Measurement D

Notes
Fast Track 1999 Process Control / Measurements Lafarge Institut Cimentier / 1

FAST TRACK
September 1999
MEASUREMENTS

Institut Cimentier
Notes
1
2
Fast Track Part 1/1999 / Process Control - Measurements / Institut Cimentier / 1
Measurements
WHY
Measurements
Flow (Pressure)
Flow (Pressure)
Temperature
Temperature
Power
Power
Notes

SLD
13:00-xx
Why measurements
Objectives:
Be able to take any given measurement for an audit
Direct other to take the measurements

Intro:
I will be looking for answers/ comments from group
therefore - don't flip ahead
Explain Objectives

Why do measurements?
Why do we need good measurements?

Measurements
As with gas laws. the important measurements to be made are in order to
obtain:
1) Pressure (total, static, and/or velocity)
2) Temperature (wet-bulb and dry bulb)
3) Flow (velocity)
MEASUREMENTS

Notes
3
4
Why do we need to MEASURE?
To obtain data used for process control
What is important when measuring?
Measurement Method
Precision
Repeatability
Airflow
Measurement Methods
Pitot Tubes (S & L)
Anemometers
Piezo metric Rings
Fan Curves
Pitot Tubes (S & L)
Anemometers
Piezo metric Rings
Fan Curves
Notes

SLD
13:00-xx
Why do we need measure?

GROUP ANSWER FIRST
Why do measurements? - Write answers on flip chart
What is important in measuring?
Why do we need good measurements?
* Make sure that they realize that without reliable and accurate measurements
(i.e. the right numbers) all further process work will be wrong and wrong
conclusions and recommendations may be made.

Airflow measurement methods

Mention that there are various methods for determining the airflow
Ask why you would use one over the other - answer that each method has
advantages and disadvantages and that knowing what they are will determine
what method to use at what location.
Pitot tubes most frequently used
Anemometers at fan inlets, usually when no suitable location for Pitot tubes is
available
Piezometric rings, for continuous monitoring
Fan curves for design numbers (lacks in precision)
MEASUREMENTS

Question
?
Notes
5
6
The Pitot Tube
Total Pressure
Velocity + Static
Static
Static
0-40
0-10
0-2
Ref
1.25
S Type Pitot Tubes
Airflow
Used in Dusty Streams
Need Calibration Factor
Either Cp or Cv
Manometer connections
+ ve to Total Pressure
- ve to Static Pressure
Used in Dusty Streams
Need Calibration Factor
Either Cp or Cv
Manometer connections
Measures Total
Pressure
Measures
Static P
Notes

SLD
13:00-xx
The Pitot tube
Mention that there are two types of Pitot tubes:
S tube
L tube
Use in conjunction with a manometer to determine the velocity pressure,
which determines the air velocity
It is the most common method used to determine airflow.

S type Pitot tubes
SHOW S PITOT TUBE

Emphasize that the S-tube is used mostly in our systems due to dirty air
streams.
The difference between Total and Static pressure is the velocity pressure.
Velocity pressure will always be positive.
S-tube has a correction factor usually c=0.85 (approximately)
Show direction of L-tube with respect to flow direction
MEASUREMENTS

Notes
7
8
L Type Pitot Tubes
Used in clean gas streams
No calibration factor (always = 1)
Same manometer connections as S
Used in clean gas streams
No calibration factor (always = 1)
Same manometer connections as S
Airflow
Measures
Static P
Measures Total
Pressure
(Vel + Static)
Pitot Tube Measurement Locations
Circular cross-section of duct
Rectangular cross-section of duct
Circular cross-section of duct
Rectangular cross-section of duct
x
x
x
x
x
x
x
x
x
x
x

x
Notes

SLD
13:00-xx
L type Pitot tubes
SHOW L PITOT TUBE

Emphasize that the L-tube is used in clear airstreams only, it plugs up easily in
dusty conditions
The difference between Total and Static pressure is the velocity pressure.
Velocity pressure will always be positive.
L-tube does not have a correction factor c = 1.
Emphasize that for both types of tubes, the connections are important.
Show direction of L-tube with respect to flow direction

Pitot tube measurement locations
Ask group where they would take Pitot tube readings?
Ask group: What do you need to take a Pitot tube reading?
Size of duct (ID or area of rectangle
Location of measurement points within the duct.
-explain that different sources offer different recomm.
- more is always better

