Describe Coriolis Mass Flowmeters
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1 Training Module Human Development
2 HDC Human Development All rights reserved. No part of this publication may be copied, reproduced, stored in a computer or retrieval system, published, distributed, or transmitted in any form or by any means whatsoever, including without limitation by mechanical means, photo copying, recording, digital or electronic media, the Internet, or otherwise, without the express prior written permission of HDC Human Development (HDC). HDC grants to the purchaser of a Single User License (as defined in the agreement with such purchaser) a limited license to store the electronic file(s) on one computer only and to make a single paper copy of this publication. HDC grants to the purchaser of a Site License (as defined in the agreement with such purchaser) a limited license to store the electronic file(s) on one local area network server accessible by individual users' computers at one site or location only and to make paper copies of this publication for a company s employees at the same site or location only. Each site or location must purchase a separate Site License for employees at that site. HDC grants the purchaser of a Corporate License (as defined in the agreement with such purchaser) a limited license to store the electronic file(s) on its intranet and on computers at company sites or locations and to make paper copies for any or all employees. Nothing in the foregoing restricts, amends or abrogates the provisions of the agreement between HDC and the purchaser of the applicable license. Any copying or use other than pursuant to such a license is illegal. For further information, please consult the applicable license agreement. This publication is designed to provide general information regarding the subject matter covered. Care has been taken to ensure the accuracy of the information and that the instructions contained in this publication are clear and reflect sound practice. The user understands that HDC is not providing engineering services. The user understands that any procedures (task steps) that are published or referenced may have to be modified to comply with specific equipment, work conditions, company standards, company policies and practices, legislation, and user qualifications. HDC does not make any representations, guarantees, or warranties of any kind whatsoever with respect to the content hereof and the results to be achieved by implementing the procedures (task steps) herein. To the maximum extent permitted by applicable law, in no event shall HDC be liable for any damages whatsoever (including without limitation, direct or indirect damages for personal injury, damages to the environment, damages to business property, loss of business profit, or any other pecuniary loss). The use of the information and procedures (task steps) herein is undertaken at the sole risk of the user. ISBN Canadian Cataloguing in Publication Data 1. Flow meters. I. HDC Human Development Consultants. TC177.D C This training kit consists of the following parts: Training Module and Self-Check Blank Answer Sheet Knowledge Check and Answer Key Job Aid Published by HDC Human Development Published in Canada HDC Human Development Website: marketing@hdc.ca Phone: (780) February, 2001
3 Contents Training Objectives 1 1 Introduction Principle of Operation The Coriolis Effect Coriolis Effect Applied Dual-Tube Coriolis Flowmeter Measuring Density 11 Components Sensor Transmitter Interface Auxiliaries 16 Strengths and Limitations Strengths of Coriolis Limitations of Coriolis 18 Accuracy and Versatility 19 6 Installation Multiple Flowmeters Orientation of Flow Tubes Anchoring for Stability and Minimizing External Vibrations Installation Guidelines 23 February, 2001 Page i of ii
4 Contents (continued) 7 8 Operations Responsibilities Operator Responsibilities Maintenance Responsibilities 25 Zeroing and Proving Zeroing Coriolis Proving Coriolis 27 9 Troubleshooting Self-Check Self-Check Answers Glossary 36 February, 2001 Page ii of ii
5 Training Objectives Upon completion of this training kit, you will be able to: Describe the purpose and importance of mass flowmeters mass flowmeter operation Describe common Coriolis mass flowmeter components mass flowmeter installation requirements Describe operations and maintenance responsibilities for Coriolis mass flowmeters mass flowmeter proving activities Describe fundamental Coriolis mass flowmeter troubleshooting techniques NOTE Refer to the glossary, located at the end of this module, for an explanation of terms. 1 Introduction Flowmeters are devices used to measure the rate of flow of fluids. Accurate flow rate measurements are critically important in industries dealing with flowing fluids (gases, liquids, and slurries), including: food and beverage automotive water and waste water treatment oil and gas pipelines chemical hydroelectric power generation pharmaceutical cosmetics A company s profit or loss can depend on measurement accuracy. Over the years, many different types of flowmeters have been developed to measure flow rates of different fluids. The goal has been to increase flow measurement accuracy and reliability in a wide range of flow rates and a wide variety of fluids. Each flow rate and each fluid offers special measurement problems. February, 2001 Page 1 of 39
