Manifold Times gained exclusive access into the mass flowmeter (MFM) production factory of Reinach-based Endress+Hauser Flow in Switzerland during February. This will be the first in a series of five articles produced offering behind-the-scenes glimpses of the intricate process on what goes into perfecting MFMs.

The following are key takeaways from the tour to understand more about MFM design and production:

Singapore’s bunkering sector, under the purview of the Maritime and Port Authority of Singapore (MPA), has depended on mass flowmeters (MFMs) to create a level playing field for marine refuelling operations since its gradual implementation from 2012.

By the end of 2023, approximately more than 340 million metric tonnes (mt) of bunker fuel would have flowed through MFMs installed onboard Singapore bunker tankers.

Arguably, the enhanced transparency and integrity brought by MFM technology have cemented Singapore’s position as the premier bunkering port of the world.

This development has led Manifold Times to Reinach, Switzerland to learn more about MFM technology manufactured by Endress+Hauser Flow – the dominate MFM vendor chosen by Singapore’s bunkering sector.

A physicist by training, Martin Anklin, Head of Department Coriolis Sensors, Endress+Hauser Flow, who has been working for the company for over 20 years welcomed the Singapore bunkering publication at its Reinach factory. He believes people to be the foundation behind every quality Swiss product produced by the company.

“I'm deeply convinced that when you want to get to the bottom of what's doable with the Coriolis measuring principle, you need good and motivated people with a lot of experience.” he said.

Research & Development – The ‘bend’ of bunkering MFMs

Anklin shared MFMs used for bunkering, such as the Proline Promass F Coriolis flowmeter widely installed on Singapore bunker tankers, starts with the product idea driven by market demand.

It has taken several years of predevelopment and industrialisation while taking into consideration factors such as measurement uncertainty, environmental conditions, required flow rate, application conditions, industry standards and safety.

It is highly important for bunkering MFMs to use Coriolis technology as it is less affected by aeration compared to other measuring technologies while offering long-term stability when compared to mechanical meters.

A challenge faced by MFM designers is balancing the amount of bend and number of oscillating flow tubes to introduce within the device.

“Generally speaking, multi-tube measuring systems lead to a better balanced MFM compared to single tube MFM. This results in higher repeatability and zero-point stability. A single-tube design would not deliver the repeatability and zero-point stability required for the variety of fuel oils,” Anklin explained.

“The more bent, the more Coriolis force is available for the measurement. However, large bends tend to trap air which results in bad measuring performance. Further, the more bent the bulkier the MFM becomes, which takes up more space onboard a bunker tanker while introducing additional costs for piping.

“With the Promass F we have found a compact solution which has a slight bend while having two oscillating flow tubes for precision. This makes it a very well balanced MFM having a compact footprint.”

In-house Swiss quality checks – Testing rigs galore

Manifold Times was next taken to the basement of the Reinach production plant and was surprised to find approximately 100 hardware testing rigs specially designed for abusing MFM protypes in the location.

“We do have numerous rigs to do qualification, where we really aim to rigorously test the meters before they are put out into the market,” revealed Anklin.

Prototypes are pressure tested to the stage of deformity to see how long performance is maintained during operation even far beyond specs. Engineers also test units for temperature shock, saltwater resistance, vibration, humidity, and more.

“Bunkering presents a challenging application for MFMs. Equipment which is installed on bunker tankers are exposed to high humidity, aggressive salty atmosphere, and vibration. Safety is a key aspect on bunker tankers. Therefore, the mechanical integrity of a MFM plays a major role,” he says.

“The MFM is designed and tested according to marine class standards to confirm its suitability for this harsh environment. Performance of the custody flowmeter must be good and installation effects must be diminished close to zero.”

Verifying the in-house MFM bunkering algorithm

Anklin highlighted bunkering as being known for its challenge of dealing with aerated fuel oil. As such, Endress+Hauser Flow has developed an intelligent algorithm which measures aerated fuel with custody transfer accuracy.

“It was a challenge developing bunkering algorithms being able to produce repeatable results based on the theory and physics behind aerated conditions with actual real-world conditions. This was also the reason why Endress+Hauser cooperated with a bunker tanker operator at Singapore port to test out the algorithm prior to commercial deployment,” he shared.

“We had to test the algorithm on all sides which includes field tests on the bunker tanker to see how the meter with the algorithm performs in various situations.

“And this also means much cooperation and communication, since the people conducting the measurement on the land are not the same as the people doing the testing on the waterfront. Further, both are not the same as the people that do the physics and analytical calculations.

“It is essential for the group to develop an excellent cooperation and build up upon the knowledge create a fully working product for the bunkering sector.”

Photo credit: Endress+Hauser
Published: 15 July 2024