Explain that with a circular duct it is best if three sample ports at 60 degrees from
each other is used. However it is most common to only have two sample ports at
90 degrees from each other

MEASUREMENTS

Question
?
Notes
9
10
Pitot Tube Measurement Locations in
a circular duct
X
1
X
2
X
3
X
4
X
n
D
Pitot Tube Measurement Locations
in a rectangular duct
Inside Number of
diameter traverse points K
1
K
2
K
3
K
4
K
5
K
6
K
7
K
8
K
9
K
10
K
11
K
12
K
13
K
14
K
15
K
16
of duct in each of 3
diameters
Less
than 8 ft 8 .021 .117 .184 .345 .655 .816 .883 .979 - - - - - - - -
8 ft thru
12 ft 12 .014 .075 .114 .183 .241 .374 .626 .759 .817 .886 .925 .986 - - - -
Greater
than 12 ft 16 .010 .055 .082 .128 .166 .225 .276 .391 .609 .724 .775 .834 .872 .918 .945 .990
Notes

SLD
13:00-xx
Pitot tube measurement locations in a circular duct

In order to obtain a representative average airflow, it is necessary to locate the
traverse measurement points accurately.
For a circular duct, according to AMCA (Air movement and control association), it is
recommended that the number of traverse points as indicated on the slide are based
on log-linear Pitot traverse method.
Explain that the circular points on the drawing are the sample points while the
equation:
X
n
= D * k
n

where X
N
= the sample location (of point n)
D = inside diameter of the duct
k
n
= the factor from the table on the slide

Mention that it is important to mark the Pitot tube (often with tape) before starting.
Another important point is not to forget the nipple size.

Pitot tube measurement locations in a rectangular duct

Similar to the circular ducts, traverse points must also be determined for a rectangular
duct.

MEASUREMENTS

Notes
11
12
What data is required to
determine airflow
Pitot Tube - Cv
Duct Dimension
Gas Density
Velocity Pressure
Pitot Tube - Cv
Duct Dimension
Gas Density
Velocity Pressure
Remember:
where V = gas velocity

P
V
= velocity pressure
C
V
= Pitot tube factor
r = gas density
V C
P
V
V
=
|
\
|
.
| *
* 2

75% Rule
Data is GOOD
when:
75% of Pv > 0.1 x Pv max
How do you know if data is good?
Notes

SLD
13:00-xx
What data is required to determine ariflow
It is important to have a well calibrated S-type Pitot tube in order to have an
accurate value for C
V
.
Remind them that C
V
= 1 for an L-tube.

With this information we will know the airflow

Remind them of the velocity equation as seen in Basic Gas Laws
with the added C
V
factor.

How do you know if data is good
GROUP ANSWER FIRST
How do you know if your data is good?

It is essential to be able to eliminate numbers that are not good.
Turbulence of flow can severely affect flow measurements.
The location of your flow measurements along the system are very important.

EXPERIENCE will the guide in the future.

MEASUREMENTS

Question
?
Notes
13
14
75% of velocity press measurements are
greater than 0.1 Pv max
A- Ideal P. Distribution
P. Max
10
P. Max
B- Good P. Distribution
P. Max
10
P. Max
C- Satisfactory P. Distribution
P. Max
10
P. Max
P. Max
10
P. Max
D- Do not use
80%
60%
P. Max
10
P. Max
E- Do not use
40%
P. Max
10
P. Max
F- Do not use
20%
35%
35%
Measurement Locations
Rule of Thumb - Good sampling location is
6 duct diameters downstream of a fitting
2 duct diameters upstream of a fitting
Rule of Thumb - Good sampling location is
6 duct diameters downstream of a fitting
2 duct diameters upstream of a fitting
A B
E F
C
D
Notes

SLD
13:00-xx
This slide is to give the students an idea of what the velocity profile can be in a
duct, as well as showing which of the profiles would seem acceptable and which
would not.

Remind them that the picture is only in 2 dimensions and things could change if we
went across the duct at another location (this is why we suggest 3 sample ports,
and insist on at least two. In many cases, unacceptable data may be OK, and
vice-versa.

Measurement locations
Ask students where they would take Pitot tube measurements.

Stress the importance of sample locations.

Mention the difficulties in plants: location, temperature, material flow, etc. (tertiary
air ducts, for example.

