HIGH PRECISION FLOW HIGH PRECISION FLOW MEASURING COUNTER - EMRMEASURING COUNTER - EMR33

(ELECTRONIC METER REGISTER)(ELECTRONIC METER REGISTER)

INTRODUCTION

• BY OUR FOREFATHERS ‘GREATNESS’, WE ARE GETTING LOT OF CRUDE OIL FROM THE EARTH.

• WE ARE TRANSFERRING THIS CRUDE OIL INTO A SEVERAL STATES OF FLUID, EVERY STATE HAS ITS OWN NAME AND OWN APPLICATION ACCORDING TO THE USAGE.(EG: DIESEL, PETROL)

• HUNDRED YEARS AFTER THERE WILL BE A SHORTAGE IN CRUDE OIL FROM EARTH.

• SO, WE MUST SAVE THE FLUID AS POSSIBLE AS BY MEASURING FOR PROTECTING THE FUTURE.

• FOR HIGH PRECISION FLOW MEASURING WE NEED A HIGH PRECISION FLOW MEASURING DEVICE.

• THERE ARE SEVERAL WAYS TO MEASURE THE FLUID FLOW BY USING SEVERAL PRINCIPLES.

• MAINLY THERE ARE TWO TYPES OF FLOW MEASURING METHODS. 1. DIRECT METHOD

E.g.: VOLUMETRIC METHOD (OVAL WHEEL FLOW METER) 2. INFERENCE METHOD

E.g.: DIFFERENTIAL PRESSURE METHOD (V-CONE FLOW METER) VERTICES MEASURING METHOD (VORTEX FLOW METER)

CENTRIFUGAL FORCE MEASURING METHOD (TURBINE FLOW METER)

• WHATEVER WAY WE ARE MEASRUING THE FLOW, WE NEED TO SHOW THE FLOW RESULTS IN THE FORM OF EASY TO UNDERSTAND.

• THERE ARE SEVERAL WAYS TO SHOW THE FLOW RESULTS WITH THE HELP OF MAGNETS, SENSORS. TRANSMISSION GEARS.

• MAINLY THERE ARE TWO TYPES OF COUNTERS AVAILABLE TO SHOW THE FLOW RESULTS BY GETTING ROTATIONAL OUTPUT FROM THE FLOW MEASURING DEVICE.

1. MECHANICAL COUNTERS(BY TRNSMISSION GEARS)

E.g. VEEDER-ROOT, E-COUNTER, D-COUNTER

2. ELECTRONIC COUNTERS(BY SENSORS)

E.g. FLUIDWELL, XC 200NX, RC 102C, EMR3

• FOR ELECTRONIC COUNTERS WE NEED A DEVICE WHICH CAN TRANSFER ROTATIONAL MOTION INTO AN ELECTRONICAL PULSES.

• ENCODER IS ONE TYPE OF DEVICE, WHICH CAN TRANSFER THE ROTATIONAL SIGNAL INTO AN EQUALENT ELECTRONIC PULSES.

• EMR3 IS ONE TYPE OF ELECTRONIC FLOW MEASURING COUNTER BY USING AN ENCODER PULSES.

COMPONENTS INVOLVED IN EMR3

1. DISPLAY HEAD:

a) FRONT PANEL DISPLAY WITH KEYS b) ENCODER

• THE DISPLAY HEAD ACT AS A COMPUTER MONITOR.

• USING THE FRONT PANEL DISPLAY AND THE KEYS ON ITS FACE, THE OPERATOR CAN CHOOSE TO DISPENSE EITHER A PRESET OR A VARIABLE QUANTITY OF PRODUCT.

• THE DISPLAY HEAD MUST BE CONFIGURED AND CALIBRATED BEFORE IT IS PLACED IN SERVICE.

• ONCE THE INITIAL CONFIGURATION AND CALIBRATION PROCEDURES ARE COMPLETE, THE DISPLAY HEAD IS SEALED FOR WEIGHTS AND MEASURES CERTIFICATION.

2. INTERCONNECTION BOX

• THE INTERCONNECTION BOX ACT AS A COMPUTER CENTRAL PROCESSING UNIT.

• THE IB BOX THAT CONTAINS EMR3 SYSTEM CONTROL CIRCUITRY.

• THE IB BOX MOUNTED IN THE PLANT OFFICE.

• THE IB PROVIDES AS INTRINSICALLY-SAFE BARRIER FOR CONNECTIONS TO ONE OR TWO DISPLAY HEADS LOCATED AT DISPENSING POINTS IN THE HAZARDOUS AREA.

SPECIFICATIONS OF EMREMR33

• SYSTEM POWER: 12 OR 24 V dc, FUSED @ 5 A

• PULSER CAPACITY: 0-1000 HZ

• COMMUNICATION BETWEEN DISPLAY HEAD AND IB: RS-485; 19200 BAUD (BITS/SECOND); 8 BIT; NO PARITY; 1 STOP BIT

• COMMUNICATION BETWEEN SYSTEM OR PRINTER: RS-232; 9600 BAUD (BITS/SECOND); 8 BIT; NO PARITY; 1 STOP BIT

• DISPLAY HEAD AND IB OPERATING TEMPERATURE RANGE: -25 TO +70˚C

• WEIGHTS AND MEASURES: DESIGNED TO MEET W&M SPECIFICATIONS

WORKING PRINCIPLE

• PULSE OUTPUT FROM THE ENCODER IS WORKING WITH THE PRINCIPLE OF QUADRATURE.

