. Numerous materials -Measuring principle that measures the mass independent of
4. Tried and tested principle temperature, pressure and medium. A measuring tube is
5. High temperatures brought into resonant vibration state.
6. No moving parts
7. Any mounting position -Sensors are fitted at the entry and exit of the measuring
Disadvantages: tube. Without flow the sensors issue signals simultaneously.
1. Susceptible to wear If there is flow a phase shift occurs between entry and exit.
2. Soiling leads to errors This phase shift is directly proportional to the mass flow.
3. Gas measurements with additional measurement of Advantages:
P and T 1. Suitable for liquids and high pressure gases
4. Inlet sections 2. Direct mass measurement
5. Limited dynamics 3. No “moving” parts
6. Gas type-dependent 4. High precision
7. Lots of potential leak points 5. Independent of flow profile
8. Need more equipment Disadvantages:
1. Require minimum medium density
C. Turbine flow metering 2. Relatively high purchase price
A rotor with turbine blades, supported on a rotating center 3. To some extent sensitive to vibrations
axis, supplies a signal that is proportional to the flow rate due
to its rotary movements. A minimum flow is required for 2. Thermal mass measurement
driving the rotor. Several versions, the main ones are:
• Immersable sensors (Mainly Industrial)
Designed as a complete fitting or plug-in probe. • Capillary flow meters
Advantages: • Thermal flowmeters
1. Suitable for liquids and gases
2. Compact design A. Immersable sensors
3. Independent of gas type Features/ Advantages
4. High precision 1. Direct Gas Mass Flow Reading
Disadvantages: 2. Fast Response (1 Sec)
1. Susceptible to wear 3. No Moving Parts
2. Risk of soiling 4. High Turndown & Rangeability
3. Gas measurements with additional measurement of 5. Negligible Pressure Loss
P and T 6. Convenient Installation
4. Pressure shocks lead to overload 7. Accuracy 1.5%
5. Measurement cannot take place from zero 8. Flexible due to modern electronics
9. Suitable up to 400 C
D. Vortex meter
Vortices are generated downstream of a defined baffle Specific Considerations/ Disadvantages
(Kármán‘s vortex street). The number of vortices (frequency) 1. Gas dependent, cal with real gas
is proportional to the flow velocity. 2. Dry gas only
Advantages: 3. Relative clean gas only
1. Suitable for liquids, gases and steam 4. Temperature bandwidth 80 C
2. High dynamics 5. Insertion: installation sensitive
3. high + Low temp suited B. Capillary flow meters
4. Calibrate with water only Advantages
5. Largely independent of changes in pressure, 1. Wetted materials: O-rings (other materials
temperature and viscosity possible, metal
6. Digital from sensor upwards. High long-term stability seal possible)
possible with non abrassive liquids. 2. Compatible with most gasses
Disadvantages: 3. Calibration with air and conversion to other
1. Pulsating or swirl flow influence the ability to gasses possible
measure low flows 4. Established, lots of manufacturers.
2. No measurement possible with low flow rates . (Not 5. Up to 700 Bar possible
suitable really for low pressure gasses) Disadvantages
3. Non-linear 1. Lots of bad manufacturers (Drift, temp comp
problems, etc)
2. Very sensitive for liquid and pollution
 3. Expensive, difficult to manufacture them -Reciprocating compressors have pressure ranges up to
properly. 30,000 psi and range from very low HP to more than 20,000
C. Thermal flowmeters: Silicone MEMS or CMOS HP per unit.
chip heat is introduced into the medium with
-Reciprocating compressors can be single stage or multistage,
constant heating output. In the presence of flow,
depending upon the compression ratio required. The
temperature sensors arranged symmetrically before and
compression ratio per stage for positive displacement
after the heating system detect a shift in the temperature compressors is limited to 4.0 (because of the valve life and
profile towards the sensor downstream of the heating discharge temperature).
system. If there is no flow both sensing elements measure
the same temperature. -Gas cylinders are generally lubricated, although a non-
Advantages: lubricated design is available when warranted.
1. Mainly for gases
2. Indirect mass measurement (medium-dependent) -Typically, high-speed compressors operate at speeds of 900
3. No moving parts to 1200 rpm and slow-speed units at speeds of 200 to 600
4. High precision rpm.
5. Independent of flow profile
-On multistage machines, intercoolers may be provided
6. Fast, dynamic measurement
between stages. These are heat exchangers which remove
Disadvantages: the heat of compression from the gas and reduce its
1. Medium-dependent temperature to approximately the intake compressor
2. Susceptible to soiling temperature.
3. Several wetted materials
4. Limited to non-corrosive gasses

Gas Compression
Type of Compressors
Depending on application, compressors are manufactured as
positive-displacement, dynamic, or thermal type:

I. Positive Displacement Type: Reciprocating

Compressors
The reciprocating compressor consists of one or more
cylinders each with a piston or plunger that moves back and
forth, displacing a positive volume with each stroke. They are
single-acting or double-acting

II. Dynamic Type: Centrifugal Compressors

-Centrifugal compressors develop the pressure required by
the centrifugal force due to rotation of the compressor wheel
that translates the kinetic energy into static pressure of the
gas.

-Centrifugal compressors can be used for outlet pressures as

high as 10,000 psia, and inlet capacity of more than 100000
cfm.

-Centrifugal compressors are usually either turbine or electric

motor driven. Typical operating speeds for centrifugal
compressors in gas transmission applications are about
14,000 rpm for 5000-hp units and 8000 rpm for 20,000-hp
units.

-In gas pipeline applications a compression ratio of 1.5 to 2.0

is usually used.
-A compressor body may hold one or several (up to 8 or 10)
stages. A compressor train may consist of one or multiple
compressor bodies. Pipeline compressors are typically single
body trains, with two or three stages.

Advantages of a Reciprocating Compressor

1. Ideal for low volume flow and high-pressure ratios
2. High efficiency at high-pressure ratios (about 4)
3. Relatively low capital cost in small units (less than
3000 hp)
4. Less sensitive to changes in composition and density
5. Have flexibility in pressure range, and can deliver
compressed gas at a wide range of pressures

Advantages of a Centrifugal Compressor

1. Ideal for high volume flow and low head
2. Simple construction with only one moving part
3. High efficiency over normal operating range
4. Low maintenance cost and high availability
5. Greater volume capacity per unit of plot area
6. No vibrations and pulsations generated

Gas Compression
Compressor Selection and Rating

-A Gas engineer in the field is frequently required to

determine the desired specifications of a new compressor
station or selecting the operating point of an existing one.
These specifications are:

-Type, number of stages, arrangements (parallel, series, inter

and after coolers), driver, speed, efficiency, power and/or
capacity of each stages or units, duty of coolers.

-For determining the above specifications, these parameters

are required: Gas Composition (or specific gravity), inlet
temperature and pressure, total pressure ratio and total gas
flow rate.