Emf Krohne

EMF Magnetic Flow Meters Presentation
KROHNE Academy 2015, Monterrey N.L.

Product Marketing EMF
2015-10-06
1. EMF
2. Theory of Operation
3. Construction & Components
4. How to Choose a Magmeter
5. Online diagnostics
6. Installation Considerations
7. Applications & Guidelines
8. Calibration

Agenda
1. EMF
8. Calibration

Agenda
EMF
Magnetic Flow Meters Presentation
EMF: The Popular Choice of Most Industries
Chemical Food & beverage Water & wastewater
Oil & gas Marine Pharmaceutical
Paper Steel Petrochemical
| EMF KROHNE Academy 2015, Monterrey N.L.

EMF: What is a EMF ?
EMF = ElectroMagnetic Flow meter
Used to measure volumetric flow rate of

liquids (with / without solids contents)
pulps
pastes
slurries
Applicable in practically all industrial sectors
Only requirement:
process product should have minimum electrical conductivity

EMF: What is a EMF ?
Boiler Feed Water
Completely Desalted Water, Ion exchanger
Normal Desalted Water
Tab Water
Sewage
Run Off Water
Fresh Salt Water , Standing Salt Water
Industrial Process Water
Concentrated Acids and Caustic

Why use EMF?
Magnetic flow meters are inherently extremely accurate
Magnetic flow meters are obstruction less
Magnetic flow meters are remarkably maintenance free
Magnetic flow meters measure wide range of fluids
When (dont) use EMF?

Magnetic flow meters are widely used for many kinds of conductive
liquids
Dont use a magnetic flow meter
on a non-conductive fluid
on fluids with a lot of entrained air
that is very much oversized for the flow rate
on a spiralling flow
Magmeter: The Almost Ideal Liquid Flowmeter
Advantages Seen by customers:
Accurate and Reliable
No moving parts
No restrictions, causing pressure drop
Favourable prices
Low Cost of Ownership, No maintenance
Application flexibility
Large dynamic range

Magmeter: The Almost Ideal Liquid Flowmeter
Features
No obstructions
Same diameter (ID) as pipeline
No internal moving parts
Wide selection of materials
Benefits
High accuracy and repeatability
Wide range ability
No clogging
No pressure loss
No wear & high reliability
High chemical resistance
Long lifetime

1. EMF
8. Calibration

Agenda
Theory of Operation
How does EMF works?
Faradays law
When conducting materials move in a
magnetic field, or when a magnetic field
changes in a region, a voltage called an
induced EMF develops spontaneously
In 1831 Michael Faraday made his

discovery of electromagnetic induction.
He hypothesized that a changing
magnetic field is necessary to induce a
current in a nearby circuit.
To test his hypothesis he made a coil by
wrapping a paper cylinder with wire. He
connected the coil to a galvanometer,
and then moved a magnet back and forth
inside the cylinder.

Theory of Operation
How does EMF works?
The faster magnet moves, the

larger induced voltage
The more loops in coil of wire,
the bigger voltage

Theory of Operation
How does EMF works?
Measuring Principle: Electrically conductive fluid flows inside electrically insulated pipe
through a magnetic field
Magnetic field is generated by current flowing through pair of field coils
Inside of fluid, induced voltage U is generated (simplified equation):
U = velocity k B D, in which:
v = mean flow velocity
k = calibration factor correcting for geometry
B = magnetic field strength
D = inner diameter of flow meter
Voltage U is measured
Using volume flow rate q = velocity Area
the indicated flow rate qi will be:
qi = U Area/ (k B)

Theory of Operation
How does EMF works?
Signal voltage U
is picked off by electrodes
is proportional to mean flow velocity v,
and flow rate q
Voltage is quite small:

typically 1mV at v = 3 m/s (10 ft/s) and
field coil power of 1W
Signal converter is used to

Supply coil current to generate magnetic
field
Amplify signal voltage
Filter it (separate from noise)
Convert it into flow proportional signals
for process control, recording, totalize,
batching...

