UniMag DT Series Magnetic Flowtubes

Transcription

1 EMCO UniMag TM Magnetic Flowmeters UniMag DT Series Magnetic Flowtubes The UniMag Magnetic Flowmeter System consists of the patented UniMag Flowtube and the 4411e Transmitter. UniMag Magnetic Flowmeters are a more cost effective solution for many applications compared to conventional mag technology, because they improve on-site measurement performance and decrease costs associated with maintenance and downtime. The UniMag is approved by Entela to UL and CSA standards for safety in ordinary locations and NEC and CSA for Class 1, Div. 2, Groups C, D, T4 and ATEX to Zone 2 explosive atmospheres. UNIMAG DT SERIES FEATURE Totally encapsulated sensor components Option for linerless flowtube construction Patented 4411e AC coil excitation (high coil current & high pulsation frequency) Large conical electrodes, high signal strength Field replaceable sensor with optional 5 year warranty Inherent redundancy from multiple sensors Sensor reference coils Internal grounding electrodes Flowtubes manufactured to any length US Patents , , , , BENEFIT Insensitive to high pipeline vibration and shock Lower initial cost; Options suitable for vacuum conditions and continuous media velocities 15 ft/sec; Eliminates the need for liner protectors Time constant of 0.03 seconds for batching and stable process control; High signal-to-noise ratio for immunity to media noise (e.g. pulp stock and mining slurries); Accuracy unaffected by electrode coatings such as sewage grease, calcium carbonate, algae or similar. Low conductivity media > 0.08 µs/cm Guaranteed to outlast any other magmeter on media that coat piping surfaces (e.g. black liquor, raw sewage, etc.) Minimizes downtime due to failures and reduces stocking costs (associated with spare parts) Output continues if sensor(s) fail with 1% - 3% of rate typical accuracy Output compensated for effects due to magnetic particles (slurries) and ambient/process temperature shifts Installation in non-conductive or lined pipe without grounding rings or external straps Meets ISO/DIS for many sizes; Simplifies installation (no spacers or alteration) 2006

2 Not Just Another Magmeter INNOVATIVE SENSOR TECHNOLOGY UniMag sensors insert into the flowtube via standpipes. Each sensor includes an exciter coil, a reference coil, and is available in various electrically insulative materials. Two conical measurement electrodes and one grounding electrode protrude through the insulative material, which also insulates the electrodes from the piping. All internal sensor components and wiring are encapsulated using a solid setting insulator material. Two sensors are installed on DT series flowtubes up to 48 in., and four sensors are used on larger sizes. The sensors are ready wired and conduited to a junction box installed on the flowtube. The cables to and in the junction box are potted with a re-enterable gel. The complete assembly is indefinitely submersible to NEMA 6 and IP68 to 30 feet (10 m) water column. The measurement electrodes are removable on sensors of various sizes. A patented high ratio exists between the distance apart of the electrodes and the flowtube diameter, such that the magnetic field is well distributed over the entire flowtube cross section. These combined effects, together with a uniquely powerful field strength, provides a truly weighted velocity signal, highly insensitive to velocity profile distortion. As a result UniMag requires typically only 5 diameters of straight pipe upstream and 2 downstream, or less. Magnetic Field Generated Inside Flowtube UniMag Sensor UniMag Sensor Each sensor uniquely incorporates a reference coil, quite separately from the exciter coil. The reference coil measures magnetic fields in the media, and compensates for it. For media containing magnetite, consult EMCO. UNLINED OR LINED UNIMAG FLOWTUBES The most cost effective UniMag DT flowtube material is carbon steel, which may be suitably coated with fusion bonded protective finishes, inside and outside. Other materials such as stainless steel, PVC and HDPE are available. Each UniMag sensor is as a complete solid state insulated magmeter. Consequently, unlike other magmeters, there is no need for further insulation by way of a liner. With UniMag a liner is only necessary to protect the flowtube from extremely abrasive or highly corrosive media. With UniMag errors due to liner microporosity or liner damage do not exist. The sensor electrodes are normally large, with conical ends in the media. While conical ends help keep the electrodes clean, reliance is not made on that. Furthermore, highly abrasive media will quickly wear the conical ends flat, without affecting accuracy. For all media, reliance on a highly reliable, good quality signal is placed on the uniquely high signal strength and high exciter frequency. Magnetic Field Flow Tube Large UniMag sensors create a magnetic field over the entire flowtube area. The flow signal represents the true weighted velocity of the flowing media and is highly sensitive to velocity profile distortion/swirl effects Sensor with Standard Conical Electrodes Sensor with Optional Extended Conical Electrodes Note: Cones wear off with abrasive media. This has no effect on accuracy.