Explain that the rule of thumb is always possible. That is when decisions must be
made and the 75% rule may be used, and other methods (anemometer or fan
curves may be used)

It is important to realize that the fan curve may be used to make sure that
measured results are in the right ballpark.
MEASUREMENTS

Question
?
Notes
15
16
- Inleakage
- Plugging of Pitot tube
- Material build-ups
- Location of Measurement
- Inleakage
- Plugging of Pitot tube
- Material build-ups
- Location of Measurement
What to watch out for in
Pitot tube measurements?
Anemometer
5.3 m/s
Needed:
Inlet Dimension
Air Density:
- temperature
- air pressure
- gas composition
(water vapour)
Needed:
Inlet Dimension
Air Density:
- temperature
- air pressure
- gas composition
(water vapour)
Notes

SLD
13:00-xx
What to watch out for in Pitot tube measurements
Remember the importance of accurate measurements.
Inleakage can drastically change results. Make sure to cover sample port as Pitot
tube is inserted.
Due to the dusty environment that are usually present during pressure measurements
at a plant, Pitot tubes plug easily.
Remember to use a S-tube in dusty ducts, but this can still plug.
Material build-ups can reduce the cross-sectional area of a duct and increase the gas
velocity, be sure that no significant build-ups are present at a sample location.
Again the importance of measurement location is imperative, so make sure to choose
wisely.

Anemometer
Show the students a vane anemometer.
Vane anemometer
Hot wire anemometer
Both measure air velocity
Explain method Show the students the two methods of getting measurements:
1) circle method (from outside of grid, go encircles until the
middle.
2) multiple measurements (average out errors)
Remember: don't stand in front of grill
watch - partially closed dmprs create Hi/lo, so need a
uniform traverse
accuracy can vary as much as 20%
Question
?
MEASUREMENTS

Notes
17
18
Anemometer - which Area?
of Grill = Area2
Plane of
measurement
= Area1
Area1 > Area2
therefore
V1 < V 2
Front View
Full Inlet
Side view
Close-up of Grill

Open Area
Anemometer - Which Area?
Which Diameter?
Scope to what point?
No problem
Notes

SLD
13:00-xx
Anemometer - Which area?
GROUP ANSWER FIRST
What area? Does one take the grill into account?

In general the grill is ignored due to its small wire mesh.
However if the mesh is large in diameter and the relative area is large, it must be
taken into account, and adjusted for.

The determination of the area is often where the error in measurement (up to 20%)
usually occurs.

Anemometer - Which area?
What area?
Want
average air flow
over
area of flow

Whatever you use, be consistent.
Without flute it is very easy.
with a flute end to the duct, an approximation of the area must be taken as shown on
diagram.
Question
?
MEASUREMENTS

Notes
19
20
Piezometric Rings
Inlet Bell Piezometer
On-line pressure
analyzer
provides continuous
measured data
Watch for:
build up on screen
dented inlet bell
On-line pressure
analyzer
provides continuous
measured data
Watch for:
build up on screen
dented inlet bell
Estimating Flows from Fan Curves
10 9 8 7 6 5 4 3 2 1 0
8
9
10
11
12
13
14
15
16
17
18
0
4
8
12
16
20
24
28
32
36
40
Volume (acfm x 1000)
S
t
a
t
i c

P
r
e
s
s
u
r
e

( i
n
W
G
)
P
o
w
e
r

( B
H
P
)
Fan Curve (Clinker Cooler Fan)
NOT CONSIDERED A GOOD PRACTICE
BECAUSE OF SYSTEM EFFECTS
NOT CONSIDERED A GOOD PRACTICE
BECAUSE OF SYSTEM EFFECTS
FAN CURVES REPRESENT FANS
UNDER IDEAL LAB CONDITIONS
FAN CURVES REPRESENT FANS
UNDER IDEAL LAB CONDITIONS
Notes

SLD
13:00-xx
Piezometric rings
The piezometric ring is used as a continuously monitoring tool.

Used in clean air streams only, due to plugging.

Not used for audit purposes due to large error possibilities (although it can be used
to cross-check Pitot tube or anemometer readings.

Often used at inlets of cooler fans in cement industry.

Estimating flows from fan curves
The last method of evaluating the airflow is with static pressure measurements, and
a fan curve.