• ENCODER PROVIDED IN THE EMR3 HAVING 100 CYCLES OR PULSES PER REVOLUTION.

WHAT IS MEANT BY QUADRATURE?

• OPTICAL ENCODERS GENERATES TWO DATA SIGNALS THAT ARE ELECTRICALLY 90˚ OUT OF PHASE WITH EACH OTHER.

• ENCODER IS CONSISTS OF SLOTTED DISK WITH TWO SENSORS.

• QUADRATURE REFERS 90˚ PHASE RELATIONSHIP.

• SINCE EACH FULL CYCLE CONTAINS FOUR TRANSITIONS, OR EDGES, AN ENCODER THAT GENERATES ‘X’ CYCLES OR PULSES/REV, NEEDS 4X EDGES PER REVOLUTION.(EG:FOR 100PPR ENCODER HAVE 4X100=400 EDGES)

• THE TRANSITIONS COMING FROM THE ENCODER WOULD ACT AS A “TRIGGER” TO CAUSE A COUNT.

• AT EACH TRANSITION, THE ELECTRONICS NOT ONLY GENERATES A COUNT, BUT ALSO DETERMINES THE DIRECTIOIN OF TRAVEL SO THAT IT KNOWS WHETHER TO COUNT UP OR DOWN.

CONSTRUCTION OF ENCODER DISK WITH SENSOR

CONSTRUCTION OF ENCODER DISK

EXAMPLE FOR TRANSITION STATES

EXAMPLE FOR TRANSITION STATES

FOLLOWING FOUR POSSIBLE TRANSITIONS STATE CHANGES ARE FORMING ONE CYCLE OR ONE PULSE IN FORWARD AND REVERSE

TRAVEL.

FORWARD TRAVEL REVERSE TRAVEL

FROM TO FROM TO

0,1 1,1 0,1 0,0

1,1 1,0 1,1 0,1

1,0 0,0 1,0 1,1

0,0 0,1 0,0 1,0

• ALONG WITH THE ABOVE EIGHT “LEGAL” STATE CHANGES, THERE ARE ALSO FOUR POSSIBILITIES MEAN TROUBLE: 0,0 TO 1,1; 1,1 TO 0,0; 0,1 TO 1,0; AND 1,0 TO 0,1.

• WHEN ONE OF THESE OCCURS , IT MEANS THAT AT LEAST ONE STATE HAS BEEN SKIPPED, AND EMR3 SHOWS ‘ENCODER PULSE ERROR’.

• WE ARE FACING THIS TRANSITION OR STATE OR PULSE SKIPPING OR MISSING PROPLEM IN OV1000 OVAL WHEEL FLOW METER AT 1000 LPM FOR THE PAST EIGHT YEARS.

QUADRATURE IS THE ONLY SOLUTION FOR PULSE MISSINIG PROBLEM.

• PULSE MISSING HAPPENS ONLY AT THE FLOW RATE RANGE 950-1030LPM DUE TO REVERSE PULSES.

• REVERSE PULSES HAPPENS DUE TO WOBBLING IN THE SLOTTED DISC EXACTLY AT 380 TO 412RPM CORRESPONDS TO 950-1030LPM.

• DUE TO THAT WE ARE GETTING ERROTIC READINGS IN ANY OTHER COUNTER EXCEPT QUADRATURE ENABLED COUNTER.

• I HAVE ALREADY SAID THAT QUDRATURE NOT ONLY GENERATES A COUNT, BUT ALSO DETERMINES THE DIRECTION OF TRAVEL.

• SO, WHILE REVERSE TRAVEL OF SLOTTED DISK IT SENSES THE TRAVEL DIRECTION AND LESS FROM THE UP COUNT.

• SO, WE HAVE PROVED THAT QUADRATURE IS THE ONLY SOLUTION FOR THE PULSE MISSING PROBLEM OR PULSE REVERSAL PROBLEM.

• SO, WE HAVE SOLVED THIS PULSE MISSING PROBLEM WITH THE HELP OF QUADRATURE AT 950-1030 LPM IN OV1000 OVAL WHEEL FLOW METER.

CABLE CONNECTION DIAGRAM FOR

INTERCONNECTION BOX ASSEMBLY.

CABLE CONNECTION DIAGRAM FOR DISPLAY

HEAD ASSEMBLY.

DISPLAY HEAD FRONT PANEL CONSTRUCTION.

BOOT-UP TEST SEQUENCE

• 12 OR 24V DC @5A POWER SUPPLY IS GIVEN TO THE POWER SUPPLY TERMINALS AND ALL WIRING CONECTIONS MADE BETWEEN THE DISPLAY HEAD AND INTERCONNECTION BOX AS WE HAVE SEEN IN THE CABLE CONNECTION DIAGRAM OF DISPLAY HEAD AND INTERCONNECTION BOX.

