Rheonics Support

What is the purpose of this article?
This article provides guidelines on how the Rheonics SRV inline viscometer or SRD density meter can retrofit the Brookfield AST-100 inline viscometer showing different installation examples.

What products are involved?
SRV - Inline Viscosity Meter and SRD - Inline Density and Viscosity Meter

TABLE OF CONTENTS

Introduction to Rheonics Type-SR sensors

Retrofits

Brookfield AST-100

• Rheonics - Brookfield AST-100 Viscometer Probe Retrofit
• AST-101 EXP / Explosion-Proof Unit / NPT variant
• AST-100FTSY / Sanitary Unit / Tri-Clamp Connection
• Rheonics Advantage

Rheonics - Brookfield AST-100 Controller Retrofit

Introduction to Rheonics Type-SR sensors

The Rheonics Type-SR sensors (SRV and SRD) measure viscosity, density, and temperature in line for process control and monitoring. The SRV measures viscosity, while the SRD measures density and viscosity. Both sensors measure temperature with an inbuilt PT1000. 

The SRV and SRD sensors are factory calibrated and do not need re-calibration over their operational lifetime, however, verification capability is provided in the Rheonics Control Panel software (RCP) software that comes with the sensor to verify calibration periodically and updated if needed in the field.

Rheonics sensors technology is based on a balanced torsional resonator (BTR), which uses a resonator that vibrates torsionally and is connected to the outside world at a node. The patented BTR technology underlying Rheonics sensors has a significant advantage over competitors in the market since a balanced torsional resonator allows the Type-SR sensors to be compact, lightweight, and unaffected by external vibrations. 

Retrofits

At times users want to replace an existing viscometer or density meter from their processes due to malfunction, lack of spare parts or simply to try out Rheonics sensors and experience the balanced torsional resonator technology.

In these cases, the user has an existing installation location of the former sensor and wants to install the Rheonics SRV or SRD probes in the same location/port. Rheonics Type-SR sensors favor retrofit installations due to the modular design of the probe. Rheonics offers different probe variants such as flush, short, and long insertion sensors with all types of process connections while ensuring consistency of performance across all these variants. 

Rheonics SRV and SRD probe variants.

Various process connections are offered with the SRV and SRD sensors.

By varying the insertion length and process connection of the probes, the Rheonics Type-SR sensors can be ordered to retrofit almost all existing installations. Figure 1 shows the SRV-X1-34N (short threaded), SRV-X3 short probe with Tri-Clamp connection, and SRV-X5 long insertion with Tri-Clamp connection.

Rheonics favors open standards, such standards provide a way for customers to order an alternative sensor when they plan to replace Rheonics ones.

Brookfield AST-100

The Brookfield AST-100 unit is composed of two parts:

1. Process Viscometer designed for inline measurements of viscosity and temperature

2.  Controller to control the viscosity of a fluid inline by using a valve for dosing intervals [1]. The AST-100 viscometer can be used with or without the unit Controller.

The Brookfield AST-100 viscometer probe is in contact with the fluid, while the controller sends signals to a valve to add dosing fluids to keep the viscosity within the expected range. These two aspects, probe, and controller, should be considered when retrofitting it with the inline Rheonics SRV or SRD sensors.

Rheonics - Brookfield AST-100 Viscometer Probe Retrofit

The installation of the Brookfield AST-100 probe is in an elbow or tee-type mount as shown in Figures 2 and 4. The Rheonics sensor probes can also be mounted in this type of installation, making the retrofit very straightforward. However, it will be important to verify the dimensions of the tee or elbow to remove or keep minimum dead zones around the Rheonics SRV or SRD probes.

Rheonics offers accessories to simplify the installation and avoid dead zones in elbow installations. Review all Rheonics accessories here. Some Rheonics accessories relevant for the retrofit of the Brookfield AST-100 are:

• Rheonics FET-XXT: Flow elbow tee with Tri-Clamp connections, offered in sizes 1.5”, 2”, 3”, 4”, etc.

• Rheonics IFC-34N: Flow cell with 3/4” NPT connections.

To do a Rheonics Type-SR - Brookfield AST viscometer retrofit, the user should:

• Define the pipeline size 

• Define the connection type and size

• Send pictures and dimensions of the current sensor installed

• Send pictures of the pipe or tee section 

Next are some examples of retrofits of the Rheonics SRV - Brookfield AST viscometer.

AST-101 EXP / Explosion-Proof Unit / NPT variant

This unit installation uses NPT male threads of 1”, according to available information from Brookfield. The unit can also be certified for Explosion atmospheres.