6 Figure 1 Relationship Between Volume and Mass The most common types of flowmeters determine flow rate by measuring one of the following: differential pressure: orifice plates, venturi tubes, pitot tubes (often called head meters) fixed volume: piston, gear (often referred to as positive displacement (PD) meters) velocity: turbine, vortex shedding, electromagnetic, ultrasonic mass: Coriolis, thermal The first three categories of flowmeters (differential pressure, fixed volume, and velocity) measure the volume flow of fluids. Volume flow is expressed as units of volume over time (e.g., m 3 /s (ft 3 /min)). Mass flow must be calculated from the measured volume flow and density. Volume is the measure of the size of a body or substance in space, i.e., the amount of space a body or substance occupies. Mass is the measure of a body s or substance s resistance to being accelerated, i.e., resistance to changes in its linear motion. Unlike volume, mass is unaffected by changes in pressure and temperature. Density is the mass of a substance per unit volume. Mass Volume = Density Note that the terms mass and weight are often (incorrectly) used interchangeably: the kilogram, a metric unit of measurement, is a measure of mass the pound, an imperial unit of measurement is a measure of weight Note: Mass is not dependant on gravity. (For example, the mass of an object is the same on the moon as on earth. However, an object weighs less on the moon than on earth.) Figure 1 illustrates the relationship between volume and mass relative to temperature: as temperature increases, volume increases, but mass remains constant. In gases, as pressure increases, volume decreases, but mass remains constant. February, 2001 Page 2 of 39
7 Mass flowmeters measure the rate of mass flow directly. Mass flow is expressed as units of mass over time (for example, kilograms per hour). Because additional measurements and calculations are not needed, mass flowmeters can provide more accurate flow measurement than volume flowmeters. Mass flowmeters are capable of handling not only gas and liquid flows but also almost all flowing media such as sludges suspensions corrosive fluids highly viscous fluids In addition to directly measuring mass, mass flowmeters can be used to directly measure density of the fluid. Mass flowmeters have a wide range of applications, including: process control applications where accurate mass flow rate/ density measurement is important product loading/transfer applications mixing applications where blending ratio/mixture concentration is critical Mass flowmeters are accurate enough to be used to measure fluids for the purposes of transfer of ownership of a product (custody transfer) and material balance determinations (i.e., ensuring the material mass feeding a process is accounted for in the products leaving the process). There are two principal types of industrial mass flowmeters: Coriolis mass flowmeters thermal mass flowmeters which introduce heat into the fluid and then measure the temperature change. The temperature change is directly proportional to the mass flow rate. February, 2001 Page 3 of 39
8 Figure 2 Typical Uses of Coriolis Custody Transfer accurately metering a product being sold seller Product Transfer from Tank Farm transferring an accurate quantity of material from a storage tank storage tank buyer tank tank Continuous Product Mixing producing a specific mixture strength by blending accurately-metered amounts of 2 products product A product B tank Mixing Batches to Fill Containers producing a batch repeatedly to fill containers on a conveyor belt each batch must have the same specific mixture strength, produced by blending accurately-metered amounts of 2 products product A mixing tank Measuring Oil Well Flows and Liquid Composition determining water content of oil well flows and total volumes of oil and water produced by the well water content is calculated from the liquid mixture density oil well fluid (gas/oil/ water) gas oil/ water oil/water separator to downstream processing product B Density Measurement measuring the density of a product by drawing a slipstream sample through the Coriolis meter concentration can be calculated from the density measurement flow line product flow slipstream sampling flow line February, 2001 Page 4 of 39
9 Coriolis This training kit describes the Coriolis mass flowmeter. The kit describes the operating principle, generic components, installation, calibration, maintenance, and proving requirements of Coriolis mass flowmeters. The kit targets process operators and maintenance personnel responsible for the safe and effective operation of Coriolis mass flowmeters. Troubleshooting techniques are also presented for generic Coriolis mass flowmeter applications. 2 Principle of Operation 2.1 The Coriolis Effect The underlying principle of the Coriolis mass flowmeter is a phenomenon of physics called the Coriolis effect. The Coriolis effect is the tendency for any moving body on or above the earth s surface (e.g., a wind or an ocean current) to drift sideways because of the earth s eastward rotation. The Coriolis effect causes moving fluids to curve to the right of the direction of main flow in the Northern Hemisphere and to the left in the Southern Hemisphere. The effect of the Coriolis force is present in any rotating system. As illustrated in Figure 3, the Coriolis effect depends on three parameters: a mass, a rotating body, and a motion of the mass relative to the rotating body. Newton's first law of motion states that a body in motion will maintain its speed and direction of motion unless acted on by an outside force. The Coriolis force is an outside force that causes a body in motion on a rotating body to follow a curved path instead of a straight path. February, 2001 Page 5 of 39