3 Not Just Another Magmeter UNIMAG SENSOR CONCEPTS Heavy Duty Polyurethane Flowtube There are four basic UniMag concepts to cost effectively cover all media types: 1) Sensors with standard conical electrodes, with fusion bonded epoxy or polyurethane protected metal flowtubes or PVC, HDPE flowtubes: used for water, sewage and similar applications. 2) As 1) above, except with extended conical electrodes: Used when media coats the flowtube thick enough to cover standard conical electrodes. The electrodes are then specially made long enough to protrude the media coating. Standpipe Wall Heavy Duty Polyurethane Sensor with Extra-Long Electrodes Note: Wear rate of liner = wear rate of electrodes Pipe Wall Flowtube with Fusion Bonded Liner or No Coating 3) Concave sensors with flat electrodes, no internal flowtube coating, externally fusion bonded flowtubes: Used for dredging slurries and similar moderately abrasive media, where adjacent pipeline is also not lined or coated internally. Standpipe Wall Sensor with Standard Electrodes Pipe Wall 4) Thick polyurethane protective liner covering the entire flowtube interior and sensors (electrodes protrude liner): Used for highly abrasive media, such as mining slurries and dredging slurries. Will provide longer life than 3) above. Used when adjacent pipework is lined. Flowtube i.d. made same as pipe i.d. UniMag flowtubes come with a 1 year limited warranty to be free from defects in material and workmanship. Effects of media erosion or abrasion are not included. UniMag sensors come with a 2 year limited warranty, except when media temperature is > 180 F (80 C) and pressures > 150 psig (10 bar g). Warranty then depends on media type and conditions. The warranty may be extended to 5 years if an EMCO service technician provides start-up. This is extended pro rata for annual service contracts. EMCO may recommend materials in contact with the media. However, EMCO cannot guarantee compatibility of those materials for any specific application. MODULAR CONSTRUCTION / TRUE FIELD REPAIRABILITY Conventional magmeters can only be repaired by the Fusion Bonded Coating or No Coating Note: Do not use fusion bonded coating with abrasive media. Cones wear off with abrasive media, and has no effect on accuracy. manufacturer. Repair can typically run 80% of the initial cost of the flowtube, and may take several weeks. Added cost of downtime, freight and insurance often far exceeds the initial cost of a conventional magmeter. Many users have adopted a repair-by-replacement philosophy and stock complete magmeters to minimize process downtime should a failure occur. With UniMag it is only necessary to stock spare sensors, with huge savings on inventory, and the flowtube never needs to leave the job site. UniMag sensors have been designed for long life in even the harshest environments, and with the most difficult media. They can be easily replaced in the field, without having to remove the flowtube from the piping, and without any special know-how or equipment. Dedicated sensor sets (preferably ordered and pre-calibrated at the factory with the flowtube) guarantee the same high accuracy is maintained after replacement. Designated sensor sets are interchangeable with UniMag flowtubes, and the same high repeatability and linearity are guaranteed.

