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Transcript of Flow Meter Technology
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© A
B B
I n c . - 1 -
9 J a
n u a r y 2 0 0 5
Flow meter Technology
Selection
Your Flow MeasurementExperts
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Emerson Confidential
Slide 2
Flow Techno logy Select ion Flow Technology Selection Process
Application/Purpose of Measurement
Performance
Cost/Economics
Select Flow meter
Purpose of MeasurementControl – to maintain proper flow
Monitoring – track usage or discharge
Custody Transfer – billing purposes
Quality – achieve proper recipe
Batch Chemical Feed systems
Installed vs. Reference Performance
****System Accuracy *****
RepeatabilityResponse Time
Upstream & Downstream Piping Permanent
Pressure Loss
Price/Installed Cost/Life-Cycle CostMaterial Cost
Installation ( Existing or new pipe )
ReliabilityMaintenance
Power / no power
Actions: Review purpose of measurement, keyperformance criteria, environmental
considerations, approvals
Actions: Complete Spec Sheet, Size Flow
meters for application, complete InstalledPerformance analysis. Min Max and averageflows. Is the pipe always full ?
Actions: Consider schedule, price, cost to Install,
operating costs (Reliability, Maintenance, Energy, etc.)
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Emerson Confidential
Slide 3
Invert to keep primary full
Flow Techno logy Select ion Any Flow meters – Piping Requirements
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Emerson Confidential
Slide 4
Flow Techno logy Select ion Types of Flowmeters
Ultrasonic7%
Anemometer
5%
Differential
Pressure29%
Vortex
4%
Mag
20%
Direct Mass
Measurement
18%
Turbine
8%
Positive
Displacement
9%
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Slide 5
Flow Techno logy Select ion Differential Pressure No Power required
ADVANTAGES
Use on liquid, gas, and steam
Good application flexibility
Suitable for extreme temperaturesand pressures
Moderate accuracy – 2 to 5%
Moderate pressure loss
No moving parts
DISADVANTAGES
Expensive to install
Limited range ability 4:1
Affected by changes in density,pressure, and viscosity
Maintenance intensive ( Bleed )
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Emerson Confidential
Slide 6
Static
Pressure
Differential
Pressure
Stagnation
Pressure
Permanent
Pressure Loss
Pressure
Flow Techno logy Select ion Differential Pressure – Theory of Operation
DP K Flow
DP Ed Y NC Q Dm
2
1
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Slide 8
Flow Techno logy Select ion Differential Pressure – Venturi and Nozzle
ADVANTAGES
Use on liquid, gas, and steam
Venturi principally used in Water & Wastewater applications
Nozzle used in Steamapplications
Low system pressure loss
Do not require upstream flowprofiling
DISADVANTAGES
Limited rangeability 6:1 &accuracy ±2%
Expensive to install Requires high Reynolds numbers
(>10,000)
Large acceptance
Venturi
Nozzle
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Slide 10
Flow Measu rement Princ iples Percent of Error versus Flow
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Slide 11
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85
Flow Rate (%)
90 100
1000:1 Turndown
Flow Techno logy Select ion “Flow Turndown” can be Misleading
20:1 Turndown 10:1 Turndown 10
%
8:1 Turndown 12.5%
4:1 Turndown 25%
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Emerson Confidential
Slide 12
Flow Coefficients not constant Solution: Embedded Flow Software
re-calculates ALL flow coefficients real-
time
Installed performance of transmitter over flow range
Solution: DP technology designed
to maximize performance in real-world conditions
Flow Techno logy Select ion 2 Sources of Flow Error
Source #2: Primary Element
Source #1: Transmitter
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Slide 13
Minimize pressure loss
Best Practices Improve Flow Measurement
12.0%0.0% 4.0% 8.0%
Quantify and
optimize installed
performance
Eliminate
impulse lines
Select in-line flowmeter
for smaller line sizes &
insertion flowmeters for
larger line sizes
Expand
flow insight
with wireless
Utilize diagnostics to
enable predictive
maintenance
Simplify and
improve with
multivariableflowmetering
Reduce
piping
requirements
Measuremass
flow
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Emerson Confidential
Slide 14
Use Flow Technologies
with Minimum Straight-
Run Requirements
Optimize Performance in
Short-Straight Run
Applications
Put flowmeter where youwant it
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Lower Installed Cost and Improve Performance