• WHEN POWER IS INTIATED TO THE DISPLAY HEAD, THE SCREEN WILL POWER UP WITH A TEST SEQUENCE THAT SATISFIES THE REQUIREMENTS OF THE LOCAL WEIGHTS AND MEASURES AUTHORITY. THE DISPLAY HEAD TEST SEQUENCE FOLLOWS BELOW:

o ROM TESTo DATA BUS TEST (MESSAGE NOT DISPLAYED)o ADDRESS BUS TEST (MESSAGE NOT DISPLAYED)o RAM TESTo CS TEST (MESSAGE NOT DISPLAYED)o NVRAM TEST(NON-VOLATILE RANDOM ACCESS MEMORY)o INIT NVRAM

DISPLAY BUTTON FUNCTIONS-STANDARD KEYPAD

• START – PRESS TO BEGIN A FUEL DISPENSE TRANSACTION. WHEN START IS DEPRESSED FOR MORE THAN 2 SECONDS MULTIPLE DELIVERY MODE IS INITIATED.

• FINISH – PRESS TO END A FUEL DISPENSE TRANSACTION. AFTER TRANSACTION IS COMPLETE, PRESSING FINISH WILL CLEAR THE DISPLAY OF THE LAST TRANSACTION AND RETURN YOU TO THE PRE-DISPENSE STATE.

• MODE – PRIOR TO PRESSING START BUTTON, PRESS MODE TO CYCLE BETWEEN VOLUME, CURRENCY, AND RATE MODES.

• PRESET – IN VOLUME MODE, PRESS TO INITIATE PRESETTING THE AMOUNT OF VOLUME TO DISPENSE. USED IN CONJUNCTION WITH THE NEXT, ‘+’, ‘-’, AND ENTER BUTTON TO SET A PRESET VALUE. THE SAME PROCEDURE WILL FOLLOW FOR THE CURRENCY AND RATE MODES.

• NEXT – PRESS TO ENTER THE VALUE FIELDS – TASK OR FUNCTION. IT IS USED ALSO TO MOVE TO THE NEXT LESSER DIGIT OR NEXT LETTER IN AN ENTRY TO A VALUE FIELD. AT THE LEAST SIGNIFICANT DIGIT IT WILL WRAP TO THE MOST SIGNIFICANT DIGIT.

• ENTER – PRESS TO ACCEPT A SELECTION, PRICE CODE OR DATA ENTRY.

•+ - PLUS BUTTON WHICH YOU PRESS TO INCREMENT THROUGH NUMERIC CHARACTERS 0 TO 9, ALPHA CHARACTERS Z TO A, AND SPECIAL CHARACTERS FOR EACH POSITION IN A SELECTED DISPLAY.

• - - MINUS BUTTON WHICH YOU PRESS TO DECREMENT THROUGH NUMERIC CHARACTERS 9 TO 0, ALPHA CHARACTERS A TO Z, AND SPECIAL CHARACTERS FOR EACH POSITION IN A SELECTED DISPLAY.

SYSTEM OPERATING STATES

• PRE-DISPENSE STATE: PRIOR TO PRESSING THE START BUTTON, THE SYSTEM IS IN THE

PRE-DISPENSE STATE. THE SETTING OF SYSTEM PARAMETERS PRICING, PRESET VOLUME, FOR A DELIVERY ARE MADE IN THIS STATE.

• DISPENSE STATE:

AFTER PRESSING THE START BUTTON , THE SYSTEM ENTERS THE DISPENSE STATE.

• FINISH STATE:

AFTER PRESSING THE FINISH BUTTON, THE SYSTEM IS IN THE FINISH STATE.

SYSTEM OPERATING MODES• VOLUME MODE:

THE DISPLAY WILL DEFAULT TO THE VOLUME MODE WHEN THE DISPLAY HEAD IS FIRST INITIALIZED. IN THE PRE-DISPENSE OR DISPENSE STATE THE DISPLAY WILL INTIATE WITH VOLUME DISPLAYED IN THE NUMERIC FIELDS. UNLESS THE MODE BUTTON IS PRESSED THE DISPLAY WILL REMIAN IN THE VOLUME MODE ONLY.

• CURRENCY MODE:

THE DISPLAY MAY BE CONFIGURED IN THE SETUP MODE TO DEFAULT TO THE CURRENCY DISPLAY. IN THE PRE-DISPENSE OR DISPENSE STATE THE DISPLAY WILL INTIATE WITH CURRENCY DISPLAYED IN THE NUMERIC FIELDS .

• RATE MODE:

THE DISPLAY MAY SHOW FLOW RATE BY DEPRESSING THE MODE BUTTON WHEN THE OPERATOR IS ABLE TO DELIVER PRODUCT. THE OPERATOR CAN’T ACCESS RATE MODE UNLESS THE START BUTTON INITIATING THE DISPENSE STATE.

• SETUP MODE:

THE USER CAN ACCESS THE SETUP MODE BEFORE A DELIVERY TO CHANGE A VARIETY OF PARAMETERS THAT ARE NOT REQUIRED TO BE UNDER WEIGHTS & MEASURE SEAL, LIKE SYSTEM ADDRESS, DATE AND TIME EDITING, VERSION NUMBER. ONCE THE DISPENSE STATE IS STARTED THE SETUP MODE CANNOT BE ACCESSED.

• CALIBRATION AND CONFIGURATION MODE:

I HAVE ALREADY SAID IN THE WIRING DIAGRAM OF DISPLAY HEAD C&C MODE WILL BE ENABLED AFTER REMOVING THE C&C MODE SWITCH. C&C MODE IS USED TO SET UP VARIOUS CALIBRATION AND CONFIGURATION PARAMETERS. ALL C&C MODE PARAMETERS CAN BE VIEWED BY THE USER IN THE SETUP MODE, BUT NO CHANGES ARE ALLOWED.

