Brookfield TT100 Manual

BROOKFIELD MODEL TT100
IN-LINE VISCOMETER
Installation, Operation, and Maintenance Instructions
Manual No. M/97-520-A899
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Brookfield Engineering Laboratories, Incorporated, cannot accept any financial or other
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Brookfield Engineering Laboratories, Incorporated
Process Viscometer Division
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Copyright© 1999 Brookfield Engineering Laboratories, Incorporated Printed in U.S.A.

TT-100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
P/N M/97-520 vi
Table of Contents
Section 1 - In-Line Viscometer Description
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Correlation with Other Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Required Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Current Draw - Starting & Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Torque Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Sensing Endcap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Stop Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Inlet/Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Drive Endcap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Drive Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Bleed Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Measuring Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Measuring Annulus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Sensing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Torsion Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Heat Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Torque Sensor Electronics Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Motor Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Double Mechanical Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Elliptical Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Perforated Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Serrated Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Flushing Endcap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

In-Line Viscometer Description
vii P/N M/97-520
Table of Contents (continued)
Section 2 - Installation
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Calculating Minimum Straight Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Flushing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Section 3 - Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Fine Zero Milliampere Calibration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Preliminary Torque Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Single Range Viscometer Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Dual Range Viscometer Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Coarse Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Fine Zero Voltage Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Section 4 - Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Mechanical Seal Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Normal Operation Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Section 5 - Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Clean-In-Place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Disassembly and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the Sensing Endcap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the Drive Endcap Assembly and Measuring Chamber . . . . . . . . . . . 5-7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Elliptical Baffle Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

TT-100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
P/N M/97-520 viii
Table of Contents (continued)
Section 6 - Service
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Sensing Endcap Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Microsyn Field Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Torque Sensor Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . 6-9
Torsion Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Sensing Endcap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Drive Endcap Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Motor and Gearbox Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Capacitor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Oriental Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Oriental Motor Gearbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Groschopp Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Groschopp Motor Gearbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Drive Endcap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Double Mechanical Seal Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . 6-28
Section 7 - Troubleshooting
Appendix A - Customer Support
Appendix B - Drawings
Appendix C - Viscosity Range Change
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Changing Range or Shear Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Speed of Rotation Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Stator Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Torsion Element Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Electronic Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

In-Line Viscometer Description
ix P/N M/97-520
Table of Contents (continued)
Appendix D - Agency Approvals
Appendix E - Warranty Information
Glossary
Index
Figures
Figure 1-1: Typical TT100 In-Line Viscometer with Oriental Motor . . . . . . . . 1-3
Figure 1-2: Typical TT100 In-Line Viscometer with Groschopp Motor . . . . . 1-4
Figure 1-3: TT100 In-Line Viscometer Product Stream Flow . . . . . . . . . . . . . 1-5
Figure 1-4: In-Line Viscometer Correlation with Other Measurement
Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-5: Typical Model TT100 In-Line Viscometer Component
Identification (NEMA 4 Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Figure 2-1: Typical In-Line Viscometer Installation . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-2:NEMA 4 - 115 or 230 VAC 50/60 Hz Installation . . . . . . . . . . . . . 2-5
Figure 2-3:NEMA 7 - Explosion Proof 115 VAC 50/60 Hz Installation . . . . . 2-6
Figure 2-4:CENELEC - 115 or 230 VAC 50/60 Hz Installation . . . . . . . . . . . . 2-7
Figure 3-1: Typical Installation Calibration Flowchart . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-2: Typical Calibration after Viscometer Disassembly and Cleaning . 3-4
Figure 3-3:Typical Calibration after Component Replacement . . . . . . . . . . . . 3-5
Figure 3-4:Torque Sensor Electronics Board Adjustment Component
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-5: Applying Torque to the Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-6: Calibration Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-7: Calibration Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-8: Microsyn Field Coil Assembly Rotation . . . . . . . . . . . . . . . . . . . 3-19
Figure 3-9: Stator Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