Minimize Piping Requirements
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Slide 15
Optimize Performance in StraightRun Applications
Coriolis
Orifice/
Nozzle
Vortex
Averaging
Pitot Tube
Magmeter
■ ■
■ ■
■ ■ 2221201918171615144 5 6 7 8 9 10 11 12 131 2 3
Conditioning
Orifice
Vortex
w/ K-FactorCorrection
4035302510 155 20
In-Plane
Out-of-Plane
0
-0.5
-1.0
-1.5
0.5
1.0
1.5
K-Factor Compensation
K - F a c t o r S h i f t
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Slide 16
DP FLOW – Straight Run Requirements
Typical Straight Run Requi rements are
10 D’s Up stream and 5 D’s Downstream………
10 D’s ? 5 D’s ?
FLOW
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Slide 17
Conditioning Orifice Plate
Each orifice hole is
positioned to help condition
flow profile irregularities
Geometry reshapes the
flow profile across the
entire pipe
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Slide 18
Cond i t ion ing Plate for Sho rt Run Appl icat ions
Concept: Measurement of DP across a
“Flow Straightener”
Requires only 2D Upstream piping to meetaccuracy specification
– Independent of disturbance
405 Version
– Line Sizes: 2” to 12” (50 to 200 mm)
1495 Version
– Line Sizes: 6” to 72” (160 to 600mm)
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Emerson Confidential
Slide 19
Minimize pressure loss
Best Practices Improve Flow Measurement
12.0%0.0% 4.0% 8.0%
Quantify and
optimize installed
performance
Eliminate
impulse lines
Select in-line flowmeter
for smaller line sizes &
insertion flowmeters for
larger line sizes
Expand
flow insight
with wireless
Utilize diagnostics to
enable predictive
maintenance
Simplify and
improve with
multivariableflowmetering
Reduce
piping
requirements
Measuremass
flow
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Emerson Confidential
Slide 20
$184/year per leak PLUS additional costs:• Value of lost process fluid
• Value of lost energy
• Personnel safety and risk
• Environmental cost, impact
• Cost of inaccurate measurement
•
Maintenance cost of repairing leaks
*U.S. Dept. of Energy
Office of Industrial Technologies
www.oit.doe.gov/bestpractices
All but 2 potential leak
points factory leak-checked.
Removing Leak Points Saves Time & Money Direct Mounting Reduces Leak Points
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Slide 21
Pot. Leak Points = 8
Leak Points
Tendency to Plug/Freeze
Inconsistent Measurement
Pot. Leak Points = 9
Traditional Installation Best Practice Installation
Pot. Leak Points = 2
Pot. Leak Points = 4
Best Practice: Eliminate Impulse L ines to Improve Reliability
Single Casting No Internal
Tubing
Potential Leak Points = 36
Corner Tap
Design
Obstructionless
Consistency
Lower Cost
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Slide 22
New DP transm it ters / More Reliab le & Cos t Effect ive Measu rement Pract ices
Traditional Installation
Direct Mount Installation
Remote
Operator
Interface
Multi-Bus Output
2X Performance
& Reliability
Integrated
Solutions
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Slide 23
A 3-Year User-study* implementing Direct Mount technology
to replace Impulse Lines has been published. The results:
• 90% reduction in work orders
• 3000 applications over 3 years resultedin
only 6 work orders
•
46% reduction in total maintenancecost
* Copy of study avail able fr om Rosemount. Document 00802-0100-2071
Direct Mounting is More Reliable
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Slide 24
How Do Our Customers Measu re Success? 18% Savings in Design & Procu rement
Traditional Practice
Specify & procure30 different parts
+
+
Design / Specify / Procure
Integrated DP Flowmeter
Single integratedassembly
Design / Specify / Procure
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Emerson Confidential
Slide 25
Propeller Meter Featu res
Designed for clean flows
Easy to install and operate
Easy to service in the field
Accuracy of +/- 2% of
reading Repeatability of +/- 0.25%
Self-clearing design
Instantaneous flow rate
Indicator & totalizer on everymodel
Flow range of up to 10:1
No Power Needed
Best sell ing ir r igation
meter in the Uni ted
States for agriculture
and turf ir r igation applications
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Slide 26
How It Works
The Propeller Meter consists of a rotatingdevice, a helical-shaped impeller, positionedin the flow stream.
When fluid passes through the meter, itcontacts the impeller causing it to spin.