SETUP MODE THE NON-METROLOGICALLY CONTROLLED SETUP MODE CATEGORIES FOR THE EMR3

SYSTEM ARE: • ENTER SECURITY CODE:

o ENABLES USER LOG IN/OUT PROCEDURE.o THIS PROMPT WILL NOT DISPLAY ON INITIAL POWER-UP OF THE DISPLAY HEAD. o IF YOU HAVE ENABLED SECURITY CODE IN THE C&C MODE, THIS WILL BE THE FIRST

CATEGORY TO DISPLAY ON ENTERING SETUP MODE.

• PRICING:

o SETS UP TO 15 DIFFERENT TAX/DISCOUNT CODE ASSIGNMENTS.

• TAX/DISCOUNT:

o SETS UP TO 15 DIFFERENT PRICE CODES WITH TAX/DISCOUNT (T/D/S) CODES WITH UP TO 6 DIFFERENT T/D MODIFIERS PER CODE.

• DEFAULTS:

o LETS YOU SET THE MODE YOU WANT THE DISPLAY HEAD TO ENTER WHEN BEGINNING PRE-DISPENSE AND DISPENSE OPERTATIONS; AND LETS YOU ENABLE/DISABLE VOLUME AND CURRENCY MODE PRESETS.

• RELAY CONTROL:

o SETS THE SHUT OFF POINTS FOR FLOE CONTROL RELAY 1 AND 2 FOR PRESET DELIVERIES.

• SECURITY:

o SETS THE USER PASSCODES AND USER ACCESS TO CERTAIN SETUP MODE CATOGORIES. (THIS SETUP ONLY DISPLAYS AFTER ENABLING SECURITY CODE IN THE C&C MODE)

• PRINTER OPTION :

o SETS OPTIONAL PRINTER TYPE AND DISTANCE FROM TOP OF TICKET TO FIRST PRINTED LINE.

• VIEW RECORDS:

o LETS YOU SELECT TO EITHER VIEW OR PRINT THE LAST 20 TRANSACTION RECORDS.

• RESTORE RECORDS:

o ALLOWS THE USER TO SELECT RESTORE (DOWNLOAD FROM IB TO DISPLAY HEAD) UP TO 20 TRANSACTION RECORDS.

• SHIFT:

o SETS UP SHIFT START/END ODOMETER READINGS AND TANK LOADINGS. ALSO WITHIN SHIFT SETUP, YOU CAN PRINTOUT SHIFT REPORTS.

• DATE FORMAT:

o SETS THE FORMAT OF YEAR, MONTH, AND DATE FOR USE IN DISPLAY AND PRINTOUTS

• TIME/DATE:

o LETS YOU ENTER THE CURRENT DATE AND TIME.

• SYSTEM ADDRESS:

o SETS THE ADDRESSING AND CONFIGURATION OF THE INDIVIDUAL EMR3 COMPONENTS AND THEIR INPUTS FROM, AND OUTPUTS TO, THE SYSTEM.

• TIME DELAYS:

o SETS THE DISPLAY AFTER WHICH THE DISPLAY WILL GO BLANK IF THERE IS NO ACTIVITY.

• VERSION NUMBER:

o LETS YOU VIEW THE SYSTEM DEVICE VERSION NUMBERS.

• C&C:

o LETS YOU STEP THROUGH AND VIEW, BUT NOT CHANGE, THE C&C MODE SETUPS.

CALIBRATION & CONFIGURATION (C&C MODE)

• LANGUAGE:

o SETS THE VOLUME, CURRENCY, SETUP, AND PRINTER LABEL DESCRIPTIONS.

• DISPLAY SYNTAX:

o SETS THE PUNCTUATION AND DECIMAL PLACES FOR DATA DISPLAYES IN THE PRESET, REGISTER, AND TOTALIZER FIELDS.

• FUEL SOURCE:

o SETS THE METER ID, METER INPUT SIGNAL TYPE, AND PRODUCT DESCRIPTIONS.

• METER CALIBRATION:

o SETS THE CALIBRATION OF THE METER BY PRODUCT USING ONE OF THREE METHODS

• CONFIGURE INPUT/OUTPUT:

o ENABLE VARIOUS INPUTS/OUTPUT SUCH AS EMERGENCY STOP AND REMOTE START & STOP OUTPUT.

• OEM MESSAGE:

o LETS YOU ENTER THE START UP OEM MESSAGE.

• DELIVERY OPTIONS:

o THIS OPTION LETS YOU TO ENABLE OR DISABLE PRICE CHANGING WITHIN THE DELIVERY STATE AS PER YOUR REGULATORY REQUIREMENTS. IN THIS SETUP YOU ALSO SELECT COEFFICIENT OF EXPANSION OR DENSITY AS THE TEMPERATURE COMPENSATION METHOD FOR DELIVERIES, ENABLE DELIVERY TIMEOUT, ENABLE TANK ID, ENABLE CUSTOM FIELDS, ENABLE TANK LOAD AND ENABLE E04 ENCODER ERROR.

• REPORT FORMATS:

o LETS YOU PRINT OR COMPOSE FORMATS FOR THE DELIVERY TICKET AND SHIFT REPORTS.