TT-100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
P/N M/97-520 x
Table of Contents (continued)
Figure 5-1: Typical Viscometer Disassembly for Cleaning . . . . . . . . . . . . . . . 5-4
Figure 5-2: Typical Stator Removal and Torsion Element Wire Cleaning . . . . 5-6
Figure 5-3: Stator Installation and Stop Post Centering . . . . . . . . . . . . . . . . . . 5-7
Figure 6-1: Sensing Endcap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Figure 6-2: Sensing Endcap Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Figure 6-3: Microsyn Field Coil Pin Identification . . . . . . . . . . . . . . . . . . . . . . 6-6
Figure 6-4: Removing the Armature Clamping Nut . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6-6: Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Figure 6-7: Torsion Element and Endcap Alignment . . . . . . . . . . . . . . . . . . . 6-14
Figure 6-8: Stator Installation and Stop Post Centering . . . . . . . . . . . . . . . . . 6-15
Figure 6-9: Motor Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Figure 6-10: Motor and Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Figure 6-11: Drive Endcap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Figure 6-12: Drive Endcap Disassembly (with Single Mechanical Seal) . . . . 6-22
Figure 6-13: Groschopp Motor and Gearbox Disassembly . . . . . . . . . . . . . . . 6-27
Figure 6-14: Drive Endcap Disassembly (with Double Mechanical Seal) . . . 6-31
Figure B-1:NEMA 4 Oriental Motor Wiring Diagram . . . . . . . . . . . . . . . . . . . B-1
Figure B-2:Groschopp Motor Wiring Diagram (Factory Mutual Housing) . . . B-2
Figure B-3:Torque Sensor Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Figure B-4:230 VAC Wiring Diagram for IP 55 Groschopp Motor . . . . . . . . . B-4
Figure B-5:CENELEC 115 VAC Groschopp Motor Wiring Diagram . . . . . . . B-5
Figure B-6:CENELEC 230 VAC Groschopp Motor Wiring Diagram . . . . . . . B-6
Figure B-7:TT100 In-Line Viscometer (NEMA 4 with Oriental Motor) . . . . . B-7
Figure B-8:TT100 Viscometer for Hazardous Areas (NEMA 7) . . . . . . . . . . . B-8
Figure B-9:TT100 Viscometer for Hazardous Areas (CENELEC) . . . . . . . . . . B-9
Figure B-10:TT100 In-Line Viscometer Double Mechanical
Seal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10

In-Line Viscometer Description
xi P/N M/97-520
Table of Contents (continued)
Tables
Table 1-1:Model TT100 In-Line Viscometer Specifications . . . . . . . . . . . . . . 1-7
Table 1-2:Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Table 3-1:Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Table 6-1:Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Table 7-1:Process Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Table 7-2:Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Table 7-3:Calibration Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Table 7-4:Correlation/Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Table C-1:Shear Rates and Factors for 2.440 ID Rotor . . . . . . . . . . . . . . . . . . . C-4
Table C-2:Shear Rates and Factors for 1.450 ID Rotor . . . . . . . . . . . . . . . . . . . C-4
Table D-1:Agency Approvals - TT100 In-Line Process Viscometer . . . . . . . . D-1

TT100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
P/N M/97-520 1-1
Section 1 - In-Line Viscometer Description
Introduction
The Brookfield Model TT100 In-Line Viscometer is a highly sensitive
versatile instrument that measures process fluid viscosity in a fully flooded
product stream under pressure or vacuum. Brookfield In-Line Viscometers
are unaffected by changes in pressure, laminar flow, or density.
The TT100 In-Line Viscometer generates a 4 - 20 milliampere (mA) or
0 - 10 Volts DC (VDC) signal proportional to process fluid viscosity. The
signal is stable, can be transmitted over long distances with minimal loss,
and is not affected by noise. Adjustable electronic damping maintains
signal quality under severe process conditions.
The TT100 In-Line Viscometer, shown in Figures 1-1 and 1-2, can be used
in a variety of industrial applications where the viscosity of chemical,
coating, fuel oil, and many other process fluids must be controlled or
monitored.
Features and Benefits
The TT100 In-Line Viscometer incorporates the following features:
• Easy start-up, operation, and cleaning
• Instantaneous response
• Optional selectable dual viscosity range
• Continuous linear output signal (4 - 20 mA) or (0 - 10 VDC)
• Coaxial cylinder measurement geometry for viscosity values at
defined shear rates
• Optional temperature compensation
The TT100 In-Line Viscometer provides the following benefits:
• Highly sensitive measuring system unaffected by changes in
pressure, laminar flow, or density.