The impeller’s rotational velocity is directlyproportional to the velocity of the flow.
The rotation is translated through a magnetic
coupling and flexible drive system to theregister, which calculates the flow rate bymultiplying the flow velocity with the cross –sectional area of the meter tube.
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Slide 27
Speci f icat ions No Power requ ired
Accuracy: +/-2%
Repeatability: +/-0.25%
Turndown: up to 10:1
Register options: optional FlowCom electronic digitalregister available; forward/reverse flow; test hand/indexwheel; anti-reverse totalizer; custom scale; extended digittotalizer
Impeller options: high temperature resistant; acid andcaustic resistant
Line sizes: from 2" to 96"
Flow Techno logy Select ion
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Slide 28
Flow Techno logy Select ion Turbine Meters No Power
DISADVANTAGES
Only for low viscosities
Require upstream and down-stream flow conditioning
Require frequent calibrationMoving parts
Sensitive to flow profile
Vibration sensitive
Straightening vanes required
Needs 20 to 30 diameters of straight run
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Slide 29
Accuracy about a 10:1 turndown
Higher accuracy at all operating ranges
r’s “Percent of Full Scale Accuracy”
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Slide 31
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THEORY OF OPERATION
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Slide 33
• Understand how magmeters use Faraday’s Law
• Pulsed DC Vs. AC Magnetic Flow Meters
• Understand the advantages and limitations of magnetic flowmeters
Objectives
F d ’ L f El t ti
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Slide 34
Faraday’s Law of Electromagnetic Induct ion
A voltage will be induced in a conductor
moving in a magnetic field (E) The magnitude of that induced voltage is
proportional
– to the velocity of the conductor (V)
– to the length of the conductor (D)
– to the strength of the magnetic field (B)
Michael Faraday (1791 - 1867)
E = k × B × D × VV
B
E
Fl T h l S l ti
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Slide 35
V
B
DEs
Es
Magnet
coil
Electrode
Faraday’s Law of
Electromagnetic Induction
ES= the induced electrode voltage
B = the magnetic field density
V = liquid velocity
D = magmeter pipe diameter
C = non-dimensional constant
Flow Technology SelectionMagnetic Flow meters – Theory of Operation
BVD
C
E s
1
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Slide 36
Magmeter Senso r Components
SensingElectrodes
Coils
LiningSST PipeFlange
E
VBD
SensingElectrodes
Coils
LiningSST PipeFlange
E
VBD
ProcessConnection
Coil Housing
M t Th
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Slide 37
Magmeter TheoryFaraday’s Law and the Flow Rate
• All of the constants (k,B,D) areconverted into a CalibrationNumber during a flow labcalibration
– V = E / Calibration Number
• Q = V × A
– Volumetric flow rate (Q) is velocity(V) times cross-sectional area (A)
A
V
T
E = k × B × D × V
CalibrationNumber
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Slide 38
Coil Exc itat ion Character ist ics
DC (0.5% of rate accuracy)
– More accurate
– Continuous automaticzeroing
– Magnetic field immune topower line disruptions
AC (1% of rate accuracy)
– Poor zero stability
– AC power required atflowtube
– High maintenance
– High power consumption – Good process noise
rejection
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Slide 39
AC Flow Signal Diagram
Positive (A1)quadrature
voltage signal
Negative (A2)quadrature
voltage signal
Positiveflow signal
Time
Negativeflow signal
90 degreesphase
differential
Transmitter sensing positive
Transmitter sensing negative
+
0
-
When A1 = A2, quadrature voltage cancels
In phasenoise signal
AC C il E i t t i M th d R lt i Mi
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Slide 40
AC Coi l Exc i tat ion Method Resu l ts in Mis- Measurement
Measurement Signal
Inductively coupled
interference voltages
High Excitation Currents and frequency results in fast
response time for a safe and stable measurement
Disadvantage: phase shift between signal and noisevaries over time
Result: Zero point drift
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Emerson ConfidentialSlide 41
0
+
-
A
M
PL
I
T
U
D
E
One Measurement Cycle =
1/10 Line Frequency (6 Hz)
V Noise
E
E
1 2 3 4 5 6 7
Flow
Signal
(E + VNoise) - (-E + VNoise) = 2E
Magnetic field transition begins
Transients present due to transitionof magnetic field
Magnetic field and flow signal stabilize
Flow signal sampled
Magnetic field transition begins
Transients present due to transitionof magnetic field
Magnetic field and flow signal stabilize
Flow signal sampled; difference takenfrom previous sample. Flow rate
calculated.