10 Figure 3 Coriolis Force Coriolis force mass trajectory of mass under the influence of the Coriolis force radial velocity (motion of mass relative to rotating body) angular velocity of rotating body and the mass Coriolis forces are at work when 3 parameters are present: - a mass - a rotating body - a motion of the mass relative to the rotating body 2.2 Coriolis Effect Applied The simplest Coriolis-type meters consist of a single straight tube through which the fluid medium flows. An electromagnet is used to vibrate the tube (i.e., create a rotating body), usually at the tube s resonant frequency. Depending on the metal the tube is made of, the tube vibrates at about 80 Hz (Hertz, cycles per second); depending on the size of the tube, the tube moves hundredths of a mm (in.) or less per cycle. When the fluid in the tube is not flowing, the Coriolis force does not influence the fluid. When the fluid is flowing, however, the Coriolis force February, 2001 Page 6 of 39
11 causes the fluid to oppose the induced vibration. This opposition causes the tube to twist in the form of a sine wave. Figure 4A illustrates a vibrating fluid-filled tube (whose vibrations are greatly exaggerated to illustrate the principle); Figure 4B illustrates the same vibrating tube in which the fluid is now flowing. Figures 5A and 5B represent the end view of a U-shaped tube, one with no flow, the other with flow. Figure 4 Single, Straight Coriolis Tubes, one with No Flow, the other With Flow A. No Flow angular velocity mass Liquid-filled tube with no flow A vibration is magnetically induced in the tube. B. With Flow Coriolis force radial velocity Liquid-filled tube with flow As the liquid flows through the tube, the liquid opposes the vibrating motion and causes the tube to twist. The amount of twist is proportional to the fluid mass flow rate. February, 2001 Page 7 of 39
12 Figure 5 Single, U-Shaped Coriolis Tubes, one with No Flow, the other With Flow A. No Flow Liquid-filled U-shaped tube (seen from the end) A vibration is magnetically induced in the tube; an electromagnet is used to make the tube vibrate. B. With Flow Liquid-filled U-shaped tube (seen from the end) As the liquid flows through the tube, the tube twists. When the vibration reverses direction, the tube twists in the opposite direction. The changes in the motion of the flow tube are minute and must be detected electronically. A magnetic detector, consisting of a magnet and coil, is installed at both the inlet and outlet ends of the tube. Either the magnet or the coil is attached to the sensor tube so that as the tube vibrates, either the magnet or the coil moves relative to the other. The movement of the magnet against the coil produces an alternating electrical current in the form of a sine wave. The output signal is a measure of the relative velocity or displacement of the tube. February, 2001 Page 8 of 39
13 Figure 6 Sine Waves Generated at the Inlet and Outlet Ends of the Sensor Tube outlet A. No Flow inlet time B. With Flow x time lag x x time lag x outlet inlet time Figure 6 illustrates the sine wave pattern produced at both the inlet detector and the outlet detector; Figure 6A illustrates the two waves created in the vibrating tube when the fluid in the tube is not flowing. The two waves are synchronized: both ends of the tube move up at the same time and down at the same time. Figure 6B illustrates the two waves when the fluid in the tube is flowing. The relative velocity or displacement at the outlet detector lags the relative velocity or displacement at the inlet detector, indicating the twisting motion due to the Coriolis effect. The time lag is proportional to the mass flow rate. As the mass flow increases, the twisting motion increases and the time lag increases. February, 2001 Page 9 of 39
14 A transmitter uses the time lag to calculate the mass flow rate. An interface translates the transmitter data into a readable form for the operator. 2.3 Dual-Tube Coriolis Flowmeter Many different tube designs are available: straight, U-shaped, delta, omega in either single- or dual-tube configurations (see Figure 7). Each design has specific applications to which it is best suited. Figure 7 Coriolis Flowmeter Tube Designs Single Tube Straight Single Tube Double Tube U-Shaped Single Tube U-Shaped Omega Shaped Delta Shaped The dual-tube loop design is a widely used type of Coriolis flowmeter. In the dual-tube flowmeter, manifolds (i.e., flow splitters) divide the flow into two equal streams at the inlets of the two tubes and recombine the flow at the outlets. The fluid to be measured flows equally through the two tubes. An electromagnetic drive coil causes both loops to oscillate rapidly, 180 degrees out of phase: as one loop moves upward, the other moves downward. Each loop is anchored at two points and February, 2001 Page 10 of 39
15 2.4 Measuring Density vibrated between these two anchors. As the fluid flows through the oscillating flow tubes, the Coriolis effect causes the flow tubes to twist. Detectors are attached at both the inlet and the outlet ends of the tubes to measure the amount of tube twisting. Because the vibrations of each tube are 180 degrees out of phase, the meter s sensitivity is doubled. Additionally, one tube serves as the other tube s reference point thereby canceling the effects of external noise such as vibration. The Coriolis mass flow meter applies two physical principles to measure density: End of Sample A full licensed copy of this kit includes: Training Module and Self-Check Knowledge Check and Answer Key Blank Answer Sheet Job Aid February, 2001 Page 11 of 39
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