In-Line Viscometer Description
1-2 P/N M/97-520
• Can be cleaned-in-place thereby minimizing downtime.
• Eliminates manual procedure for lab viscosity analysis. Provides
early detection of anomalous processing.
• Accurate and proven control - optimizes product consistency and
quality.
• Provides a permanent record for quality control when used with a
recorder or integrated computer system.
• Due to the unique design of the torsion element, pressure does not
affect its response.
• Operates continuously and instantly responds to changes in
viscosity.
• Minimal pressure drop.
• Linear output signal is proportional to viscosity and compatible
with most industrial process control equipment.
• Installs directly in-line or in a by-pass line.
• Optional features and accessories are available to enhance In-Line
Viscometer performance.

TT100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
P/N M/97-520 1-3
Figure 1-1: Typical TT100 In-Line Viscometer with Oriental Motor

In-Line Viscometer Description
1-4 P/N M/97-520
Figure 1-2: Typical TT100 In-Line Viscometer with Groschopp Motor
NEMA 7
CENELEC

TT100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
P/N M/97-520 1-5
Theory of Operation
The product stream flows through the inlet into the TT100 In-Line
Viscometer measuring chamber, as shown in Figure 1-3, where it pushes
against a cylinder or rotor driven by a drive motor. The rotation of the rotor
causes a gentle pumping action forcing the product to flow into the
measuring annulus between the rotor and the stator. The viscous drag of the
product on the stator is resisted by a torsion element which transmits an
angular deflection signal to a rotary transformer drive transducer. This
signal is processed through solid state torque sensor electronics in a remote
enclosure to produce a linear 4 - 20 mA signal proportional to the
viscometer’s viscosity range.
Measuring range and shear rate can be varied by changing rotational speed
(via gearbox or by speed control) or by changing the rotor and/or stator as
specified in Table D-1. Refer to Appendix D for more information on
changing geometrical components.
Figure 1-3: TT100 In-Line Viscometer Product Stream Flow
TORSION ELEMENT
STATOR
MEASURING ANNULUS
MEASURING CHAMBER
DRIVE MOTOR
ROTOR
INLET
OUTLET
PRODUCT
STREAM
PRODUCT
STREAM
DRIVE ENDCAP
OUTPUT SIGNAL
TO ENCLOSURE
GEARBOX

In-Line Viscometer Description
1-6 P/N M/97-520
Correlation with Other Measurements
Typically, there is a difference between laboratory and process viscosity
measurements. Laboratory measurements, for a given fluid, are usually
higher than process measurements.
Viscosity measurements are unique among common types of fluid
measurement in that, for most fluids, numerical values that are generated
are dependent upon flow conditions in the fluid being measured (shear rate
or velocity gradient). Other factors such as temperature change,
turbulence, and pressure among the most prominent, also affect the
readings.
Frequently it may become necessary to correlate readings provided by
your on-line viscometer to those factors that influence viscosity obtained
by other methods. The correlation consists of holding the viscosity
dependent factors constant, as mentioned above, and plotting the on-line
viscosity value against the other reading as shown in Figure 1-4. A
successful empirical correlation will assure the process operator that an on-
line reading can be matched to a viscosity value derived by the other
method. The correlation of these readings may be instrumental in
educating process operators how the process stream relates to bench-top
derived viscosity measurements.
Many factors beyond those noted above, which are more difficult to control
in an on-line situation than in a laboratory environment, can potentially
affect your correlation. Refer to Appendix A and contact Brookfield
Engineering Laboratories, Inc. for assistance in generating an empirical
correlation.
Figure 1-4: In-Line Viscometer Correlation with Other Measurement Techniques
CORRELATION
ACCEPTABLE LIMIT
ACCEPTABLE LIMIT
ONLINE VISCOMETER READING (cP)
AT PROCESS TEMPERATURE
LAB/QC VISCOMETER READING (cP)
AT STANDARD TEMPERATURE