1
1-2
2-3
3-4
4
4-5
5-6
6-7
EVENT SEQUENCE
Output Stage of transmitter is updated 12 timesper second regardless of coil drive frequency
Normal meter coil current 0.5 A
Pulsed DC Flow Elim inates Zero Drif t
Flow Techno logy Select ion
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Emerson ConfidentialSlide 42
Flow Techno logy Select ion Magnetic Flow meters – High-Powered Pulsed DC Coil Excitation
ADVANTAGES
Higher Coil Current Than ConventionalPulsed DC -0.7 to 5 A
Higher Exciter Frequency
– up to 33 Hz
Improved Signal-to-Noise Ratio compared toConventional Pulsed DC
Reads Lower Flow rates below 2 feet /second
DISADVANTAGES Only applies to sensors <20 in.
Exciter Frequency >15 Hz create zero drifterror
Higher Power Consumption than Conventional
Pulsed DC Higher Sensor Cost
C il E it t i
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Emerson ConfidentialSlide 43
Coil Excitat ion Zero Po in t Dri ft
AC-magmeter DC-magmeter
% Error
of actualflow rate
5 / 1 1 / 9 85 / 1 0 / 9 8 5 / 1 2 / 9 8 5 / 1 3 / 9 8
1 0
6
1 4
2
- 2
- 6
- 1 0
0
- 1 4
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Flow Meter Accuracy
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Flow Master
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Unsurpassed Performance Comparison
CompanyStandard WW
METER
Accuracy
HighAccuracy
Accuracy at0.5 ft/sec
Accuracy at 2ft/sec
±0.4% ±0.2% ±1.5% ±0.4%
±0.5% ±0.2%* ±3% ±0.75%
±0.5% ±0.25% ±2.5% ±0.5%
±0.5% ±0.2% ±2.0 ±0.7%
±0.5% ±0.25% ±1.0 ±0.5%
±0.35% ±0.2% ±0.5 ±0.35%
±0.5% N/A ±2.2% ±0.5%
±0.5% ±0.2% ±7.8% ±0.65%
±0.5% N/A ±2.0 ±0.5%
Flow Master
Magnetic f low Meter Performance
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Emerson ConfidentialSlide 48
gAdvantages
No obstructions to the flow
No moving parts to wear or break
Maintenance free
Wide flow range
Worry-free accurate
measurement Debris or solids will not clog the
meter
No head loss
Bi-directional flow
Empty pipe detection
Unaffected by changes indensity and viscosity
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Emerson ConfidentialSlide 49
Why NOT use Magnetic Flowmeters?
• Magmeters require a conductive process fluid
– No gases or steam
– Entrapped air, foam, or two-phase flow cause errors
– Minimum 5 µSiemens/cm
• Conductance is the reciprocal of Resistance and is measured inSiemens (formerly Mhos)
• 10 Siemens/cm = 0.1 Ohm• 5 µSiemens/cm = 200 kOhm
• Liner temperature limits
• Power consumption of 4-wire device
• Existing Line Flow meter now required
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INSTALLATION
Object ives
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Emerson ConfidentialSlide 51
Identify the best practices recommended for installing magmeter devices
Describe the importance of proper grounding and wiring for remotemount transmitters
Object ives
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Emerson ConfidentialSlide 52
Best Practices
Sizing
– Review of Instrument Toolkit Materials of Construction
– Ensure liner and electrodes arecompatible with the process
– Gaskets for mounting betweengrounding rings
Handling – Careful handling to prevent damage
Pipe Orientation – Ensure the pipe stays full
– Straight run requirements
Meter Orientation – Electrode plane
Process Connections – Flanged, Wafer, Hygienic/Sanitary
– Wafer mounting kits
Fl T h l S l t i
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0 - 0.4 ft/sec Difficult to measure accurately
0.4 - 1.0 ft/sec Measurable in most applications
1.0 - 5.0 ft/sec Measurable, reduced velocityrecommended if fluid contains
abrasive solids
5.0 - 12.0 ft/sec Good flow measurement
13.0 - 25.0 ft/sec Measurable, relatively high
pressure drop will result
Flow Techno logy Select ion Liquid Pipeline Velocities
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Sizing
Verify Sizing Results
– Make sure flow rates are acceptable for the sensor line size
– Common for sensor size to match line size