• RESTART:

o ALLOWS YOU TO REBOOT WHILE MAINTAINING CURRENT SETUPS, OR TO REBOOT AND RESET ALL SETUP SELECTIONS TO FACTORY DEFAULT SETTING AS WELL AS REMOVING ALL CURRENT TRANSACTION RECORDS.

• SECURITY CODE:

o ALLOWS YOU TO ENABLE SECURITY CODE PROTECTION TO LIMIT ACCESS TO SELECTED SETUP MODE.

METER CALIBRATION• FROM THE ABOVE ALL CALIBRATION & CONFIGURATION MODES METER

CALIBRATION MODE IS THE ONLY MODE WHICH INVOLVES ABOUT CALIBRATION DETAILS FOR A PARTICULAR METER AND ALSO FOR A PARTICULAR PRODUCT.

• AFTER ENBLING THE C&C MODE, BY USING KEYPAD PROVIDED IN THE DISPLAY HEAD, ENTER IN TO THE C&C MODE.

• THEN ENTER IN TO THE METER CALIBRATION MODE.

• IN EMR3 THIS IS POSSIBLE TO CALIBRATE AND SAVE THE CALIBRATION DETAILS FOR FOUR TYPE OF PRODUCTS.

• AFTER FINISHING THE CALIBRATION WE CAN ABLE TO SELECT THE PRODUCT (CALIBRATION DETAILS OF A PARTICULAR PRODUT) WHICHEVER WE REQUIRE IN THE NORMAL MODE.

• IN EMR3, METER CALIBRATION WILL BE DONE IN THE FOLLOWING THREE WAYS.

1. AUTO CALIBRATION2. MULTI CALIBRATION3. MANUAL CALIBRATION

• FROM THE ABOVE THREE WAYS WE CAN USE ANY ONE TYPE OF CALIBRATION MODE TO DO THE METER CALIBRATION.

AUTO CALIBRATION

• IF THE CUSTOMER IS DECIDED TO DISPENSE A PARTICULAR PRODUCT IN A SINGLE FLOWRATE ONLY ITS APPLICABLE TO CALIBRATE BY THIS WAY.

• THIS IS ALSO CALLED AS A SINGLE POINT CALIBRATION.

• IN THIS METHOD JUST ENTER IN TO THE AUTO CALIBRATE MODE AND ENTER START DISPENSE AND COLLECT THE DELIVERED FLUID IN A PROVING CAN.

• THEN PRESS FINSH BUTTON WHEN YOU HAVE DISPENSED A CALIBRATED AMOUNT .

• AFTER PRESSING THE FINSH BUTTON EMR3 WILL ASK TO ENTER THE COLLECTED VOLUME IN THE PROVING CAN.

• ENTER THE COLLECTED VOLUME IN THE PROVING CAN BY USING THE KEYPAD BUTTONS +, -, NEXT. THEN PRESS ENTER BUTTON UNTIL YOU RETURN TO METER CALIBRATION MODE.

• EMR3 WILL AUTOMATICALLY CALCULATE THE COUNTS/VOLUME VALUE AND TAKE IT AS A CALIBRTAION RATE FACTOR.

ESTIMATING CALIBRATION FACTOR AND FLOW RATE

• BY DEFAULT ENCODER COUNTS /VOLUME IN EMR3 IS 96 COUNTS/VOLUME & FLOW RATE IS 60 VOLUME/MINUTE.

• EMR3 WILL CALCULATE THE TIME TAKEN DURING THE PERIOD OF AUTO CALIBRATION.

DEFAULT COUNTS/LITRE = 96COUNTS/LITRE

QUANTITY OF VOLUME SHOWN AFTER = 130 LITRE DISPENSING IN EMR3

PROVING CAN VOLUME = 3132.61 LITRE

CALIBRATION FACTOR = (96*130)/3132.61 = 3.983898

NEW COUNTS/LITRE = 3.983898 COUNTS/LITRE

TIME TAKEN DURING DISPENSING = 2 MINUTES 15 SECONDS = 2.25 MINUTES

FLOW RATE = PROVING CAN VOLUME/TIME TAKEN = 3132.61/2.25 LITRE/MINUTE

NEW FLOW RATE = 1392.2711 LITRE/MINUTE

NON LINEAR CALIBRATION

• EVERY RANGE OF FLOWRATE HAVING ITS OWN CALIBRATION FACTOR DUE TO LOSES WITH RESPECT TO VELOCITY OF FLUID.

• BY DOING THE CALIBRATION WITH DIFFERENT RANGES OF FLOW RATES CORRESPONDS TO THE PARTICULAR CALIBRATION FACTOR IS CALLED NON LINEAR CALIBRATION.

• FOR THE PURPOSE OF BATCHING ACCURACY AND PREVENTING THE BACK PRESSURE, WE ARE USING EVERY FLOW MEASURING DEVICE IN DIFFERENT RANGES OF FLOW RATES BY ADJUSTING THE VALVE OPENING OF CHECK VALVE.

• IF THE DISCHARGE OR FLOW RATE IS VARYING MEANS CORRESPONDINGLY THE ACCURACY OF THE FLOW MEASURING DEVICE ALSO GETS VARYING.

OVAL WHEEL FLOW MEASURING DEVICE:

• IN OUR OVAL WHEEL FLOW METER ALSO ACCURACY OF THE METER IS VARYING WHILE DISCHARGE IS VARYING.