Theory of Operation
How does EMF works?
Theory shows:
The formula qi = U Area / (k B) does not contain
any physical parameters of liquid
Result:
The volume flow measurement of mag flow meters
is independent of liquid properties and process
conditions such as:
- Pressure
- Temperature
- Viscosity
- Density
- Consistency
- Electric conductivity (as long as > minimum
conductivity)
- Electrode contamination (within limits)

1. EMF
8. Calibration

Agenda
Construction & Components
How does EMF works?
Flow sensor
Measuring tube
non ferro-magnetic (stainless
steel, ceramic or plastic)
Liner
only for metal tubes
Pair of electrodes
for sensing signal voltage
Pair of coils
for magnetic field production
Magnet-foil
return circuitry for magnetic field
Coil house and connection box

How does EMF works?
STAINLESS STEEL LINER CONSTRUCTION ELECTRODE

TUBE SELECTION
COIL CONSTRUCTION METER ASSEMBLY

How does EMF works?
Flow tube construction
Stainless Steel
Spool Piece
with Carbon
Steel or SS
Flanges

How does EMF works?
LINER
Flow tube construction MATERIALS
PFA
PTFE
Tefzel
Ceramic
Liner Hard Rubber
Linatex
Soft Rubber
Neoprene
Polyurethane
Cermet

How does EMF works?
Standard electrodes Hot Tap removable electrode

How does EMF works?
Electromagnetic Field Coil Wiring

How does EMF works?
Field coils:
terminals 7
&8&9
Spool piece with
coils and
electrodes
Meter body
terminal 1 Electrodes: 24

terminals 2 & 3
How does EMF works?
Flow tube components
Conduit connections Junction box
Meter body
Grounding
straps
| EMF KROHNE Academy 2015, Monterrey N.L. Earth Ground

How does EMF works?
flow converter
flow sensor
=
flowmeter

1. EMF
8. Calibration

Agenda
How to Choose a Magmeter
Magmeter Selection Criteria
Liquid conductivity
Clear liquid, slurry or emulsion
Sized according to flow rate & flow velocity
Material compatibility (corrosion, erosion, etc)
Process conditions (pressure & temperature limitations)
Control requirements (outputs, digital protocol, etc)

Liner Material

Liner Material
Lining | selecting material
Selection criteria based on process requirements
diameter range
maximum process temperature
chemical resistance
abrasion resistance
vacuum resistance
liner stability, e.g. after changes in temp. or press.
Note:
lining determines lifetime of flow meter
do not select liner at its specified max. temperature and pressure

Liner Material
Polyurethane
Hard Rubber
- Durable, Long Lasting
- Vulcanized
Neoprene Soft Rubber
Teflon
- SS Grid Reinforced Injection Molded Ultra Pure PFA
- Securely Bonded Tefzel ETFE
- Low Cost Slip Fit Teflon PTFE
- Glued FEP
Polypropylene
Irathane
Linatex
High Technology Zirconium Oxide ZrO2
- High Accuracy
- Abrasion / Corrosion Resistant
Fiber Glass Reinforced Polypropylene
Ceramic Tile in Soft Rubber Matrix
- Abrasion Resistance
- With Shock Absorption
Etc . . . .

Liner Material
PTFE
from hot lye to hot concentrated acids
PFA
(see PTFE) with integrated SS grid
ETFE
very good abrasion & vacuum resistance
Polypropylene
for (waste) water applications
good abrasion resistance
Hard rubber
for (waste) water applications
large diameter range
Soft rubber
large diameter range
Polyurethane
excellent abrasion resistance
Ceramics
best corrosion and abrasion resistance
absolute vacuum resistant
very high accuracy and stability

Liner Material
Characterisation of Plastic deformation
Max. chemical resistance Possible
Lining Abrasion with pressure / Vacuum
liquid
material (for detailed information resistance temperature (loss of DN-sizes resistance
temp.
check individually) accuracy)
180 C From hot lye to hot concentrated Dep. on design, Dep. on design and size, low 10 600 Dep. on design and
PTFE
356 F acids poor up to fair to high 3/8 24 size, poor to fair
PFA + SS- 180 C From hot lye to hot concentrated 2,5 150
Fair Low Very good
grid 356 F acids 1/10 6
120 C 200 2000

ETFE From hot lye to hot acids Very good Low Very good
248 F 8 80
90 C Heavily dependent on type of 25 150