4 Not Just Another Magmeter INHERENT SIGNAL REDUNDANCY In the unlikely event of a sensor coil failure, the remaining sensor(s) will provide a signal without any loss in repeatability or linearity, and with a typical accuracy of 0.5% - 1% of rate, depending on flowtube size and straight pipe lengths available. The measurement will be interrupted should an electrode fail, but can be quickly restored by some simple rewiring at the flowtube. Consult EMCO for more information. The measurement signal will not be interrupted if the optional UniMag liner or coating should ever become worn in spots. Electrode leaks and/or liner tears/holes will generally create a catastrophic (coil) failure in a conventional magmeter, causing loss of signal. UniMag will generate a useful signal under the same conditions, allowing you to conveniently schedule downtime for sensor replacement. Costly bypass piping is unnecessary since the sensors can be removed for repair and can be immediately replaced by a new sensor or temporary blanking flange. SIMPLIFIES INSTALLATION AND RETROFITS UniMag flowtubes can be manufactured to any convenient face-to-face dimension, including those recommended in ISO/DIS This greatly facilitates replacement of existing meters, without having to cut or alter the piping, or use costly spacers. In addition, UniMag flowtubes can be ordered with optional side ports for installing pressure, temperature, analytical or sampling instrumentation also being used on the process. See also DeltaMass data sheet. UNIMAG -- THE COST EFFECTIVE SOLUTION The UniMag has the features and sturdy construction to make it cost effective for simple or difficult applications. The sensor design and patented Pulsed AC coil excitation create a powerful magnetic field with low power consumption (typically < 15 W). The low power consumption allows Advanced Flow Technology to totally encapsulate the sensor components. The sensors are highly insensitive to shock and vibration since the encapsulation prevents movement of the coil assembly relative to the flowtube and electrodes. Unlined or fusion bond coated flowtubes with PEEK sensors may be used reliably to full vacuum. The grounding electrodes bond the UniMag to the process piping and prevent any stray currents from effecting the output signal. External grounding straps, or grounding rings are not normally required, even when installing the meter on non conductive piping. UniMag flowtubes can be sized for continuous media velocities as high as 15 to 30 fps (4 to 10 mps), depending upon the nature of the fluid, without any expected decrease in the mean-time-before-failure. Such high velocities, which often exist with older applications where it is not feasible or cost effective to modify existing piping, cause frequent electrode seal leakage and thin liner failures in conventional magmeters. UniMag solid state sensors overcome this problem. The high coil current and exciter frequency used with UniMag flowtubes creates a signal-to-noise ratio that is up to 3x higher than a conventional Continuous AC magmeter, and up to 50x higher than a conventional Pulsed DC magmeter. UniMag flowtubes can be used on slurries that create high media noise, like pulp stock and mining slurries. UniMag flowtubes can also be used to measure fluids with conductivity as low as 0.08 µs/cm (for deionized, demineralized or distilled water, consult factory). UNIMAG CALIBRATION The EMCO flow calibration facility is the largest NIST traceable available, having a capacity of 120,000 gpm (27,000 m 3 /h). 1/2 to 16 in. flowtubes are calibrated in either a pump loop using master meters, or in a weigh tank/diverter system. Larger flowtubes are calibrated in a submerged state within a tow tank, using master meters or swept volume. Facility accuracy is 0.1% for the weigh tank system, and 0.25% for the systems using master meters. All calibrations are traceable to the National Institute for Science and Technology (NIST). Each UniMag is shipped with a calibration certificate.

5 UniMag DT Flowtube Specifications See specifications for 4411e transmitters ACCURACY ± 0.5% of rate for flows 1.5 fps (0.45 m/s) ± fps (± m/s) for flows < 1.5 fps (0.45 m/s) Accuracy is traceable to the National Institute of Science and Technology. A NIST traceable calibration certificate is provided with each flowtube. Accuracy is unaffected by electrode coatings such as sewage grease, calcium carbonate, algae or similar. Note: For media such as ferric chloride, ferric sulphate (Odophos), high temperature paper mill liquors, lime mud or similar highly conductive media, flowmeter performance can be adversely affected. Please consult EMCO for these types of applications, otherwise performance guarantee is null and void. MINIMUM STRAIGHT PIPING RUNS Piping Upstream Piping Requirement Downstream Piping Requirement Minimum Requirement 5 Diameters 3 Diameters Single elbow, or tee upstream 5 Diameters 3 Diameters Two elbows coupled in same plane 5 Diameters 3 Diameters Two elbows, close coupled and out of plane 10 Diameters 3 Diameters Pump, blending point, control valve upstream 20 Diameters 3 Diameters Pump, control valve downstream Note: For lesser straight diameters consult EMCO. FLOW RANGE 0-2 f/s (0-6 m/s) minimum to 0-50 f/s (0-15 m/s) maximum or 0-5D 2 gpm minimum to 0-120D 2 gpm maximum, where D is in inches ( D 2 m 3 /h minimum to D 2 m 3 h maximum, where D is in millimeters) COIL EXCITATION Pulsed AC excitation. Consult data sheets for 4411e for more information. MEDIA CONDUCTIVITY > 1 µs/cm (1 micromho/cm) > 0.08 or < 5 µs/cm use UniMag pre-amplifier option For deionized, distilled, or demineralized water, consult EMCO. ENVIRONMENTAL PROTECTION 5 Diameters NEMA 6 and IP68 indefinitely submersible to 30 ft. (10 m) water column, or NEMA 4X & IP65 GROUNDING Internal grounding electrode on each sensor NOTE: 1. For cathodic protected pipes, consult. 2. For transmission to a remote transmitter > 100 feet (30m), or when excessive unequal potentials exist between the pipeline and the flowmeter cable shields, it may be necessary to have a grounding ring or other grounding arrangement installed. Such excessive unequal potentials are beyond the control of EMCO and additional cost of remedy is extra to that of our normal supply. CABLE TYPE There are 3 separate cables used to the remote 4411e transmitter: 1 cable is for the sensing electrodes, 1 cable for the energizing coils and 1 cable for the reference coils. Each cable is 2-core multistranded and overall shielded, 2 x 18 gauge (US) e.g. Beldon #8760 or 2 x 0.75 mm 2. Additional cable of the same type is used for a pre-amp in the junction box. For ATEX Zone 2 applications IEC approved cables must be used, with 4411e in the safe area. For Class 1 Div. 2 applications cables must run in conduits or Teck metal clad cable, with 4411e in the safe area.