• ACCORDING TO OUR OVAL WHEEL PRINCIPLE WHEN THE VISCOSITY OF A FLUID IS INCREASING THE ACCURACY ALSO GETS INCREASING.

PRINCIPLE OF MEASURING IN OVAL WHEEL FLOW MEASURING DEVICE

• THE SPACE BETWEEN THE MEASURING CHAMBER AND MINOR DIA OF OVAL WHEEL ONLY THE MEASURABLE LIQUID FOR EACH REVOLUTION BY OUR OVAL WHEEL PRINCIPLE OF MEASURING.

• FOR EACH REVOLUTION ITS DISCHARGING STANDARD AMOUNT OF FLUID.

PERFORMANCE CURVE FOR OVAL WHEEL FLOW

MEASURING DEVICES

IF THE DISCHARGE OR FLOW RATE IS VARYING WHY THE

ACCURACY ALSO GETS VARYING?

• FROM THE PERFORMANCE CURVE OF OVAL WHEEL FLOW MEASURING DEVICE, WE KNOW THAT FROM FLOW RATE RANGE 20% TO 70% WE ARE GETTING GOOD LINEAR ACCURACY.

• IN LOW FLOW RATE OR DISCHARGE (1-20%) ACCURACY VARIATION IS VERY HIGH AND ALSO IN NEGATIVE. BECAUSE OF CONTINUOUSLY FLUID IS ESCAPING BETWEEN THE MAJOR DIA OF OVAL WHEEL AND MEASURING CHAMBER.

• DUE TO THAT MORE FLUID IS ESCAPING WITHOUT MEASURING, SO THAT THE PERFORMANCE CURVE IS GETTING NEGATIVE ERROR CURVE.

• IN HIGH FLOW RATE OR DISCHARGE (71% TO 100%) ACCURACY ALSO GETS VARYING. THIS HAPPENS DUE TO SLIPPAGE OF FLUID BETWEEN THE PIPE INTERNAL CIRCUMFERENTIAL SURFACE AND FLUID FLOW.

• SLIPPAGE HAPPENS DUE TO HYDROPHOBIC EFFECT AND VISCOUS FORCE IN PIPE WALL.

HYDROPHOBIC EFFECT

• WE ARE ALL KNOW THAT AFTER RAIN, WATER DROPLETS PRESENT IN THE TREE LEAF IS IN THE FORM OF GAS BUBBLES SURROUNDED BY A LIQUID LAYER.

• FROM THE PREVIOUS EXAMPLE, THE LEAF SURFACE IS CALLED HYDRPHOBIC SURFACE AND THE WATER IS CALLED HYDROPHILLIC LIQUID.

• WHEN HYDROPHPHILIC LIQUID FLOWS THROUGH HYDROPHOBIC SURFACE OR HYDROPHOBIC LIQUID FLOWS THROUGH HYDROPHILIC SURFACE, THE FIRST LAYER OF LIQUID GETS DEPLETED AND FORMS A GAS BUBBLE ON THAT FIRST LAYER. THE ABOVE EFFECT IS CALLED HYDROPHOBIC EFFECT.

• MOST OF THE HYDROCARBON FLUIDS ARE HYDROPHOBIC FLUIDS, WHAT OUR CUSTOMERS ARE USING.

• MOST OF THE PIPE MATERIALS ARE HAVING HYDROPHILLIC SURFACE .

• WHEN HYDROCARBON FLUIDS OR HYDROPHOBIC FLUIDS ARE FLOWING IN A HYDRPHILIC WALL IT WILL FORM A DEPLETED GAS BUBBLES ON THE FIRST LAYER OF FLUID.

• THE ABOVE FIRST LAYER OF GAS BUBBLES HAVE A THICKNESS IN NANO METER.

EXPLANATION OF SLIPPAGE • WE KNOW THAT VISCOSITY(FLUID FRICTION) PRESENT IN THE FLUID IS PEAK AT THE

PIPE INTERNAL CIRCUMFERENTIAL SURFACE.

• THERE ARE TWO POSSIBILITIES OF VISCOSITY (FLUID FRICTION) FORMATION IN FLUID.

1. SHEAR STRESS OR FRICTION BETWEEN THE FLUID AND PIPE INTERNAL CIRCUMFERENTIAL SURFACE.

2. FRICTION(VISCOUS SHEAR STRESS) BETWEEN EACH AND EVERY FLUID MOLECULES SHEAR WITH ONE ANOTHER.

• SLIPPAGE OF FLUID HAPPENS DUE TO SHEAR STRESS BETWEEN THE FLUID PARTICLE AND INTERNAL CIRCUMFERENTIAL SURFACE OF PIPE LINE AND HYDROPHOBIC EFFECT.

• DUE TO HIGH SHEAR STRESS OR FRICTION BETWEEN THE HYDROPHILIC SURFACE AND HYDROPHOBIC FLUID, THE FIRST LAYER OF FLUID GETS DEPLETED AND FORM A GAS BUBBLES ON THAT FIRST LAYER.

• DUE TO THE ABOVE GAS BUBBLES FORMATION OF FIRST LAYER WITHOUT FLUID, OUR INSTRUMENT IS MEASURING THE ABOVE FIRST LAYER ALSO.

