Key points
The many benefits of Coriolis flowmeters have led them to be regarded as the gold standard in flow measurement across an expanding variety of industrial applications. David Bowers, Pressure and Process Flow Product Manager UK&IE for ABB Measurement & Analytics, explains the key advantages they offer over other flowmeter types and looks at the top five applications where Coriolis flowmeters are delivering the best results.
Since their introduction in the 1980s, Coriolis mass flowmeters have become one of the most versatile and reliable means of measuring the flow of liquids or gases. Recognised for their ability to measure multiple attributes over sustained periods with high repeatability and very little maintenance, they have steadily established a reputation for accuracy, versatility and durability that has led to their use in a growing range of industries.
Coriolis flowmeters work by measuring the mass flow rate and density and temperature of a fluid as it flows through a vibrating tube. By also measuring density, the meters enable additional calculations about the substance’s concentration.
By measuring mass flow, density, concentration and temperature, a single Coriolis meter can do the work of multiple instruments, eliminating the cost of purchasing separate devices and minimising the requirement for spare parts and overall maintenance.
This combination of measurements can be highly useful in many applications. In oil extraction, for example, the combined measurements available using a Coriolis meter can help determine how much water is coming out of the ground with the oil, providing a useful indicator of overall production efficiency.”
The working principles of Coriolis meters offer several distinct advantages. With no moving parts that come in direct contact with the measured substance, whether gas or liquid, they require little maintenance or upkeep. Once calibrated at the factory, they also tend to remain calibrated throughout their lifecycle.
In addition, because Coriolis is the only principle capable of measuring mass flow of gas and liquids without any calculation, results are independent of changes in temperature or pressure. The use of Coriolis flowmeters also allows for density measurement, making them a true multi-variable metering solution for filling operations in chemical, food and other such process industries.
Today’s Coriolis flowmeters are highly accurate. Accuracies of the new ABB CoriolisMaster flowmeter models, for example, range from 0.1 to 0.4 percent of measured value for liquids and 0.5 to 1 percent of reading for gases. High accuracies make Coriolis flowmeters obvious candidates for a wide range of applications – these are explored in the following section.
Five applications for Coriolis flowmeters
Chemical Coriolis flowmeters
The chemical industry is a major adopter of Coriolis technology, with safety being the number one reason. When dosing chemicals such as acids or alkalines to get a reaction, it can be dangerous to under or over fill the chemical. In some cases, overdosing can also impact a company’s profits.
Alongside accuracy, the durability and flexibility of Coriolis flowmeters are another reason why this technology is popular in the sector. For example, certain aggressive chemicals could potentially rupture the primary measurement tube. However, Coriolis flowmeters have a secondary containment that will hold a fluid to a precise pressure for a certain period.
In addition, if the wetted materials are suitable for the chemical being dosed, a Coriolis flowmeter can be used to measure multiple chemicals without production disruptions caused by having to switch between different set ups.
The high accuracy of Coriolis flowmeters also makes them an ideal solution for allocation applications where quantities of chemicals are sold to third parties. By eliminating any deviations in the measurement, Coriolis flowmeters can help to ensure that quantities sold exactly match what has been ordered.
Oil & Gas Coriolis flowmeters
Safety and financial factors are major drivers for the use of measurement equipment in the oil and gas industry. Accurate results are needed for safety reasons, and with operators now extracting oil and gas at deeper locations, the associated higher pressure has implications on measurement technologies.
From a financial perspective, in custody transfer applications where supplies of oil and gas need to change hands, relevant taxes need to be paid to the authorities. A failure to do so can result in fines and, in some cases, imprisonment. And in many cases, with several parties including governments and upstream operators owning a percentage of an oil or gas field, accurate measurement is required to ensure all parties receive the revenues they are entitled to.
With accuracy being of paramount importance, the oil and gas industry takes measurement to a different level. For this reason, the cost of the measurement device is rarely an influencing factor, with the industry choosing the best instruments for the job. For this reason, Coriolis flowmeters have tended to be widely adopted in oil and gas applications.
As well as using Coriolis flowmeters to measure flows of gases and liquids, the industry also cross references Coriolis readings against separate temperature, pressure and flowmeter devices and follows ISO guidance to ensure the actual readings are as accurate as they can be. A flow computer is then used to check these measurements and provide a record to the concerned businesses. Operators even have a redundant line so testing can be replicated if needed.