System effects
May or may not be significant, but will drastically affect your results
It is good practice to use it as a check

If the differences in fan curve vs. Pitot tube or anemometer results are significant
one can:
quantify the cost of system effects

MEASUREMENTS

Notes
21
22
Which is the right method
to determine the airflow?
Pitot Tubes (S & L)
Anemometers
Piezo metric Rings
Fan Curves
Pitot Tubes (S & L)
Anemometers
Piezo metric Rings
Fan Curves
Notes

SLD
13:00-xx
Break

Give 10 minute break exactly (optional if time is available)

Which is the right method to determine airflow?
Ask students what the right method is.

Answer: it is still debated, but several rules are present.

1) When an ideal location with steady flow is available, Pitot tubes are
recommended.
2) Anemometers can be used at fan inlets only, when no appropriate
Pitot tube location is available.
3) Piezometric rings and fan curves should be used as cross-checks
or last resorts only.

Experience will guide, and it is a very good practice to use two different methods
in order to verify answers as much as possible.
Question
?
MEASUREMENTS

Notes
23
What tools do we have to
measure Temperature?
- Thermometer
- Sling thermometer
- Infrared Temperature gun
- Thermocouple
- Pyrometers
- Calorimeter
- Thermometer
- Sling thermometer
- Infrared Temperature gun
- Thermocouple
- Pyrometers
- Calorimeter
Notes

SLD
13:00-xx
What tools do we have to measure temperature?

Bring as many of these as possible.
Explain the uses and limitations of each.
1) Thermometer: low temp. only (good accuracy.
2) Sling thermometer: low temp only, dry and wet bulb temps, difficult to use in
ducts.
3) Infrared gun, poor accuracy, but used for difficult to access places as a
quick guide or to determine surface temps.
4) Thermocouples: - high temp applications (can also obtain wet bulb temps by
adding moist end. ( Very high use to obtain temperatures in ducts and other
enclosed areas in cement industry)
5) Pyrometers:(2-color or hot wire) = high accuracy, measures surface
temperatures
6) Calorimeter: Clinker exit temperature by temperature change of water.

Question
?
MEASUREMENTS

Notes
24
Dry Bulb Temperature
The gas stream temperature
Get the thermocouple junction upstream of
the port to avoid cooling from leak air
Leak air
T/C
Gas flow
162
Notes

SLD
13:00-xx
Dry bulb temperature

The dry bulb temperature is required in most cases.
In most cement plant applications, a thermocouple is used to determine the
temperature of the stream.

Gas stream temperature is obtained by placing the thermocouple into the flow.
Remember that inleakage is a concern since it could lower the temperature
reading.

There will be areas where the flow is so small that there is not directional flow, at
this point inleakage becomes even more important to prevent.

Inleakage can be minimized by covering the port opening with your hand as the
probe is inserted.
MEASUREMENTS

Notes
25
26
Wet Bulb Temperature
Start with wick thoroughly soaked
Evaporation will lower temp from DB temp (if
not the gas is saturated already)
When the temperature comes to equilibrium you
have the wet bulb temp
Super heated vapor
Air & H
2
O
130
Sat Vap Wet rag wick
Wrapped on T/C
Power Measurements
Types of Motors (most common)
Types of Motors (most common)
Motor shaft power equations work for the above motors
Motor shaft power equations work for the above motors
1) Variable Speed
a) Variable Speed (AC)
b) SCR (DC)
1) Constant Speed
a) Induction (AC)
b) Synchronous (AC)
Notes

SLD
13:00-xx
Wet bulb temperature
Wet-bulb temperature readings are important but very difficult in cement plants.
In ducts, sling thermometers can not be used and thermocouples are once again
the instrument of choice.
The tip of the thermocouple must be covered in a wet rag (or other) to insure 100%
moisture.
The temperature should hit stability as the wet bulb temp., but in reality, the
equilibrium position is often very difficult to accurately determine, because dust
clogs the rag or the water evaporates too quickly or there is too large a gap
between the rag and the tip of the thermocouple which allows inleakage.
Practice wet bulb measurements before an audit situation where time is of the
essence.