• WE KNOW THAT WHEN FLOW RATE OR DISCHARGE IS INCREASING THE SHEAR STRESS BETWEEN THE FLUID AND PIPE INTERNAL SURFACE ALSO GETS INCREASING, RESULTS TO INCREASE THE THICKNESS OF FIRAST LAYER GAS FORMATION AND FINALLY INCREASE THE SLIPPAGE AMOUNT.

• SO, WE CONCLUDE THAT WHILE FLOW RATE IS VARYING CORRESPONDINGLY THE ACCURACY OF FLOW MEASURING DEVICE ALSO GETS VARYING.

• IF THE FLOW MEASURING DEVICE IS TELLS WRONG , EMR3 IS ABLE TO CORRECT IT AND DISPENSE THE EXACT BATCHING QUANTITY IN DIFFERENT FLOW RATES.

• THERE ARE TWO PARAMETERS INVOLVED TO OVERCOME THE FLOW MEASURING DEVICE ERROR IN DIFFERERNT FLOW RATES.

1. CALIBRATION FACTOR.(ENCODER COUNTS/VOLUME)2. VARIOUS RANGES OF FLOW RATE.

• DUE TO SLIPPAGE AND FLUID ESCAPING WE ARE GETTING ERROR IN THE DELIVERED QUANTITY WITH DISPLAYED QUANTITY FOR DIFFERENT FLOW RATE RANGE.

• SO, FOR DIFFERENT RANGES OF FLOW RATE, WE HAVE TO GIVE THE CORRESPONDING CALIBRATION FACTOR FOR THE PARTICULAR FLOW RATE.

• IN EMR3 , THIS IS POSSIBLE TO MEASURE THE FLUID IN EIGHT DIFFERENT FLOW RATES ACCURATELY.

MULTI CALIBRATION (EIGHT POINT LINEARIZATION)

• MULTI CALIBRATION IS SIMILAR TO AUTO CALIBRATION.

• IN AUTO CALIBRATION WE HAVE DONE THE CALIBRATION FOR SINGLE FLOW RATE, WHRE AS HERE WE WILL HAVE TO DO THE CALIBRATION FOR EIGHT DIFFERENT FLOW RATES FOR OVER COME THE ERROR FROM FLOW MEASURING DEVICE.

• BY ADJUSTING THE NOZZLE OPENING PROVIDED IN CHECK VALVE, WE ARE ABLE TO VARY THE FLOW RATE RANGE.

• DO THE AUTO CALIBRATION PROCEDURE FOR EIGHT MAIN RANGE OF FLOW RATES.

COMPARISON OF % OF ERROR WITH EMR3 AND SOME OTHER

COUNTER

FLOW RATE

IN LPM

150 300 600 950 1000 1250 1500

ERROR IN % WITH EMR3

-0.12

-0.00

+ 0.00

+ 0.00

+ 0.01

+ 0.02

+ 0.02

FLOW RATE

IN LPM

200 500 900 1200

ERROR IN % WITH SOME OTHER COUNTER

- 0.01

+ 0.08

-0.02

- 0.05

MANUAL CALIBRATION

• IN MANUAL CALIBRATION PROCEDURE WE NEED A METER ERROR CHART

• BUT THIS IS MUST TO DO ONE AUTO CALIBRATION PROCEDURER FOR THIS CALIBRATION METHOD.

• BEFORE MANUAL CALIBRATION DO THE AUTO CALIBRATION PROCEDURE FOR MIDDLE FLOW RATE 950LPM, AND GET THE ENCODER COUNTS /VOLUME.

METER ERROR CHART FOR A PARTICULAR OVAL WHEEL METER:

FLOW RATE IN LPM

ERROR ERROR IN %

300 -0.00001 -0.001

600 0.00002 0.002

950 0.00002 0.002

1250 0.00024 0.024

1500 0.00018 0.018

CALCULATION OF ENCODER COUNTS/VOLUME

ENCODER COUNTS/VOLUM FOR 950 LPM IN AUTO CALIBRATION = 3.988644 ENCODER COUNTS/LITRE

BY USING THE ERROR TABLE WE CAN CALCULATE THE ENCODER COUNTS/VOLUME FOR OTHER FLOW RATES.

1500LPM: 3.988644 * [1 + (-0.00018-0.00024)] = 3.9869691250LPM: 3.988644 * [1 + (-0.00018)] = 3.987926

600 LPM: 3.988644 * [1 + (+0.00002)] = 3.988724 300 LPM: 3.988644 * [1 + (+0.00002+(-0.00001))] = 3.988684

• AFTER FINDING THE CALIBRATION RATES FOR OTHER FLOW RATES WE NEED TO ENTER THE CALIBRATION FACTOR WITH THE CORRESPONDING FLOE RATES IN MANUAL CALIBRATION MODE.

• USING THE MANUAL CALIBRATION METHOD THE DIFFERENCE IN ADJACENT ENCODER COUNTS MUST BE LESS THAN 0.25%.

• IN OUR PREVIOUS CALIBRATION FACTOR CALCULATION, ALL ADJACENT ENCODER COUNTS ARE LESS THAN 0.25%. EVEN THE DIFFERENCE BETWEEN THE HIGH(3.988724) AND LOW(3.986969) CALIBRATION FACTOR IS LESS THAN 0.25%!