Oil and gas will always have mixed mediums in them because natural resources will have entrained water or particles in them when first extracted. A Coriolis flowmeter can read many different values and measure different fluids. This makes them ideal for accurately measuring flows where mixed fractions of gas, liquid and entrained particles may be present.
Hydrogen Coriolis flowmeters
Hydrogen is set to be of one for the future for Coriolis flowmeters. As countries around the world look for alternative methods of meeting their energy demands, for the use of hydrogen is set to grow, and at a significant rate.
According to Grand View Reasearch3, the global hydrogen generation market size was valued at USD 120.77 billion in 2020 and is expected to expand at a compound annual growth rate (CAGR) of 5.7% from 2021 to 2028. An exponential increase in the demand for clean and green fuel due to rising pollution levels, coupled with growing government regulations to control and curb the sulphur content in fuels, is expected to drive this growth.
Part of the switch to cleaner energy will see the natural gas networks in the UK and Europe switch from methane to hydrogen, and Coriolis flowmeters are well placed to support the switch. Coriolis flowmeters have a major advantage over other technologies as they can measure gases as accurately as they do liquids, with an exceptional turndown ratio.
Food & Beverage Coriolis flowmeters
The food and beverage sector is the biggest growth market for Coriolis flowmeters. In this industry, the inherent versatility of Coriolis flowmeters enables them to be used for measuring a wide range of foods and beverages, from yogurts and milk through to alcohol and olive oil. With food and beverage producers typically selling by both volume and mass, the industry fully understands the accuracy, versatility and turndown advantages of Coriolis flowmeters compared to other measurement technologies.
Like the chemicals industry, Coriolis flowmeters are used to support the dosing of concentrated ingredients required for production. In the alcohol industry, the high accuracy and performance of Coriolis flowmeters means they are widely used by distillery companies both to ensure production of high-quality whisky during the distilling process and for custody transfer purposes to make sure that the companies pay the correct taxes to authorities.
This same benefit also extends to other food and drink production processes, where factors such as ingredient strengths, costs and the need to consistently achieve precise mixtures requires careful dosing measurement and control. For applications such as concentrate dosing, the accurate measurement that can be achieved by using Coriolis flowmeters can help to achieve the right levels of product quality whilst also minimizing production costs.
Engine Testing Coriolis flowmeters
Due to climate change, the need to accurately measure exhaust emissions is a major priority for automotive companies, emission testing centres, and governing bodies. Each time a manufacturer develops an engine, they need to demonstrate how it complies with emissions.
While the turndown and accuracy of Coriolis flowmeters make it an attractive choice for the industry, the flexibility of the technology is offering major advantages. For example, efficiencies can be realised as the same Coriolis flowmeter and set-up can be used to measure the emissions of a range of engine sizes, with no need for recalibration when different test fuels are used. As such, Coriolis flowmeters are becoming a more attractive measurement technology compared to more established – and potentially more costly – methods such as gravimetric measurement systems.
Meeting coriolis flowmeter targets
While Coriolis flowmeters might not be the most cost-effective option in terms of initial purchase cost, their low cost of ownership, and utilisation of verification software enables prolonged time between interventions and maintenance activities. Verification software at the very minimum can double the period between a QA wet calibration test, enabling increased productivity through reduced downtime.
Their ability to deliver versatile, highly accurate measurement in a compact, easy to install and use design, make them the better alternative to other flowmeter technologies in an expanding range of situations.
Added benefits are also possible through the addition of Power over Ethernet (PoE) technology, which is now available for ABB’s CoriolisMaster flowmeter. PoE offers several benefits for process engineers, as it omits the need for a separate DC power infrastructure, providing power and communications via the same cable. This brings new agility as flowmeters can be installed wherever needed. Offering a modular design allows the combination of both worlds and ensures that devices are future-proof, increasing the longevity of the flowmeters.
Furthermore, flowmeters with Ethernet connectivity increase simplicity, flexibility and reliability for operations in process automation, while enhancing real-time visibility of data. Previously hidden data in field devices, such as measurement values on density, conductivity or concentration of the medium, can be unlocked, enabling customers across all industries to identify redundant measurement points in their plants to achieve savings along the way.
References
1 – Flow Meter Market Size & Share | Industry Report, 2021-2028 (grandviewresearch.com)
2 – Chemical industry worldwide – statistics & facts | Statista
3 – Global Hydrogen Generation Market Size Report, 2021-2028 (grandviewresearch.com)