6 UniMag DT Flowtube Specifications See specifications for 4411e transmitters CABLE LENGTH TO TRANSMITTER 50 feet (15 m) as standard supply. Special distance cabling maximum 300 feet (30 m). For cable lengths > 100 feet (30 m) a pre-amp is installed in the junction box. Note: For distances up to 30 feet (10 m) all cables may run in the same conduit. Longer distances require that the cables run in separate conduits, approximately 1 foot (300 mm) apart. The energizer coil and reference coil cables may run in the same conduit longer than 30 feet, but the electrode cable must be separate. For applications to ATEX Zone 2 requirements only one cable is permitted per cable connector. MAXIMUM CABLE LENGTH < 3 micros/cm: max. 30 feet (10 m) > 3 micros/cm: max. 100 feet or (10 x C) feet or 30 m max. or (3 x C) m UNIMAG MATERIALS OF CONSTRUCTION (REFER TO ORDERING CODE) FLANGES/FLOWTUBE Carbon steel, 316 stainless steel or HDPE (high density polyethylene) For PVC flowtubes see separate data sheet. Standard 1 year warranty against material defects and bad workmanship, but not including media compatibility, erosion and abrasion, or for media > 180 F / 80 C. The warranty may be extended to 5 years if an EMCO service technician provides start-up. This is extended pro rata for annual service contracts. Maximum pressure and temperature rating of the flowtube may be limited by the flange type selected (refer to appropriate flange specifications). Flowtubes can be specially ordered with plain ends or with butt weld ends. NOTE: For pressure and temperature ratings of HDPE flowtubes, consult factory. MAXIMUM TEMPERATURE (Maximum pressure based on sensor) LINERS/COATINGS Fusion Bonded Epoxy -40 F to +240 F (-40 C to +116 C) Conforms to USA National Sanitation Foundation Standard NSF61 and AWWA Standard C213 for drinking water. Polyurethane Tefzel Ryton ELECTRODES SENSORS (See ordering code for applicable gaskets and electrode seals) 175 F max (80 C max) (Not recommended for high vacuum applications) Conforms to NSF61 and AWWA C213 for drinking water. Heavy duty polyurethane is suitable for high velocity mining slurries and similar media (See Note 3). 240 F max (115 C max) based on water. Not recommended for high vacuum applications. Other media may reduce this temperature. 350 F max (177 C max). Used for paper mill liquors, lime muds and similar high conductivity media. AISI 316 stainless steel, Hastelloy B and C, Titanium, Tantalum, Monel Polyurethane -175 F max and 150 psig max (80 C max and 10 bar g max). Conforms to NSF61 and AWWA C213 for drinking water PVDF -240 F max and 356 psig max (115 C max and 25 bar g max). Full vacuum capability. The temperature rating shown is for water and may be lower for other media due to corrosion considerations (consult manufacturer). PVDF is approved by the US Food and Drug Administration #21 CFR UHMWPE -175 F max and 150 psig max (80 C max and 10 bar g max). PEEK -350 F max and 356 psig max (176 C max and 25 bar g max). Full vacuum capability. NOTES 1. Sensor assembly includes a non-wetted carbon steel cover flange, fusion bonded polyethylene protected. 2. Sensor assemblies are supplied with outer cover flanges, 30 ft (10 m) of cable, re-enterable potting gel, junction box, conduit and stainless steel bolts. Special length cable on request. 3. Temperature differential between process and ambient limited to 140 F (60 C) for polyurethane sensor, and 212 F (100 C) for PVDF sensor 4. Standard 2 year warranty against material defects and bad workmanship, but not including media compatibility, erosion and abrasion, or for media > 180 F / 80 C. Sensor Electrode Seals Sensor Gaskets Viton, Kalrez, Chemraz or Teflon (GoreTex) Elastomer, Teflon (See ordering code for sensor combination) Sensor retention flange is carbon steel with stainless steel bolts.