• IF THE DIFFERENCE BETWEEN ANY OF THE TWO ADJACENT CALIBRATION FACTOR IS GRAEATER THAN 0.25%, AGAIN WE WOULD HAVE TO USE A LOWER FLOW RATE FOR THE NEXT CALIBRATION POINT.

• DURING ENTERING THE CALIBRATION FACTOR IN MANUAL CALIBRATION MODE, IF THE DIFFERENCE BETWEEN ANY OF THE TWO ADJACENT CALIBRATION FACTOR IS GRAEATER THAN 0.25% EMR3 WILL SHOW CALIBRATION ERROR.

DELIVERY ERROR CODES

• E04 - ENCODER PULSE ERROR:

o THIS ERROR IS AN INDICATION THET AN ILLEGAL QUADRATURE STATE HAS OCCURRED.

o I HAVE ALREADY SAID IN THE QUADRATURE SECTION, THERE ARE FOUR ILLEGEL STATES POSSIBLE TO MAKE A ABOVE ERROR.

SYSTEM ERROR CODES

• E50 – IB COMM FAILURE:

o IF THE WIRING BETWEEN THE DISPLAY HEAD AND INTER CONNECTION BOX IS WRONG THE ERROR WILL OCCUR.

CALIBRATION ERROR CODES

• E65 – CALIBRATION ERROR:

o ALREADY EXPLAINED IN THE MANUAL CALIBRATION METHOD, ONE OF THE MULTI POINT CALIBRATION VALUES IS DIFFERENT BY 0.25% OF THE PREVIOUS VALUE.

o FOR EXAMPLE IF CALIBRATION POINT 1 IS 4.0 THAN CALIBRATION 2 MUST BE BETWEEN 3.75 AND 4.25 COUNTS.

ADVANTAGES OF EMR3 • THE MAIN ADVANTAGE OF EMR3 IS, SPECIALLY DESIGNED TO MEET THE

WEIGHTS AND MEASURES REQUIREMENTS.

• QUADRATURE TYPE PULSE ENCODER GIVES MORE PRECISION PULSE COUNTING, SO THAT THERE IS NO POSSIBLITY FOR PULSE MISSING.

• EIGHT POINT LINEARIZATION GIVES MORE PRECISE MEASUREMENT IN BATCHING APPLICATION.

• INTER CONNECTION BOX HAVE A RS 232 COMMUNICATION BETWEEN THE SYSTEM AND IB, SO WE CAN ABLE TO EDIT THE CALIBRATION AND CONFIGURATION PARAMETERS, SYSTEM OPERATING PARAMETERS AND SETUP MODE PARAMETERS BY UPLOADING TO AND DOWNLOADING FROM EMR3 .

• ONE DISPLAY HEAD IS CAPPABLE TO HANDLE FOUR DIFFERENT PRODUCTS.

• ONE INTER CONNECTION BOX IS ABLE TO OPERATE TWO DISPLAY HEADS, SO WE CAN ABLE TO OPERATE UPTO EIGHT DIFFERERNT PRODUCTS (4*2 DISPLAY HEADS) IN A SINGLE SYSTEM.

• AUTO CALIBRATION METHOD OF CALIBRATION IS EASY TO CALIBRATE A METER AND ALSO REDUCING THE TIME TAKEN FOR CALIBRATION.

• THERE IS NO NEED CALIBRATION CALCULATIONS ARE REQUIRED FOR AUTO CALIBRATION, EMR3 IS ITSELF ABLE T0 CALCULATE FLOW RATE AND CALIBRATION FACTOR.

• THIS IS POSSIBLE TO SAVE UPTO LAST 200 TRANSACTION FOR EVERY PRODUCT IN EMR3.

• THERE IS A POSSIBILITY TO GET TICKET PRINTOUT FOR EACH TRANSACTIONS WITH THE HELP PRINTER INTERFACE.

• THIS IS POSSIBLE TO GET TWO SCALED PULSE OUTPUTS .

• THERE TWO RELAY OUTPUTS PROVIDED FOR BATCHING APPLICATION

DISADVANTAGES OR LIMITATIONS OF EMR3

• EMR3 REQUIRES INPUT POWER SUPPLY OF 24 V DC AND 5 AMPS CURRENT, BUT THE USUAL 24 V DC POWER SUPPLY HAS 300 MILL AMPS ONLY. SO, WE HAVE TO SPECIALLY ORDER FOR 24 V DC 5 AMPS POWER SUPPLY REQUIREMENT.

• EMR3 WON’T WORK WITHOUT A RS 232 COMMUNICATION. SO, WE NEED TO CONNECT THE INTER CONNECTION BOX WITH EITHER PRINTER OR COMPUTER.

• THIS IS NOT POSSIBLE TO OPERATE THE DISPLAY HEAD WITHOUT AN IB BOX. SO, THE HANDLING AND SHIFTING FROM PLACE TO PLACE IS CREATING TROUBLE.

• MAXIMUM FREQUENCY OF THIS ENCODER IS 1000 Hz. SO, THIS IS NOT SUITABLE FOR HIGH FREQUENCY OR HIGH SPEED FLOW MEASURING DEVICE.

• THE MAXIMUM OPERATING TEMPERATURE OF EMR3 IS 70º. SO, THIS IS NOT SUITABLE FOR HIGH TEMPERATURE FLOW APPLICATIONS.

THANK YOU.