PP + SS-grid Good Low Very good
194 F liquid 1 6
90 C 25 3000
Hard rubber Low concentrations Low Low Fair
194 F 1 124
60 C 25 3000
Soft rubber Low concentrations Good Low Fair
140 F 1 124
60 C 50 1600
Polyurethane Low concentrations Excellent Low Good
140 F 2 62
Zirconium From warm lyes ( 50%) to hot No deformation at all (high
180 C Most abrasion 2,5 250 Absolutely vacuum
oxide concentrated acids ( 100 C, long term stability even with
356 F 212 F)
resistant
small diameters) 1/10 10 resistant
Ceramics
| EMF KROHNE Academy 2015, Monterrey N.L. This short guide only for a coarse pre-selection only! Pls. check applications individually!
Liner Material
PTFE (Teflon)
Advantages
1 D d D>d Chemical resistance
PTFE tube stainless steel

flow meter tube
Temperature range
Disadvantages
2
Vacuum resistance
Wear effects

Liner Material
PFA (Teflon) molded
stainless steel flow tube
reinforcement grid
PFA
Advantages Disadvantages
Chemical resistance Limited diameter range
Temperature range
Vacuum resistance
Wear effects

Liner Material
SS Grid Reinforced PFA Liner
Slip Fit PTFE LINERS
PFA LINER
Stainless steel grid
Potential for abrasion
Mating flange
Smooth surface eliminates potential for abrasion

Liner Material
SS Grid Reinforced PFA Teflon Liner
Grid is welded to inner diameter of tube
Teflon Beads are injection molded into grid
and Dove Tail joint in flange face
Extra Thick for Long Life
Leak Proof
Absolute Vacuum Resistant

Electrode Material
Electrode in contact with process liquid
Purpose: transfer signal voltage from

product to flow converter
Criterion: correct material
Demands
leak tight
absolute corrosion resistance

Electrode Material
Hastelloy C22 KROHNE standard
Hastelloy C4
Stainless Steel
Tantalum
Titanium
Platinum
Cermet
- Ceramic and Platinum Mixture
- Leak Proof Conical Back Seated
Low Noise Also called Bullet Nose Exceptional Sealing
- Teflon (Graphite Impregnated)
- Rubber (Graphite Impregnated)
- Aluminum Oxide Coated with base matl. (Hast.,
Platinum, Tantalum, and St. Stl.)
Hot Tap Removable
- Clean without process shut-down
Non-Wetted
- Capacitive Coupled through liner
- Lower Conductivities, 0.05 S/cm! Hot-Tap Standard
- Immune to Coating Removable without
Etc. . . . Process shutdown

Electrode Material
Minimizing Noise with Special Low Noise
Electrodes:
The basic types of Low Noise Electrodes:
Conductive PTFE and Conductive Rubber:
These electrodes are the best choice for
chemically homogeneous liquids
with high contents of solids
e.g. for water with high contents of sand
or high consistency pulp,
if no chemicals are added upstream of the meter.
Combination possibilities of electrode and lining
materials:
Conductive PTFE
available with Optiflux 4000 PFA lining 1"- 6"
"Conductive Rubber available with
Irathane and Soft Rubber linings 1"- 6
Soft Rubber / Neoprene available with Hard
Rubber linings in large diameters

Electrode Material
The basic types of Low Noise
Electrodes:
Ceramic Coated Low-Noise Metal

Electrode
This electrode type is the best choice for
chemically inhomogeneous liquids,
even with high contents of solids
Example:
Downstream of chemical injection points.
These chemicals reactions often are not
finished when the liquid enters the metering
section.

Flow Converter
User interface
Two versions
Compact (on top of flow sensor)
Separate (field, wall mount or 19
rack)
Flow converter is used to

Amplify measured voltage
Filter measured voltage (separate from
noise)
Convert measured voltage into signals for
process control, recording, totalise
volumes, batching...