7 UniMag DT Flowtube Ordering Information You must order UniMag and transmitter separately (see appropriate data sheet) for a complete flowmeter DT 08 C E T X R 1 A A DT = UniMag DT Flowtube Nominal Size 02 = 2 in. (50 mm) 2H = 2½ in. (65 mm) = 3 in. (80 mm) to 80 in. (2000 mm) O Flowtube / Flange Materials C = Carbon Steel T = All 316 Stainless Steel A = 316 Stainless Steel Flowtube, Carbon Steel Flanges H = HDPE Flowtube, Non-Wetted Carbon Steel Flanges Transmitter Supply A = 120V, 60 Hz transmitter supply B = 230V, 50 Hz transmitter supply C = 120V, 50 Hz transmitter supply S = Special Options A = Pre-amplifier (note 5) B = Extra Long 316 stainless steel electrodes (note 6) W = Special Warranty (EMCO discretion) - No extra charge E = Extra Length Cables L = Special Lay Length P = Sampling Port ¾ NPT female N = Sampling Port 1½ NPT female O = No Options - No Extra S = Special - may be a combination of features (note 1) Sensor Materials (Note 9) E = PVDF with elastomer gaskets, Viton seals D = PVDF with Teflon gaskets, Viton seals P = Polyurethane with elastomer gaskets, Viton seals F = PVDF with Teflon gaskets, Kalrez seals K = PEEK with Klinger gaskets, Chemraz seals U = UHMWPE concave, elastomer gaskets, Viton seals H = PEEK, Klinger gaskets, Teflon seals (note 8) C = Polyurethane concave, elastomer gaskets, Viton seals (> 16 / 400 mm diameter) T = Concave Teflon, Teflon gaskets, Kalrez seals Electrodes (Viton Seals) (Note 6) T = AISI 316 Stainless Steel B = Hastelloy B (small) C = Hastelloy C (small) I = Titanium W = Hastelloy C (large - see note 7) X = Hastelloy B (large - see note 7) A = Tantalum H = Hastelloy C high compression (note 8) M = Monel Flowtube Liners and Coatings X = Fusion Bonded Epoxy Coating (note 2) P = Polyurethane inside and outside M = Heavy Duty Polyurethane inside, epoxy enamel outside (note 3) Z = Heavy Duty Tefzel (ETFE) (note 4) N = No Coating Inside, Fusion Bonded Epoxy Outside R = Ryton coated inside, epoxy enamel outside NOTES Process Connections 1 = ANSI 150 RF (< 28 in.); ANSI/AWWA C207 Class D FF ( 28 in.) 2 = ANSI 300 RF 3 = AWWA FF (specify class) 4 = DIN/BS4504 PN6 5 = DIN/BS4504 PN10 6 = DIN/BS4504 PN16 NOTE: Options 4, 5, 6 have the same dimensions up to 6 in. (150 mm) 7 = J1S10krf 8 = BS/AS2129 Table D 9 = BS/AS2129 Table E C = Plain Ends Transmitter Installation R = 50 ft. (15 m) cables NEMA 6/IP68 indefinitely submersible to 30 feet w.c. X = Entela approved to NEC/CSA Class 1, Div. 2, Grp C, D, Temp. T4. 50 feet cables (15 m) C = Entela approved to ATEX Zone feet cables (15 m) 1. All special orders must include a complete description along with the ordering code. Use for combinations. 2. Version X is fusion bonded inside and outside. 3. Recommended for mining slurries and similar fluids. Please include internal piping diameter of mating pipe so UniMag can be manufactured to match. 4. Do not use with abrasive slurries. Tefzel is inside and outside. 5. Pre-amp required in junction box for fluid conductivity < 1 µs/cm. For demineralized, deionized or distilled water, consult EMCO. 6. Extra-long electrodes are provided for thick, non-fluidic coating applications. 7. Use W or X electrodes with K PEEK sensors only. 8. Use H electrodes on paper mill liquors, and lime mud > 200 F (93 C). Use with H sensors only. 9. For PVDF, PEEK, UHMWPE and Teflon sensors for > 14 (350 mm) diameter, consult EMCO.

8 UniMag DT Series Dimensions and Weights W/2 (Clearance Over Bolts) W Lifting Lugs for flow tubes greater than 6 in diameter (Over Raised Face) L Junction L/2 (Over Raised Face) Box Optional sample or pressure port downstream of sensors Flange Size Nominal Size D Dimension L * Dimension W Approximate Weight Inches mm Inches mm Inches mm LB KG * Note: For flowtubes 6 Ø and less having ¾ or 1½ NPT sampling or pressure ports Dimension L = 15.0 (380 mm), a division of Spirax Sarco, Inc Lefthand Circle, Suite C Longmont, CO Phone: or Fax sales@emcoflow.com website: