PROCESS VISCOSITY

On-line viscosity analyzersfor hydrocarbon and process applications

Reliableaccurate on-line industrial viscosity solutions...

Measurement of viscosity is a key factor in manyindustrial processes. Solartron’s field-proven, on-lineviscosity analyzers provide a continuous real-timemeasurement of base and referred viscosity, givingsignificant advantages over traditional off-line ‘sampled’techniques, to:

• minimize waste

• reduce lead times

• improve product quality and uniformity

• give greater operational flexibility and control

• increase safety

Choosing a viscosity analyzer

Solartron’s extensive product range gives a choice of twotechnologies, one based on the well-proven rotationalprinciple, the other on a vibrating element.

Closing the loop on process control...

7827 is unique digital viscosity analyzer. Using a vibratingelement, it provides continuous measurement of viscosity,density and temperature in a single rugged unit. The advantages over conventional viscometers include:

• no moving parts

• virtually zero maintenance

• hygienic design

• lower cost

However the shear rate is not controlled, and therefore it isbest suited to Newtonian fluids such as hydrocarbons, or tonon-Newtonian fluids where measurement repeatability is themain criteria.

Covimat-105 is a rotational viscosity analyzer where the shearrate is fully defined, and is thus capable of providing accuratemeasurements on any type of fluid. The modular designenables the metering cell to be detached from the meteringhead to minimize maintenance.

Quench oil

Quench oil temperature control is criticalto product quality in olefin or ethylenecracker distillation. Viscosity is the mosteffective control parameter, but has onlybecome practical with the advent ofSolartron's 7827 system, which canovercome the operational problems oftemperature and solids contamination,and - using specially developed referraltechniques - provide a continuous,accurate measurement of base viscosity(and hence molecular weight) foreffective and reliable process control.

Meter factor correction

Flow meters are often affected by theviscosity of the product passing throughthem. When transporting fluids where theviscosity of the product can changesignificantly, accurate on-line viscositymeasurement is essential forautomatically selecting the correctmeter factor.

Pump efficiency

The efficiency and failure rate of a pumpis proportional to the viscosity of theproduct being transferred. Viscosity measurement can determinethe proper switching of pumps and forpipeline companies can also indicate achange in tariff rate.

Pipeline interface detection

The capability of measuring viscosityand density simultaneously makes the7827 an ideal sensor for interfacedetection.

Oil blending

Oil is generally sold to a specificviscosity specification at standardconditions - usually 100°C/212°F or40°C/104°F. Oils of different viscositiesare blended together until the targetviscosity specification is achieved.Continuous on-line viscosity controlhelps to maintain the quality of theproduct and maximizes the efficiency ofthe plant operation

Quality Control

Viscosity is a very effective indicator ofthe final quality of many products,including glycol, clays, shampoos,glues, resins, detergents, elastic fibre,cellulose, varnish, gelatine andpolymers. In the food industry viscositydetermines the quality of syrups,chocolate, tomato sauce, fruit juice,cheese and other milk products.

Coating Control

Viscosity is used extensively in theprinting & coating industry for processcontrol. If the viscosity is too low theproduct will tend to run; too high, andthe coating becomes uneven. Typicalapplications are: colour TV picture tubecoatings, fluorescent light tubecoatings, printing ink control,manufacture of lithographic printingplates.

Molecular weight determination

For polymer reactions the molecularweight of the product (proportional toviscosity) is often a critical controlparameter, used to determine the end-point. Solartron's on-line viscositymetering eliminates the inaccuraciesand hazards inherent in manualsampling methods.

...whatever the application.

The 7827 is a unique digital processanalyzer designed for applicationsrequiring continuous on-line liquidviscosity measurement in pipelinesor static tanks. In addition toviscosity, the sensor simultaneouslymeasures the density andtemperature of the fluid, allowingdynamic and kinematic viscosity tobe accurately determined. Basevalues can also be determined usingmethods developed for the oilindustry and based on API andASTM D341 standards.

The analyzer comprises a vibratingsensor and drive electronics. It is easilyinstalled in a by-pass, pipeline, opentank, pressurised vessel, or flow-throughsample chamber. A choice ofconstruction materials and flangeconnections allows the sensor to beused in a broad range of applications.

Each measurement range isindependently calibrated to achievemaximum accuracy. For applicationswhere the measurement extends overmore than one calibrated range an autoranging facility is provided.

7827 viscosity ana

Principle of Operation

The sensor is a simple tuning forkmaintained in resonance electronically.The frequency of the resonance isdetermined by the density of the fluid,and the bandwidth is a function ofviscosity.

7827 digitally measures the resonancefrequency at a point A (the lower -3dbpoint) and then at point B (the upper -3db point) - see diagram. From thesetwo measurements the 795x SeriesSignal Converter can calculate thebandwidth (B-A), resonant frequency((A+B)/2) and hence the Quality Factor(Resonant Frequency/Bandwidth), togive digitally determined values of thedensity and viscosity for the fluid.

Resonant Frequency

Bandwidth

Q ∝1

√ Viscosity

Q =

Flow-throughchamber

Specification

Viscosity range 1 to 20,000 cPViscosity accuracy ±1% FS (0.2 cP in 0.5-10 cP range)*Factory calibrated ranges 0.5 to 10; 10 to 100; 100 to 1,000;

1,000 to 12,500cP**Viscosity repeatability ±0.5% reading

Density accuracy ±0.001 g/cc (20˚C, 1 bar A, 1 cP)Density range 0 to 3 g/ccCalibrated range 0.6 to 1.6 g/ccRepeatabilty ±0.0001 g/cc/˚C (corrected)

Temperature range -50 to 200˚C (-58 to +392˚F)Viscosity temperature effect NegligibleDensity temperature effect ±0.0001 g/cc/˚C (corrected)

Maximum operating pressure 177bar (2566 psi)

Material of wetted parts 316L st. steel, Hastelloy C22, or Monel 400

Flow velocity (maximum) 0.5 m/s (1.6 ft/s)

Power supply (from signal converter) 24 to 27 Vdc, 50mAOutput signals Viscosity & density: frequency, 3 wire

Temperature - 100Ω PRT 4 wire

Environmental rating IP66Weight (max.) 6.7 kg, (14.7lb)Safety CENELEC/EN50018

EEx 'd' IIC T4 Ex 91C1359CSA Class 1, Division 1, Group CBS EN50081-1:1992BS EN50082-2:1995

*Accuracy holds for Newtonian fluids only over the calibrated ranges**Calibration for flow-through chambers not available above 1000cP

lyzerAuto-ranging

Virtually nomaintenance

Line density

Linetemperature

Dynamic and

kinematic viscosity

121mm (4.7")

190mm

(7.5")127m

m (5")

Ø 35mm (1.37")

DimensionsInstallation

Three recommended methods are detailed below. However, for the optimumconfiguration to suit your application, contact your local sales office for advice.

Free-stream: 7827 directly in the main fluid flowPipe diameter: >100mm (4in) for horizontal flow

>150mm (6in) for vertical flowTypical flow rate: 0.3 to 0.5m/s (1 to 1.6 ft/s) at 7827

T-piece: 7827 entirely contained within a side pocket off the main pipeline.Pipe diameter: >100mm (4in)Typical flow rate: 0.3 to 3m/s (1 to 10ft/s) at main pipe wall

Flow-through chamber: 7827 installed in L-shaped chamber as a local fast loop (slipstream) on main pipelineTypical flow rate through chamber: 10 to 30 l/min (2.6 to 8 USgal)

For pipeline and flow-through chamber fittings, see Accessories brochure B782703

Covimat105The Covimat 105 range of variablespeed rotational on-line viscometershas been specifically designed foron-line measurement of viscosity atdefined shear rates, making it idealfor non-Newtonian fluids.

The system consists of anexplosion-proof metering headwhich is magnetically coupled to ameasurement cell containing thefluid to be measured.

Covimat is designed to minimiseservicing costs. Thanks to its ruggedconstruction virtually no maintenance isrequired, and for all configurations themetering head can be separated fromthe measuring cell without interruptingthe production process.

There are five standard rotationalspeeds available, and these can bereduced by a factor of 10 for themeasurement of highly viscousproducts (Z version). In addition, anexternal rotational speed control isprovided, enabling the meter to becontrolled to any speed in the range 1to 200 rpm.

Immersion and in-line systems areavailable to suit a wide variety ofdifferent applications. The selection of asuitable measuring system isdetermined by the viscosity range of theproduct, the pressure, temperature andflow rate.

Principle of operation

Covimat measures viscosity by the wellproven rotational principle, allowing adirect comparison with laboratoryresults. A rotating bob in a stationarymeasurement cell is driven by a motorin the metering head at constant speedthrough a magnetic coupling. The driveis coupled in the metering head via atorsion element. A change in viscosityof the product causes the angle of twistof the torsion element to alter. Thischange is measured inductively andwhen combined with the rotationalspeed and measuring bob geometry,provides a measurement of viscosity.

No seals

Lowmaintenance

Hightemperature

Viscositymeasurement to 750,000cP

Controlledshear rate

Specification

Viscosity range Depends on measurement cell

Achievable accuracy ±1% FS

System repeatability ±0.5% of reading

Motor speed range: Standard 10 to 200 rpm1 to 20 rpm (Z version)

Fixed speeds: Switched 10, 21, 44.7, 94.6, 200 rpm1, 2.1, 4.47, 9.46, 20 rpm (Z version)

External speed control 0 to 20mA or 0 to +10VTransfer function 10 rpm/mA or 20 rpm/VRotational speed accuracy ±0.4% of set value at 20°C(68°F)Temperature coefficient - speed -0.02%/°C

Output signal 4-20mA proportional to torque/viscosity

Torsion angle measurement InductiveMaximum torque 4mN-mTorque tolerance ±0.3% at 20°C(68°F) at output 1-5VTemperature coefficient - torque +1.3%/°C, (+0.07%/°F)Linearity ±0.3%

Temperature range 0 to 50°C (32 to 122°F)

Supply voltage range +20 to 28Vdc

Supply current <200mA at 24Vdc

Weight 8.1 kg (17.86lb)

SafetyStandard version PTB approved to EEx d IIB T6Switch version Designed to EEx d IIB T6

EMC ratingEmissions BS EN 50081-2:1994

Heavy industrial environmentImmunity BS EN 50082-2: 1995

Heavy industrial environment

Covimat105Covimat Metering HeadThe Covimat metering head is designed to be usedwith a range of measurement cells, which are chosento meet the demands of the application. These aredescribed in the following pages.

The metering head is available in two versions:

Standard PTB approved to EEx d IIB T6, thisversion enables the speed of rotation tobe controlled via a 0-20mA or 0.5-10Vinput signal. The Z version reduces thespeed by a factor of 10.

SwitchThis version is designed to beexplosion-proof to EExd IIB T6. Thespeed of rotation is set to one of fivepre-set speeds, using an internalswitch; it can also be controlled by a 0-20mA input signal. The Z versionreduces the pre-set speeds by a factorof 10.

The output of both versions is a 4-20mAsignal proportional to the measuredtorque/viscosity. This signal can beused with the Solartron 795x Series ofSignal Converters, as the basis of acomplete viscosity measurementsystem offering enhanced functionality.

Dimensions

For industrial ap

386mm(15.2in)

150mm(5.91in)

228mm(8.98in)

45mm (1.77in)

60mm (2.36in)

200mm (7.87in)300mm (11.81in)or500mm (19.68in)

mm (1.77in)

Covimat 105-TOApplication: Open, unpressurised vessels

Covimat 105-DDApplication: Low-viscosity,homogeneous products

Utilises both single and twin gapdesigns for the flow-through cell. The small measuring cell volume is also an advantage for batchprocesses where there are onlylimited amounts of the product.

Specification

Viscosity range 1 to 13,200cP

Achievable accuracy ±1% FS

Viscosity range (via Model Viscosity range (cP)interchangeable cylinders) DDA005* 1 to 460

DDA006* 5 to 1,350DDA007* 10 to 3,100DDA008 15 to 5,000DDA009* 30 to 8,800DDA010 40 to 11,200DDA011 50 to 13,200

Max. temperature of product 90°C (194°F)

Max. pressure 20 bar (290 psig)

Max. flow rate 5 l./min (1.32 USgall./min)

Material of measuring cell Corrosion-resistant steel 316 S11

Material of seal Synthetic rubber/NBR

Weight 11.1kg (24.4lb)

*Twin gap measuring cells

Dimensions

Specification

Viscosity range 2 to 358,000cP

Achievable accuracy ±1% FS

Viscosity range (via interchangeable bobs)Dia. (mm) Viscosity range (cP)

Standard with Z option69.5 2 to 189 20 to 1,89068.0 3 to 895 30 to 8,95063.0 12 to 2,460 120 to 24,60046.0 31 to 10,865 310 to 108,65031.0 175 to 35,800 1,750 to 358,000

Max. temperature of product 65°C (150°F)

Max. pressure Atmospheric

Material of measuring cell Corrosion-resistant steel 316 S11

Measurement system bearing Teflon/hard metal

Immersion lengths (mm) 200, 300 or 500

Weight 10kg (22lb)

Dimensions

pplications...

44mm (1.73in)

195mm(7.68in)

138mm(5.43in)

44mm (1.73in)

210mm (8.27in)

145mm(5.71in)

Covimat 105-DC rangeApplication: For high temperatures and pressures

DC40EThe DC40E range is designed forcontinuous measurement of viscosity atlow pressures and high temperatures. A thermowell is provided to accept atemperature sensor for directmeasurement of the producttemperature. There is a range of flangeoptions.

DC40DThe DC40D range is suitable forcontinuous measurement of viscosity athigh pressures and high temperatures.To prevent heat losses - and to avoidcrystallization and hardening processesat low throughputs or at hightemperatures - the DC40D cells have aisothermal (jacketed) wall. A range offlange options is available and for directmeasurement of the producttemperature, a thermowell is providedfor a temperature sensor.

Specifications Covimat DC40E Covimat DC40D

Viscosity range 1 to 720,000cP

Achievable accuracy ±1% FS

Viscosity ranges (via interchangeable cylinders)Dia. (mm) Standard (cP) with Z option (cP)DS* 1 to 190 10 to 1,90059 9 to 920 90 to 9,20057 20 to 2,000 200 to 20,000 51 60 to 6,000 600 to 60,000 35 240 to 24,000 2,400 to 240,00024 720 to 72,000 7,200 to 720,000

Max. temperature of product 250°C (482°F) 300°C (572°F)

Max. pressure 25 bar (362 psig) 170 bar (2,465 psig) or to flange rating or to flange rating

Max. flow rate 40 l./min (10.57 USgall./min)

Material of measuring cell 316L stainless steel

Material of seal Asbestos free

Approx. weight of cell + adapter 9.5 kg (20.95 lb) 18 kg (39.69 lb)(depends on flange)

*Twin gap measuring cells

Dimensions

...interchangeability means flexibility.

Solartron’s 795x family of signalconverters is the perfectcomplement for 7827 and Covimat-105 transducers, providing flexibleviscosity measurement systemswhich are accurate, easy to set upand use, and interface simply withyour process and plant systems.

Solartron’s signal converters boast aunique architecture, based on standardhardware platforms – panel or wallmounted – supported by product-specific application software, offeringextensive functionality. The benefits ofthis approach include hardwarereliability and interchangeability, cost-effectiveness, and a user interfacewhich is optimised for the purposerequired.

The 795x family accepts inputs from awide variety of transducers, includingviscometers, densitometers,temperature, pressure and differentialpressure transmitters. Viscosity specificsoftware enables the user to realise thefull potential of the 7827 and Covimat-105, including speed control forrotational viscometers. On-line datavalues – from direct measurement, orbuilt-in calculations include:

• Line viscosity

• Line density

• Kinematic viscosity

• Temperature

• Base viscosity and density, includingAPI and ASTM D341-based methodsfor hydrocarbons

• % concentration, molecular weight, S.G., S.S.U., and other derivedparameters

Simple to useThe simple-to-use menu-drivenkeyboard provides complete access toall database variables andconfiguration, with password/keyswitchprotection if required.

Remote configurationThe signal converter's configuration caneasily be altered remotely using a PCequipped with the appropriate software.

CommunicationsThe 795x family offers unprecedentedcommunications and interfaces directlyto RTUs, PLCs, DCSs, 'smart'instruments and other flow computers.

795x signal conveThe user interface

rters

Hardware specification Note: different versions of 795x signal converter software may not make use of all the hardware facilities

Model 7950 (wall mount) 7951 (panel mount)

Viscosity (7827) or density inputs 1 1Viscosity (Covimat) inputs* 1 1Analog (0/4 - 20mA) inputs 4 (8†) 4 (10†)PRT (4 wire) inputs** 4 4Digital/status inputs 8 18Digital/status outputs 8 16Analog (0/4 – 20mA) outputs 4 (8†) 4 (8†)Communication ports (RS232/RS485) 3 3† With Option card fitted *Each Covimat-105 uses one analog input channel and one output channel **Each PRT input uses one analog input channel

Option Cards

Additional Analogue I/O Yes Yes

Environment

AC power 90-265V, 50-60Hz N/ADC power 21-30V @25WOperating -10 to 50˚C, 14 to 122˚FNon operating -30 to 70˚C, -22 to 158˚FEnclosure NEMA4X IP65 NEMA12 IP52

Regulations

Emissions EN50081-2: 1994(Heavy industrial)Immunity EN50082-2: 1995(Heavy industrial)

Software specification – Viscosity application

Speed control for Covimat-105 viscometersCalculation of:

Conversion between Dynamic and Kinematic viscosity(utilising available density value)

Base viscosity- Viscosity referral via ASTM D341 equation- Viscosity/temperature matrix

Base density- API base density- Density/temperature matrix

Derived parameters% solids, % concentration, % mass, deg Brix, deg API, S.G., S.S.U.

Special equationsUser specified – e.g., Molecular weight

7827- XXXXXXXX InstallationS = Free streamT = 2" schedule 40

(Range U,L,M only)

Viscosity range(one or more rangescan be selected)H = 1,000 to 12,500cPM = 100 to 1,000cPL = 10 to 100cPU = 0.5 to 10cP

Flange type and ratingA = 2" ANSI 150 RFB = 2" ANSI 600 RFC = 2" ANSI 1500 RFE = 2" Ladish tri-clampF = 2" IDF hygienic flangeG = 3" Ladish tri-clampJ = 50mm DIN 2527

RF DN 50/PN 40K = 50mm DIN 2527

RF DN 50/PN 100P = 2" ANSI 300 RFN = 1.5" compression fitting** For sample pockets and weldolets only (see brochure B782702)

Safety rating C = EEx d IIC T4E = CSA Class 1 Div 1 Group C

Material of wetted parts A = 316L stainless steelE = Hastelloy C22F = 316L stainless steel with PTFE coated tines*G = Hastelloy C22 with PTFE coated tines*H = Monel 400

Covimat DD Flow Cell

Description Order No.

Measuring cell(excluding cylinder/bob) 00112405

Covimat Measurement Head 4-20mAoutput for DD Flow Cells

Description Order No.

PTB approved 81051 CP

Switch version no PTB 81051 CA

Cylinders/bobs

Range Order No.

1-460 cP* 00112443

5-1,350 cP* 00112444

10-3,100 cP* 00112445

15-5,000 cP 00112446

30-8,800 cP* 00112447

40-11,200 cP 00112448

50-13,200 cP 00112449

*Twin gap measuring cells

7827 viscosity analyzerOrdering Information

*The PTFE coating reducesproduct build-up on tinesand is not designed forcorrosion resistance.Other finishes, includingelectro-polishing, may alsobe applicable; contact yourlocal Sales office.

Covimat Measurement Head 4-20mAoutput for TO and DC Flow Cells

Description Order No.

PTB approved 81051 AP

Z version PTB approved 81051 BP

Switch version no PTB 81051 AA

Z & switch version no PTB 81051 BA

Covimat TO Immersion system

Immersion length Order No.

200mm (7.87in) 00112812

300mm (11.81in) 00112813

500mm (19.68in) 00112814

Covimat DC40D Flow Beakers

Description Order No

DN25 PN100 RTJ 81053AAA

11/2" ANSI 150 RF 81053AAB

11/2" ANSI 600 RF 81053AAC

11/2" ANSI 900 RF 81053AAD

DN32 PN40 RF 81053AAE

DN25 PN100 RF 81053AAF

Covimat DC40E Flow Beakers

Description Order No

2" ANSI 150 RF 81053BAB

DN50 PN40 RF 81053BAE

2" TRI CLAMP 81053BAG

2" IDF 81053BAH

Cylinders/bobs

Size Order No.

24mm 00112309

35mm 00112307

51mm 00112305

57mm 00112303

59mm 00112302

Double-split 00112242

Signal Converters

Type Order No.

7950 wall mount (Klippon) 7950 AA

7951 panel mount (Klippon) 7951 AA

7951 panel mount (D-type) 7951 AB

Cylinders/bobs

Size Order No.

69.5mm 00112350

68mm 00112349

63mm 00112348

46mm 00112347

31mm 00112273

Coupling piece 00112810

Covimat 105Ordering Matrix

PT100 Temp. Sensor(optional) 81053748A

W OR

LD

CL

AS

S

ME

ASUREM

EN

TS

OL

UT

ION S •

Solartron Victoria Road, Farnborough

Hampshire GU14 7PW England

Telephone +44 (0) 1252 376666

Fax +44 (0) 1252 547384

Solartron19408 Park Row, Suite 320

Houston, Texas 77084, USA

Telephone +1 281-398-7890

Fax +1 281-398-7891

B1210

Solartron pursues a policy of continuous development and product

improvement. The specifications in this document may therefore be changed

without notice.

Issue 03/0401 © Solartron 2001

Solartron is part of the Roxboro Group PLC. The

company is a market leader in supplying precision

measurement solutions for the power, oil and gas,

aerospace and process industries, and our reputation

for excellence is based on over 50 years’ experience

in these fields.

Solartron manufactures a range of transducers and

instrumentation for on-line continuous measurement

of viscosity and density in liquids and gas. These

products are renowned for their accuracy and

reliability. Solartron is dedicated to providing quality,

value and service in fluid measurement worldwide.

The company’s Quality System is approved to BS EN

ISO 9001:1994. Comprehensive calibration facilities

include two NAMAS laboratories.

All our products carry the mark, showing that they

are fully compatible with EC Directive 89/336/EEC.

Solartron maintains a world-wide network of Service

Centres, committed to ensuring that our customers

enjoy the maximum benefit from all their

instrumentation. Services available include

installation, commissioning, maintenance, repair and

calibration of instruments and systems.

CERTIFICATENo.FM1709

Installation accessories

Correct installation is a key factor in the quest for accuratelong-term measurement, particularly where viscosity isused as a critical control parameter and where line valuesmust be referred to base conditions.

The flow-through chamber is designed for installation as a local

fast loop (slipstream) on a main pipeline, and gives the following

advantages:

• minimizes the need for on-site calibration

• improves accuracy

• enhances viscosity referrals

• increases tolerance of solids and entrained gas

• reduces maintenance

Flow-through chambers are available with 1" or 2" NB inlet/outlet

tubes, with a choice of weld ends, compression fittings or

flanges, and an optional thermal jacket.

For direct pipeline fitting and improved thermal performance,

Solartron’s range of prepared collars (weldolets) are available for

transducers with a compression fitting. They are available for

pipe diameters of 4", 6", 8" or 10" nominal bore.

See brochure B782703 for more details

More details of Solartron transducers, signal convertersand flow computers are given in the following brochures:

Density Transducers B1025

Gas Density and Specific Gravity Products B1253

795x Series Signal Converters B1251

795x Series Flow Computers for the gas industry B1248

795x Series Flow Computers for oil and refined products B1249

Modular Computer System B1250

Installation accessories B782703

Email: trn info@solartron.com Web: http://www.solartron.com

a Roxboro Group company