Power measurements
Ask group why we measure power?
Explain that power is the amount of energy drawn by a motor.
We must measure power because this is one of the important costs to a cement
plant.
Motors fall into two categories:
Alternating Current (AC) and
Direct Current (DC)
Motors are also either constant speed or variable speed (variable speed motors are
more expensive, but they draw less power. They are used when the motors output
demand varies greatly).
Question
?
MEASUREMENTS

Notes
27
28
Motor Shaft Power
If the motor is greater than 5 HP and operating at 90% or more of FLA:
either of the following may be used
[ ][ ]
A) H
mo
= [NPH]
H
mo
= Motor Shaft Horsepower
NPH = Nameplate Horsepower
FLA = Full Load Amps
NPV = Nameplate Voltage
NLA = No Load Amps
Measured values the average for 3 phase
MEAS AMPS
FLA
MEAS VOLTS
NPV
[ ][ ]
B) H
mo
= [NPH]
MEAS AMPS - NLA
FLA - NLA
y
Equation A is within 5% for motors > 5 HP and < 90% FLA
Use average of A and B for motors < 5 HP or > 90% FLA
If H
mo
is less than 50% of NPH error can be 15% or more
Single Phase, Direct Current & 3
Phase Motors
H
mo
=
[Amps] [Volts] [Power Factor] [Motor Eff]
746
Single Phase or DC Motors
Single Phase or DC Motors
For DC motors
Delete Power Factor from the formula
Use armature Amps and Volts
H
mo
=
3 [Amps] [Volts] [Power Factor] [Motor Eff]
746
3 Phase Motors
3 Phase Motors
Use the average of the measured phase values
For variable frequency motors measure at the motor
Notes

SLD
13:00-xx
Motor shaft power

Explain the equations (they are straight forward).
Explain that there are potential errors involved in power calculations.
Give example (allow 2 minutes to solve), then correct.

NPH = 20 Hp
MEAS Amps = 12 Amps
FLA = 15 Amps
MEAS Volts = 25 V
Nameplate voltage = 28 V

Single phase, direct current phase motors

Single Phase, DC and 3 phase motors are measured differently. It is important to
note that all results are in Horsepower.
Give the formulas as stated.
Explain that power is a calculated number (often calculated by a monitor).
Big push from TYTP to reduce power.
H
mo
= 20 Hp
12 V
15 V
*
25 V
28 V
H
mo
= 14.3 Hp
MEASUREMENTS

Notes
29
Gas Analysis
High temperature fibres
PROBE
Filter
Leak-free
Pump
Gas Analyzer c/w Flowmeter
Length of hose for cooling
Dryer
Oxygen
CO
CO
2
SO
2
NOx
Stack
Exhaust Gas Circuit
Preheater Exit
Preheater Cyclone
Kiln Exit
Notes

SLD
13:00-xx
Gas analysis
Another important measurement that is important to have is gas analysis.
These are obtained primarily by on-line gas analyzers as shown.

Explain "typical" setup
see drawing
auxiliary pump may be needed
(are a problem area for inleakage)
filters may plug
desiccant needed to be changed
REMEMBER results will be on a dry basis

It is important to realize that Consultants are often hired to obtain results:
they are often wrong
watch for "standard air"
watch for dry or wet basis
cross-check (e.g. overall sulfur balance)

Portable oxygen analyzers are also common.

MEASUREMENTS

Notes
30
Calibration of Equipment
Process equipment must be
calibrated
Many pieces are very sensitive to
operating conditions
Poorly calibrated instruments will
lead to WRONG conclusions
Process equipment must be
calibrated
Many pieces are very sensitive to
operating conditions
Poorly calibrated instruments will
lead to WRONG conclusions
Notes

SLD
13:00-xx
Calibration of equipment
It is essential to stress the importance of properly calibrated equipment.

State that a full audit may be put into question if poorly calibrated equipment is used
(this includes weigh feeders also).

State that there are enough difficulties in obtaining good results (such as uneven
flow, dusty conditions, difficult to access areas, difficult temperatures to obtain,
clinker at kiln exit) without adding poor measurement tools.
MEASUREMENTS

Notes
31
32
Recap
Flow (Pressure)
Flow (Pressure)
Temperature
Temperature
Power
Power
Measurement - Completed
See you tomorrow
Notes

SLD
13:00-xx
Recap

This afternoon we covered how to measure flow temperature and power.

Remember that the choice of the appropriate equipment is important.
Reiterate the importance of measurement location.
Calibration is important.

The measurement process is very important, prepare before measuring by
knowing EVERYTHING that you wish to before starting to measure.

Measurement - completed

State that this is the end of day.

Tomorrow, they will start with fan systems
MEASUREMENTS

Measurement D

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Notes

Fast Track 1999 Process Control / Measurements Lafarge Institut Cimentier / 1

Fast Track Part 1/1999 / Process Control - Measurements / Institut Cimentier / 12

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