To retrofit the AST-101 EXP with Rheonics sensors, the following can be used:

For Viscosity measurements: 

• Use the SRV-X1-34N in the IFC-34N-SRV flow cell, 3/4” NPT connections.

• Use the SRV-X5-AXXX-B1N25 in the IFC-1N25-1N0 flow cell, 1” NPT connections.

For Density measurements: 

• Use the SRD-X1-34N in the IFC-34N-SRD flow cell, 3/4” NPT connections.

• Use the SRD-X5-AXXX-B1N25 in the IFC-1N25-1N0 flow cell, 1” NPT connections.

A direct retrofit of the Brookfield AST-101 EXP would require the use of the 1” NPT Rheonics flow cell mentioned above. Despite this if reducing the line size from 1” to 3/4” is possible, then users may find the 3/4” cell a better option due to the lower price and standard probe design used.

Rheonics sensors can be ordered with Ex Certifications. Learn more here.

AST-100FTSY / Sanitary Unit / Tri-Clamp Connection

This unit has a Tri-Clamp connection and is mounted in a Tri-Clamp tee section. According to available information from Brookfield, the tee dimension is 2,5” and the outlet is 2”, but sizes can vary. 

To retrofit the AST-100FTSY with Rheonics sensors, the following information is needed:

Share with Rheonics the dimensions of the Tee Section (total length, ID, TC size, and distance to outlet center). With this information, Rheonics can confirm if the SRV or SRD can be mounted in the existing Tee section, which would simplify the new installation.

If the existing Tee section can’t be reused, the next options can be considered:

For Viscosity measurements: 

• Use an SRV-X3-XXT mounted in a FET-XXT-XXT, where XX is the size of the Tri-Clamp connection.

• Use an SRV-X5-AYYY-BXXT mounted in a FET-XXT-XXT, where XX is the size of the Tri-Clamp connection, and YYY is the insertion length. This option is useful for high-viscosity fluids, or fluids prone to create deposits or sedimentation near the TC port.

For Density and Viscosity measurements: 

• Use an SRD-X3-XXT mounted in a FET-XXT-XXT, where XX is the size of the Tri-Clamp connection.

• Use an SRD-X5-AYYY-BXXT mounted in a FET-XXT-XXT, where XX is the size of the Tri-Clamp connection, and YYY is the insertion length. This option is useful for high-viscosity fluids, or fluids prone to create deposits or sedimentation near the TC port.

Rheonics sensors can be ordered with Hygienic Certifications 3-A and EHEDG. Learn more here.

Rheonics Advantage

Rheonics Type-SR sensor probes offer advantages over competitors due to the following reasons:

• Smallest and compact probes with simple and different installation options

• Streamline hygienic probe design allows easy cleaning and no places for solids or deposits to attach.

• Customizable probe length allows deeper insertion in the line when needed. The sensing element can then be exposed to better flow in line, avoiding dead zones, plugging, and deposits. This is useful for fluids that can create deposits or stagnant areas near the installation port, like slurries (lime, battery, etc.).

• Sensor electronics allows the use of calculation models for kinematic viscosity, concentrations, temperature-compensated viscosity and density, etc.

Rheonics - Brookfield AST-100 Controller Retrofit

The controller used by the Brookfield AST viscometer takes the viscosity reading and is capable of sending a signal to an external valve for the addition of solvents or additives to maintain the viscosity within the expected range.

The same is possible with Rheonics viscosity and density sensors. Integrating the sensors with an existing controller is easy thanks to the multiple Industrial Communication Protocols offered by Rheonics (Modbus, Profinet, Ethernet/IP, HART, etc.) and the Rheonics support articles on this topic.

If a control system is required, the next options are possible:

1. Standard controllers: These controllers use a PID or related control strategy and can be programmed using physical buttons, an example is next using a Yokogawa controller. These controllers can receive signals from the Rheonics SRV or SRD sensor and output a signal for the activation and deactivation of an external valve.

Figure 7: PID Controllers

2. PLC Controllers: Programmable Logic Controllers include different control methods as well as multiple input and output signals. If the client has an existing PLC unit, the Rheonics SRV or SRD sensor’s signals can be sent to the PLC via an Industrial Communication Protocol to read real-time values of the fluid and take action as needed. Review all Industrial Communication Protocols here: Electronics and Communication

3. Rheonics RPS System: Rheonics also offers an Integrated System, RPS, that enables the control of viscosity and/or density based on the Type-SR sensors. Contact Rheonics for more information.
   
   

References

[1]: AST-100 Viscosity Controller - Brookfield