1. EMF
8. Calibration

Agenda
Online diagnosis
Diagnosis of process unit or plant

information by various field instruments
Plant environment
Diagnosis of direct environment
process diagnosis/application check Local (direct)
environment
performed in instrument or external
application & process
interface
Diagnosis of EMF core functionality
self test performed in instrument
Flow meter

Online diagnosis
Automatic & continuous testing

flow sensor
IFC 300 flow converter
local process conditions
Information whether flowmeter is
properly applied
properly installed
measuring within specifications
And if not:
indication of possible error causes
timely warning before it malfunctions

Online diagnosis
Possible causes of malfunctioning

change of process conditions
cavitations
over-temperature or vacuum
incorrect installation
impropriate electrode / liner material
abrasion through solids
electrode scaling/fouling
external magnetic fields
defective instrument components

Online diagnosis
Improved availability
provides certainty even in difficult
applications
Continuous verification
Instrument functionality in application
Self calibration check
Pro-active maintenance means cost
savings on:
periodic and preventive maintenance
corrective emergency maintenance
Increased process availability
Quality improvements
Focus on production improvements

1. EMF
8. Calibration

Agenda
Installation Considerations



Absolutely
Best
Not!
Discouraged
Flow direction
Good
52

Horizontal Pipe Run Flow direction
Open Feed or Discharge
Flow direction
Down pipe Over 16 ft. in Length
Flow direction
53

1. EMF
8. Calibration

Agenda
Applications & Guidelines
Applications Magmeter is best choice:
Conductive Liquids or Slurries
( < 30% solids)
Simplicity and reliability required
Volumetric Flow rate for Controlling
Batching
Totalizing
Chemical injection
Pulsating flows (turn on converter setting!)
Custody transfer (buying or selling)
Short straight runs available (5D up / 2D down)
Additional measurements useful:
Conductivity
Temperature

General Guidelines
Choose compatible liner material
- Abrasion / Erosion
- Impact resistant
- Chemical compatibility
Choose compatible electrodes
- Std. Hastelloy C, most universal, many others
- Low noise
- Conductive rubber / Teflon
- Ceramic coated
- Hot tap removable to facilitate cleaning
- Note: Some compatible metals are poor electrode choice CONSULT
KROHNE!
Size meter to required flow rates
- Normally 5 to 15 ft/sec for clean liquids
- < 9 ft/sec for abrasive slurries
Non-conductive, lined, or coated pipes
- Always use grounding rings
General Guidelines
Choose compatible liner material
- Abrasion / Erosion
- Impact resistant
Choose compatible electrodes
- Std. Hastelloy C, most universal, many others
- Low noise
- Conductive rubber / Teflon
- Ceramic coated
- Hot tap removable to facilitate cleaning
- Note: Some compatible metals are poor electrode choice CONSULT
KROHNE!
Size meter to required flow rates
- Normally 5 to 15 ft/sec for clean liquids
- < 9 ft/sec for abrasive slurries
Non-conductive, lined, or coated pipes
- Always use grounding rings
Success Applications
Pipe size 4
Pipe material: PVC
Medium: sea water
Flow range: 0 100 m3/hr
Solution: Optiflux 2300W 4

With virtual reference

Success Applications
Pipe size 4
Pipe material: PVC
medium: waste water
Flow range: 0 594 LPM
Solution: Optiflux 1100W 4

With SS grounding rings





1. EMF
8. Calibration

Agenda
Calibration
Calibration Guideline:
A true calibration of any measuring device

requires a direct comparison of the
measured value to a known standard,
typically at least 3 times more accurate
then the device being tested.
For volumetric flow meters, this means a

direct comparison to a known volume.

Calibration
Precision Level-switches (24)
Start,
Release of counting
Measured Reference
00000.00
03903.61
03811.16
03713.19
03617.95
03522.88
03347.44
03158.77
03046.72
02949.45
02856.30
02758.48
02665.88
02569.95
02475.46
02380.25
02285.04
02190.03
02094.62
01999.41
0190420
01810.99
01713.78
01618.57
01523.36
01428.15
01332.94
01237.73
01142.52
01047.31
00952.10
00856.89
00761.68
00666.47
00571.26
00476.05
00380.48
00285.63
00190.42
00095.21
03999.60
03446.20
03237.14 04000.00 0.01% deviation
Volume-pulses
e.g. 100 pulses per Gallon
Stop KROHNE
IFC 090
End of counting Flowrate

+.......-
........S
totalizer
I..........P
Overrang
e
KROHNE
Valve
Calibration and Accuracy
Calibration
Calibration Facilities
KROHNEs Netherlands Facility houses
the Worlds largest and most
accurate flow calibration rig

Calibration
The Calibration Certificate..
Diameter Measuring range (=100%) Range Deviation
mm inch m3/h m/s % %
500 20 2200.026 3.112 92 - 0.03
61 - 0.01
30 + 0.05
600 24 4072 4 90 - 0.06
60 + 0.15
29 - 0.08
1000 40 5655 2 90 - 0.09
60 + 0.01
30 + 0.09
1200 48 12000 2.947 79 + 0.14
40 + 0.24
10 - 0.27
5 - 0.25
1600 64 14476.46 2 89 - 0.02
59 - 0.01
30 - 0.02
2500 100 19000 1.075 90 - 0.06
60 + 0.01
30 + 0.32
KROHNE Highest Accuracy, Certified!

69 | WATERFLUX 3070 Applicatons | 2010-09-27

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EMF Magnetic Flow Meters Presentation

KROHNE Academy 2015, Monterrey N.L.

EMF Magnetic Flow Meters Presentation

EMF Magnetic Flow Meters Presentation

Chemical Food & beverage Water & wastewater

Oil & gas Marine Pharmaceutical

Paper Steel Petrochemical

| EMF KROHNE Academy 2015, Monterrey N.L.

EMF = ElectroMagnetic Flow meter

Used to measure volumetric flow rate of

Applicable in practically all industrial sectors

process product should have minimum electrical conductivity

| EMF KROHNE Academy 2015, Monterrey N.L.

Boiler Feed Water

Completely Desalted Water, Ion exchanger

Normal Desalted Water

Industrial Process Water

Concentrated Acids and Caustic

| EMF KROHNE Academy 2015, Monterrey N.L.

When (dont) use EMF?

Advantages Seen by customers:

Accurate and Reliable

No restrictions, causing pressure drop

Low Cost of Ownership, No maintenance

Large dynamic range

| EMF KROHNE Academy 2015, Monterrey N.L.

| EMF KROHNE Academy 2015, Monterrey N.L.

EMF Magnetic Flow Meters Presentation

In 1831 Michael Faraday made his

| EMF KROHNE Academy 2015, Monterrey N.L.

The faster magnet moves, the

| EMF KROHNE Academy 2015, Monterrey N.L.

| EMF KROHNE Academy 2015, Monterrey N.L.

Voltage is quite small:

Signal converter is used to

| EMF KROHNE Academy 2015, Monterrey N.L.

| EMF KROHNE Academy 2015, Monterrey N.L.

EMF Magnetic Flow Meters Presentation

| EMF KROHNE Academy 2015, Monterrey N.L.

STAINLESS STEEL LINER CONSTRUCTION ELECTRODE

COIL CONSTRUCTION METER ASSEMBLY

| EMF KROHNE Academy 2015, Monterrey N.L.

Flow tube construction

| EMF KROHNE Academy 2015, Monterrey N.L.

| EMF KROHNE Academy 2015, Monterrey N.L.

Standard electrodes Hot Tap removable electrode

| EMF KROHNE Academy 2015, Monterrey N.L.

Electromagnetic Field Coil Wiring

| EMF KROHNE Academy 2015, Monterrey N.L.

Conduit connections Junction box

| EMF KROHNE Academy 2015, Monterrey N.L. Earth Ground

| EMF KROHNE Academy 2015, Monterrey N.L.

EMF Magnetic Flow Meters Presentation

Clear liquid, slurry or emulsion

Sized according to flow rate & flow velocity

Material compatibility (corrosion, erosion, etc)

Process conditions (pressure & temperature limitations)

Control requirements (outputs, digital protocol, etc)

| EMF KROHNE Academy 2015, Monterrey N.L.

| EMF KROHNE Academy 2015, Monterrey N.L.

| EMF KROHNE Academy 2015, Monterrey N.L.

| EMF KROHNE Academy 2015, Monterrey N.L.

| EMF KROHNE Academy 2015, Monterrey N.L.

120 C 200 2000