Process Control Project (IPC) April 10, 2012

Coriolis meter and its Applications in Chocolate milk production

Adit Gupta
Indian Institute of Technology, Gandhinagar

Rahul Pancholi
Indian Institute of Technology, Gandhinagar

adit.gupta@iitgn.ac.in

pancholi@iitgn.ac.in

Coriolis meter
[1.1] Principle of Operation
In 1835, Gustave-Gaspard Coriolis demonstrated that the rotation of the Earth produced a circular motion in the planets winds and weather patterns. That same principle can be applied to fluids in a moving pipe. The fluids inertia causes a lag in the movement of the tube on the inlet side, and an acceleration of the tube on the outlet side. Sensors can be placed on the tube to measure fluids effect on the tubes movement. The magnitude of the change in the tubes movement can therefore be measured, and is directly proportional to the mass flow of the fluid moving through the tube.

[1.2] Features:
1. Mass flow meter for nearly all fluids, including high viscosity liquids, slurries and multiphase media. 2. Refined digital signal processing enables accurate and stable measurement. 3. A special detector decoupling system isolates the detector from external loads or vibrations. 4. Simple flow path means self-draining, sanitary and simple to clean (3A compliance) 5. High accuracy and high stability over a wide range, not just under lab conditions. 6. Accurate density measurement (+/- 1 g/l
Figure 1: Coriolis meter, Luigi Chiesa photograph, Wikipedia

/ .062lb/ft3). 7. Two analog outputs, 2 pulse outputs or status-out and one status-in as standard I/O. Wide temperature range 200C to 350C / 328F to 662F. 8. Microprocessor-based multifunction capability. 9. EEPROM protects parameter settings and totalized values during power failure of any duration. 1

Process Control Project (IPC) April 10, 2012

Standard Specifications
[2.1] Model:
RCCS34,RCCS36,RCCS38,and RCCS39: 2 tube design with RCCF31 converter Fluid to be measured: Liquid, gas or slurries Measurement items: Mass flow, density, temperature and concentration, volumetric and net flow

[2.2] Mass Flow Measurement:

Type Qmax Qnom Qmin tons/ hr tons/ hr tons/ hr RCCS34 5 2.7 0.00135 RCCS36 15 9 0.0045 RCCS38 50 32 0.016 RCCS39 120 85 0.0425

Liquid: - RCCS3X + RCCF31 : + 0.1% of measured value Gas (option /GA): - RCCS3X + RCCF31 : + 0.5% of measured value

[2.3] Pressure Dependency:

The stiffness of the Rotamass tubes is slightly line pressure dependent. The static pressure effect of mass flow and density can be corrected by setting the static pressure manually via a menu.
Type SS % of rate per bar HC Ti RCCS34 NA NA NA RCCS36 -0.0023 -0.0036 -0.0038 RCCS38 -0.0058 -0.0092 -0.0095 RCCS39 -0.0087 -0.014 NA

[2.4] Density Measurement:

Measuring range: 0.3 to 5 kg/l Accuracy (at calibration conditions):
Type Density Accuracy gm/l RCCS34 3 RCCS36 2.2 RCCS38 1.5 RCCS39 1.5

[2.5] Diameter of measuring tubes:

Type Inner Diameter Wall Thickness mm mm RCCS34 7.6 0.9 RCCS36 13.4 1.2 RCCS38 22.1 1.65 RCCS39 37.2 2.6

Process Control Project (IPC) April 10, 2012

[2.6] Process Temperature Limits:

Power supply and power consumption: 90 to 264 V AC, 47-63 Hz or 20.5 28.8 V DC For Ex version 250 V AC max. Consumption max. 25VA / 10W
Type Standard Detector Standard MT HT Integral Detector Hazardous area application Standard MT HT RCCS34 180C to 150C 180C to 230C 0C to 350C 40C to 150C 40C to 150C 40C to 220C 0C to 350C RCCS36 180C to 150C 180C to 230C 0C to 350C 40C to 150C 40C to 150C 40C to 220C 0C to 350C RCCS38 180C to 150C 180C to 230C 0C to 350C 40C to 150C 40C to 150C 40C to 220C 0C to 350C RCCS39 180C to 150C 180C to 230C 0C to 350C 40C to 150C 40C to 150C 40C to 220C 0C to 350C

[2.7] I/O signal standard:

Two current outputs: 4 to 20 mA DC, galvanic separatedfrom other signals, Load resistance: 20 to 600 Failure current according NAMUR NE43 Ambient temperature effect: <0.05% ofspan/10C Two Pulse output / status outputs: passive transistor contact output,30V DC, 200 mA Output rate: Output 1: 0 to 10000 pulses/s Output 2: 0 to 2000 pulses/s Active pulse output is not isolated fromcurrent output 2 Option /AP: active output, 12V, 6mA, As frequency output: Output 1: 20Hz to 10000Hz Output 2: 20Hz to 2000Hz Additional error of 0.1% may occur below 800 Hz Status input: Voltage-free contact, Closed: <200 Open: >100 k

[2.8] Process Pressure Limits: Type Pressure Limit RCCS34 psi 3045 RCCS36 2682 RCCS38 2175 RCCS39 2175

[2.9] Pressure loss:

Pressure loss depends on velocity, viscosity and density ofthe fluid. For Newtonianfluid the pressure loss is shown in the tables. Type Qmax Qnom psi psi RCCS34 RCCS36 RCCS38 RCCS39 36.25 43.6 51.9 34.1 14.9 15.9 15.2 13.7 3

Process Control Project (IPC) April 10, 2012

Pressure loss curves for individual models:

[2.10] Cost
While Coriolis flowmeters are loved by many end-users, price is often an issue. Coriolis flowmeters are the most expensive meter made, in terms of average selling price. The average selling price of Coriolis flowmeters are between $5,000 and $6,000.6 Some suppliers have introduced low-cost Coriolis flowmeters in the $3,000 range. Performance specifications for the lower-cost flowmeters are not at the same level as those of the higher-priced meters. 6

Process Control Project (IPC) April 10, 2012

Chocolate Milk Production process

[3.1] Process descriptionThe process of chocolate milk production requires supply of milk and chocolate syrup to be pumped at a certain rate for mixing such that the final desired product has a certain density. These flow rates are controlled by pressure valves, before being mixed in a static mixer tube. The Coriolis meter (F1) measures the mass flow rate of the flavored milk while the magnetic flow meter (F2) measures the volumetric flow rate. Then these measured variables are used to determine the density of the chocolate milk to be sure that a proper amount of chocolate has been added. The Temperature sensor typically a Thermocouple is used to detect the temperature of the final flavored milk. This is controlled by a feedback mechanism to the cooling unit which uses cooling water to cool the final product. Hence in this process the controlled variables are the density and temperature of the flavored milk. The manipulated variables are the flow rate of chocolate syrup and milk. The disturbance variables are the composition and density of pure milk and chocolate syrup. The controlled variable measured by the flow meter is used by the controller in order to control the valve for the milk flow. If the density of the flavored milk is too low then the valve for chocolate syrup will allow higher flow rate of chocolate syrup.

Process Variables and their types:

Variable Temperature Density Milk Flow rate Chilling water flow rate Chocolate syrup Flow rate Type Controlled Controlled Manipulated Manipulated Disturbance Value <4C 4000 g/L

Static MixerThe static mixer is a tube with vanes inside that cause turbulence and force the fluid passing through to mix.

ValveThe valve is used to proportionally meter fluid. It uses air pressure to open the valve from 0 % to 100 % and to close it. There are two gauges on the front of the meter. The right gage shows the supply pressure. The user must supply the valve with maximum of 20 PSI. The left gage shows the amount of pressure that the valve is being commanded to apply. This gage will show between 3 and 15 PSI. 3 PSI will completely close the valve and 15 PSI will completely open it. The user supplies a current signal to the valve of 4 to 20 milliamps.

Process Control Project (IPC) April 10, 2012

[3.2] Process Diagram:

Key for the Flow/Control Diagram : V1 V2 P1 , P2 F1 F2 T FFC FC Valve for Milk Flow Valve for Cooling water Flow Pumps Coriollis meter (Mass flow rate) Magnetic flow meter (Volumetric flow rate) Temperature of the Chocolate milk Flow Fraction controller Flow controller

Process Control Project (IPC) April 10, 2012

[3.3] Control Loops description: The two identified control loops for this project are detailed below. The First control loop involves controlling the true density of the chocolate flavored milk to about 1.16 g/ml . This is obtained by measuring the density of the fluid using the Coriolis meter and feeding this variable into a controller which would then control the flow rate of the milk according to the chocolate syrup flow rate. The Chocolate syrup flow rate being highly viscous is assumed as the free flowing component and the flow rate of the skimmed milk is controlled using the Flow Fraction controller (FFC) as shown in the Diagram 3.2 to maintain the density. Typically the milk industry allows only 0.03 g/l fluctuation in the milk density (as Elaborated in the) since it drastically affects the taste of the chocolate milk and cost of the chocolate milk, hence this control loop is highly essential. The Second loop comprises of the temperature control of the final milk to about 4C which can be controlled by manipulating the chilling water flow rate. This control loop would cool the flavored milk via a feedback type of control by measuring the milk temperature in the storage tank and cooling the inflow stream accordingly.

Table 1 : American Dairy Science Association, 2004

Process Control Project (IPC) April 10, 2012

[3.5] Advantages and Characteristics of Good control: If the temperature of the chocolate milk exceeds 4C for a prolonged period of time it would cause the milk to get spoilt due to certain microbial activity. The flavoured milk is hence closely monitored with respect to its temperature and a good control system typically delivers a temperature control to about 0.1 C of the desired value. Since the potability of the milk would depend on the temperature indirectly a good refrigeration cycle and control loop must be applied here. The density control is of the utmost importance in this industry since it defines the quality of the chocolate milk for consumption. If the milk is even slightly off the desired density of 1.16 0.03 g/ml then the taste of the milk and cost would be drastically affected. The net result would be the loss in revenue for the company. Thus good control is essential in controlling the delivered density of the chocolate flavored milk to the customer. The characteristics of good control in the milk was again obtained from the American Dairy Science Association Journal 2004. The Dairy industry cannot compromise greatly on good control for these of Temperature and density to parameters since it would directly or indirectly affect their sales and brand value.

[4.1] References: 1- General Specifications YOKOGAWA ROTAMASS 3-Series Coriolis Mass Flowmeter All Standards and specifications of the Coriolis meter was obtained from this specifications paper.
2- Gujarat Co-operative Milk Marketing Federation LT websiteD. 3- Wisc-Online Process Control Tutorial: The Chocolate Milk Machine Author(s): Jon Stenerson

Wisc-Online.com 1999-2012 4- J. Dairy Sci. 87:2031 American Dairy Science Association, 2004.Effects of Milk Powders in Milk Chocolate B. Liang and R. W. Hartel Department of Food Science, University of Wisconsin 5- Mass flow meter : Density and volume measurements from Wikipedia 6- Cost of Coriollis meters: http://www.flowcoriolis.com/