Application Recommended
Minimum
Recommended
Maximum
ConfigurationLimits 0 ft/sec 39.97 ft/sec
Clean Fluid 2 ft/sec 20 ft/sec
Abrasive
Slurry3 ft/sec 10 ft/sec
Non-abrasive
Slurry 5 ft/sec 15 ft/sec
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Emerson ConfidentialSlide 55
Materials of Construction
Liner Materials
– PTFE, PFA, ETFE,Polyurethane, Neoprene,Linatex
– Temperature Limits
Electrode Materials – SST, Nickel Alloy, Platinum,Tantalum, Titanium
– Grounding Electrode to beused on water applications only
Material Selection Guide – Compatibility and Corrosion
Ratings
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Liner Materials
ETFE – Tefzel
– Very Good Chemical Resistance(slightly less than PTFE)
– Excellent Abrasion Resistance(superior to PTFE)
– Liner Bonds to Sensor
– Max Temp = 300°F (149°C)
– Sensor Sizes = 0.5” - 16” (4mm -400mm)
– Recommended for sludge
applications that requirecontinuous submergence
– Recommended for chemical feedMeters
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Liner Materials
PFA
– Excellent Chemical Resistance(similar to PTFE)
– Excellent Abrasion Resistance(superior to PTFE)
– Liner Bonds to Sensor and WireMesh
– Recommended for sludgeapplications WAS, RAS , Thickened
– Sensor Sizes = 0.15” - 16” (15mm -300mm)
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Liner Materials
Neoprene
– Good Abrasion Resistance
– Good Chemical Resistance
– Max Temp = 185°F (85°C)
– Sensor Sizes = 1.5” and up (40mmand up)
– Softer, Rounded Edges into Sensor
– Used when temps are too high for poly or when some chemicals arepresent
– Recommended for use with saltwater and in O&G water applications(since hydrocarbon carryover iscommon)
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Electrode Materials
316L Stainless Steel
– Good corrosion resistance – Good abrasion resistance
Nickel Alloy 276 (Hastelloy C-276)
– Improved corrosion resistanceover 316L SST
– Good abrasion resistance
– Recommended for slurryapplications with a highpercentage of solids
Tantalum
– Excellent corrosion resistance
– Excellent for hydrochloric acid – Do not use in caustic applications
(or applications with CIP)
– Avoid Abrasive Applications
Titanium
– Good chemical resistance – Excellent Abrasion resistance
– Good in caustic applications
80%Platinum - 20%Iridium
– Excellent corrosion resistance
– Good Abrasion resistance
Other material options available
– Consult Factory
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Emerson ConfidentialSlide 61
Handl ing
Lifting
– 3-Inch and larger sensors have liftinglugs
End caps
– Prevent liner damage
– Prevent PTFE flare
– Only remove
immediately beforeinstallation
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Emerson ConfidentialSlide 62
• Vertical flow up is best practice
– Ensures electrodes are always covered
– Sufficient back pressure
• Horizontal flow is acceptable
– Electrodes must be covered
• Vertical down is least desirable
– Electrodes not always covered
– Insufficient back pressure may causeprocess noise on electrodes
Pipe Orientation
Flow Techno logy Select ion
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Emerson ConfidentialSlide 63
Invert to keep primary full
Flow Techno logy Select ion Any Flow meters – Piping Requirements
Flow Techno logy Select ion
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Emerson ConfidentialSlide 64
NO!
BEST GOOD
(Up Elbow
Preferred)
NO! Straight Run Required
Flow Techno logy Select ion Most Flow meters – Installation
Flow Techno logy Select ion
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Emerson ConfidentialSlide 65
Flow Techno logy Select ion Magnetic Flow meters – Piping Requirements
90oElbow 5 None
Tee 5 None
Reducer None None < 8o
Control Valve 10 2
Check Valve 10 None
Butterfly Valve 10 2
Gate Valve None None Fully open
Pump 10 None
Configuration Upstream Downstream Comments
Type Pipe dia. Pipe dia.
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Emerson ConfidentialSlide 66
Straight Run Requirements
• 5 pipe diameters upstream and 2 pipe diameters
downstream – Measured from the measurement electrodes (center of the sensor)
• Distorted flow profiles will cause small shifts usually <2.0%
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Emerson ConfidentialSlide 67
Meter Orientation
The sensor should be mounted in a position that
ensures the electrodes are covered by the processfluid
– Avoid false empty pipe detection caused by air pockets atthe top of the pipe
– Some sensors have a 45° offset
built in for common mountingpositions
Flow arrow should point inthe flow direction
– Can be used as a bi-directional flowmeter
– Reverse Flow detection can be turned on or off
Process Connections
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Emerson ConfidentialSlide 68
Process ConnectionsFlanged Sensors
Flanged sensors are bolted to process flanges
– Gaskets are user supplied
• Metallic or spiral-wound gaskets can damage the liner
– Follow bolt torque specifications in the manual
Process Connections
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Emerson ConfidentialSlide 69
ocess Co ect o sWafer Sensors
Wafer sensors are bolted between process flanges
– Gaskets are user supplied
• Metallic or spiral-wound gaskets can damage the liner
– Centering alignment/spacer rings are supplied at no charge
– Studs, nuts, and washers are available as options
Spacer Ring
Wafer Sensors
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Emerson ConfidentialSlide 70
Wafer SensorsCentering Alignment Rings
• Alignment rings are critical for accurate and reliable
operation – 0.15” to 1” (4 mm to 25mm) meters have studs that mount
through the meter body
– 1.5” to 8” (40mm to 200mm) meters have centering alignmentrings/spacer rings which are used for positioning
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Emerson ConfidentialSlide 71
Grounding
• Two types of grounding
– 1. Earth Ground
• Safety
• Establishes low noise environment in sensor
– 2. Process Reference Ground (connect through terminals 17
and ground)• Sensor at same potential as the process fluid
• Established by one of four methods
– Grounding straps
– Grounding electrode – Grounding ring(s)
– Lining protector(s)
Process Reference Ground
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Emerson ConfidentialSlide 72
Process Reference Ground Ground ing Methods
Mostcommon
Ground OptionConductivityRequirement
Process Piping Material
Relative Price Notes
Conductive (MetalPipe)
Non-conductive(Plastic, etc) Conductive Lined
Grounding Straps 5 uS NA NA No ChargeProvided with every E-series Mag
Tube
GroundingElectrode
100 uS LowLeast Expensive option, provides
convenient grounding for non-conductive and lined pipe applications
GroundRings
5 uS High Provides best ground for non-
conductive and lined pipe applications
Lining Protectors 5 uS HighestMost expensive, pro tects leading edgefrom wear in tough slurry applications
Grounding Methods
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Emerson ConfidentialSlide 73
g- Ground Straps
Ground Straps
– Connected toconductive pipe
– Most common
method
Grounding Methods
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Emerson ConfidentialSlide 74
g- Ground Rings/L in ing Protectors
Ground Rings/LiningProtectors
– Connected groundstraps
– Continue connection topipe if conductive
Grounding Methods
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g- Ground Elect rode
Ground Electrode
– Only Earth Ground isrequired
– Requires minimum
conductivity of 100µS/cm
– Not recommended for use in plastic pipe or
electrolytic applications – Potential for sludge to
coat
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Emerson ConfidentialSlide 76
Remote Mount Transmitters
Require additional wiring between transmitter and
sensor
Remote Moun t Transm it ters
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Emerson ConfidentialSlide 77
Remote Moun t Transm it ters Wiring Preparat ion
Up to 1”
Limit the amount of exposed (unshielded) wire at
termination points
Remote Mount Transm it ters
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Electrode (+)Electrode (-)Shield (groundreference)
ShieldCoil (-)Coil (+)
Wir ing Connect ions
4-20 mA Output (+)4-20 mA Output (-)
Power 90 - 250 VAC
or 12 - 42 VDC
Maximum LengthE-Series: 1000 ft100 ftCombo Cable:330 ft
Remote Mount Transmitters
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Emerson ConfidentialSlide 79
Conduits
The electrode and coil drive cables can be run in the
same conduit – Must have a dedicated conduit for each sensor and
transmitter
WRONG!
Remote Mount Transmitters
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Emerson ConfidentialSlide 80
Correct!
Conduits
Correct conduit configuration for two separate
systems
Review Questions
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Emerson ConfidentialSlide 81
Review Questions
Earth Ground, Process Reference Ground
Ground Straps, Ground Rings, Ground Electrode,Lining Protectors
False: Coil Drive = 14 AWG, Signal = 20 AWG
• What are the two types of grounding required for amagmeter system?
• What are the four possible options for providing a processreference ground?
• True/False: The coil drive cable and electrode signal cableshould be the same gauge cable.
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TROUBLESHOOTING
Object ives
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Emerson ConfidentialSlide 83
Name some of the most common problems that occur in magneticflow meter installations
List some of the top causes for common problems
Understand methods and tools used for basic troubleshooting
Object ives
C M t P bl
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Common Magmeter Problems
Bad zero
– System reads flow when thereis no flow
Reads an unexpected flow
– Reverse flow
– Unstable flow – No flow
Reads inaccurate flow
– Higher than expected
– Lower than expected
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R di hi h th t d
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Emerson ConfidentialSlide 86
360.0
GPM
327.5
295.0
262.5
230.0
I . ,
TimeSeries
aut8703.dat
01/05/96
422-FX-226-AUTO
PRISCREEN REJFLOW
2560 5 12 769 1025
Mean =300.373 2Sig = 21.8 (7.26%)
Sec
Readings higher than expected
Moisture in terminal block area
Configuration Errors
– Incorrect sensor line size – Incorrect Analog or Pulse
output range
– Incorrect calibration number
– Control system configured
incorrectly
System Upsets
Moisture in the
Terminal Block orSensor Housing
R di l th t d
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Emerson ConfidentialSlide 87
Readings lower than expected Configuration Errors
– Incorrect sensor line size – Incorrect Analog or Pulse
output range
– Incorrect calibration number
– Control system configured
incorrectly Sensor Faults
– Shorted/Open Coils
– Shorted/Open Electrode(s)
– Moisture in terminal block or
coil housing Process Issues
– Low conductivity
– Coated Electrode(s)
Moisture in the
Terminal Block orSensor Housing
Reading an unexpected flow rate
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Emerson ConfidentialSlide 88
Reading an unexpected flow rate Reverse Flow
– Installed backwards – Wires reversed
Unstable Flow
– Bad wiring
– Slurry or high solids content
– Entrained air/gas bubbles
– Chemical reaction or chemicaladditives
No Flow
– Transmitter/Sensor faults – No conductivity
– Coated Electrode(s)
Magmeter Troubleshooting Procedure
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Emerson ConfidentialSlide 89
Work form easiest to hardest
– Transmitter → Wiring → Sensor → Process
Magmeter Troubleshooting Procedure
Transmitter Troubleshooting
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Transmitter Troubleshooting
Check transmitter status for error messages
Verify basic configuration parameters
– Calibration Number, Line Size, Flow Units, Range Values
– Pulse Output Factor if using Pulse Output
Operation with control system
– Loop Tests (Analog and Pulse)
Reference Calibration Standard
– Similar to attaching a “perfect” sensor to the transmitter
– Excellent for troubleshooting
– Works on all transmitters
– Spare electronics
– Replace with known good electronics
Wiring Troubleshooting
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Emerson ConfidentialSlide 91
Wiring Troubleshooting
Signal and Coil Drive must be
twisted / shielded pairs Combination Cable must be
Rosemount Proprietary
Shields must be connected at
both ends Separate conduit each
magmeter system
– Signal and Coil Drive can be insame conduit
Strip back cable 1”
Run known goodwire
Sensor Troubleshooting
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Emerson ConfidentialSlide 92
Sensor Troubleshooting
Visual Inspection
– Installation – Terminal block
– Process connections
– Process Ground
Manual Sensor Tests
– Coil continuity and insulation – Electrode continuity and
insulation
– Shield continuity to case
Required Tools
– DVM (all tests for sensor out of line)
– LCR Meter (required for electrode measurements if sensor is full of process fluid)
Sensor Troubleshooting – Full
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Emerson ConfidentialSlide 93
DVM for Coil Tests
– 1 to 2 (Continuity of Coil) – 1 to GND (Insulation of Coil to
ground)
– 2 to GND (Optional, should besame as 1 to GND)
– 17 to Ground Screw (Continuity
of shield to case)
LCR for Electrode Tests
– 17 to 18 (Continuity of frontelectrode to ground)
– 17 to 19 (Continuity of back
electrode to ground) – 18 to 19 (Continuity of electrode to
electrode)
Full
1 2 18 1917
Sensor Troubleshooting – Empty and Installed
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Emerson ConfidentialSlide 94
Empty and Installed
DVM for All Tests
– 1 to 2 (Continuity of Coil) – 1 to GND (Insulation of Coil to
ground)
– 2 to GND (Optional, should besame as 1 to GND)
– 17 to Ground Screw (Continuity
of shield to case)
– 17 to 18 (Insulation of frontelectrode to ground)
– 17 to 19 (Insulation of backelectrode to ground)
– 18 to 19(Insulation of electrode
to electrode)
Moisture in pipe can causefalse electrode short readings
Conductive coating can causefalse electrode short readings
1 2 18 1917
Process Troubleshooting
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Emerson ConfidentialSlide 95
Process Troubleshooting
The minimum conductivity is 5 µS/cm
– Hydrocarbons generally too low in conductivity
– Non-conductive fluid mixed with conductive may work(water & glycol)
• Dependent upon % and homogeneous mix
Fluids with components that coat electrodes mayinterfere with the electrode measurement signal
– Oil, sewage at low flow rates, corrosion inhibitors
Solids, chemical additions, or entrained air can
create noisy readings
Electrolytic processes or cathodic protectionsystems can interfere with readings
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Meter Verif ication
SMART Meter Verif ic ation Greatly Reduces Cal ibrat ion Veri f icat ion Cos ts
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Emerson Confidential
Slide 97
I Would L ike to Veri fy the Magmeter Cal ibrat ion
Without Removing It From The Line Or Using Extra Equipment .
It Would Reduce Maintenance Time and Cost.
Verifying mag calibration historically
involved removing the flowmeter from theline or using extra equipment
SMART™ Meter Verification Diagnosticprovides calibration verification withoutremoving the product from the line or requiring the purchase of extra
equipment
Historically Verifying Meters has been time-consuming and forced shutdown
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Emerson Confidential
Slide 98
consuming and forced shutdown
Typical Meter Verification Capabilities
Trip to field
Technical knowledge andExtra equipment
No formal report
No deviation values
More than 120 minutes
May require a processshutdownMust shutdown,
remove meter
from the line, pay
for proving.
Prover External
Equipment
Meter Verification Theory of Operation
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Emerson Confidential
Slide 99
A baseline signature of the
magnetic field is taken at thetime of factory calibration
– Signature is independent of temperature and flow-rate
– Signature (and calibration)will change if there is amechanical shift of the coilsover time due to vibration,
thermal cycling, etc
Meter Verification Theory of Operation
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Diagnos t ic/Veri f icat ion Measurements
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Emerson Confidential
Slide 101
Sensor
Precision Measurements:
– Coil Inductance
– Coil Resistance
– Electrode Impedance
– Electrode Voltage
Fingerprint stored inside the
sensor Transmitter self-checks the sensor
based on technology
Measurements:Elec. R E1: 0.919 kElec. R E2: 1.855 k
Elec. C E1: 100000.094 nFElec. C E2: 100000.094 nF
DC Back Off V: 0.007 VCoil & Cable R: 48.43Coil L: 41.78 mH
Sensor L Shift: 0.53%TX Av. Gain Shift: 0.06%TX Av. Gain Value: 110
Continuous SMART Meter Verification isalways running
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Slide 102
y g
Continuous Meter Verification and AnalogLoop Verification can be found here
Magnetic Flow Meter
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Emerson Confidential
Slide 103
Standard Diagnostic functions:
Electrode coating
Electrode short circuit
Empty pipe / partially full
Extended Diagnostic functions (in preparation):
Gas bubbles detection
Signal noise indication
Electrode corrosion
Low conductivity detection
Liner damage
Partially full pipe
Veri f icat ion Systems Verification System – Calibration Certificate
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Slide 104
Equipment Certification
Verification Certainty Options1. Fingerprinted by
manufacturer• 99% certainty calibration
is within ±0.2%2. Retrofitted in the Field• 98% certainty calibration
is within ±0.2%
Independent Testing
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Specify or replace existing Flow Meters with a Meterthat has the coil drive power to read low flow rates.
Apply the proper electrode and liner material for your
application.
Install the meter in a location ensuring that the meter is
always full and is away from obstructions.Specify a meter with diagnostics that will continuously
monitor your meter and offer solutions to fix noted
issues. If the meter is below grade ensure that the
electronics or meter housing is NEMA 6P
Do this and you should never need to reference this
presentation