TT100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
P/N M/97-520 1-7
Specifications
The TT100 In-Line Viscometer is available in standard or optional
configurations as listed in Table 1-1.
Table 1-1: Model TT100 In-Line Viscometer Specifications
Parameter Standard Configuration Optional Configuration*
Viscosity Range
(See Note 1) 10 - 500,000 cP 10 - 500,000 cP
Shear Rate Range 10 - 1000 sec-1 0.02 - 12,000 sec-1
Temperature Range
(See Note 2) -40º - 300º F -40º - 500º F
Pressure Range
(See Note 3) 0 - 200 psi Vacuum to 500 psi
Reproducibility ± 0.5% of span ± 0.5% of span
Signal Output 4 - 20 mA 0 - 20 mA, 0 - 10 VDC
Power Requirements 115VAC 50/60Hz
100 Watts 230VAC 50/60 Hz 100 Watts
Chamber 300 Series S/S
1 inch NPT (Female)
inlet and outlet
316 S/S wetted parts
construction
1, 1 1/2, or 2 inch threaded or
flanged, 4 inch flanged
Motor Single-speed synchronous Multiple-speed with speed
control
Dimensions 5 x 5 x 17 inches
(127 x 127 x 431.8 mm) 5 x 5 x 17 inches (127 x 127 x 431.8 mm)
Construction NEMA 4
Water tight and dust tight Refer to Appendix D
Weight 50 lbs. (23 kg) 50 lbs. (23 kg)
* Optional Configurations offer dual range capability, custom mounting and/or special viscosity ranges and shear
rates.
NOTE 1: Range is calibrated with a 0 cP lower limit. The upper limit can be any value between 10 - 500,000 cP.
NOTE 2: Under certain conditions, temperatures as high as 700º F may be accommodated.
NOTE 3: Under certain conditions, pressures as high as 1000 psi may be accommodated.

In-Line Viscometer Description
1-8 P/N M/97-520
Required Utilities
The TT100 In-Line Viscometer requires the utility connections listed in
Table 1-2 to operate.
Current Draw - Starting & Running
The normal running power requirement for TT100 In-Line Viscometer is
100 watts. However, the instantaneous starting current requirement for the
TT100 drive motor can be at least five times greater.
Brookfield Engineering Laboratories, Inc. recommends that any inverter,
transformer, or similar device that is used with the Model TT100 should be
rated at 750 volt-amperes or greater.
Table 1-2: Utility Requirements
Parameter Value
Supply Voltage 115/230 VAC
Line Frequency
(See Note 1) 50 or 60 Hz
Power 100 Watts
Flushing Requirements
(See Note 2) 3 - 10 gpm 30 - 40 psig
1/8 inch pipe thread endcap connection
Barrier Fluid Pressure
(See Note 3) 20 psi above maximum process flow pressure
NOTE 1: Variations in line frequency will affect instrument span and accuracy.
NOTE 2: If viscometer is equipped with flushing option.
NOTE 3: If viscometer is equipped with double mechanical seals.

TT100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
P/N M/97-520 1-9
Cleaning
To ensure proper viscometer operation, it is important to properly clean or
flush the viscometer at regularly scheduled intervals. Solids can build up
on the opposing cylinder surfaces and interfere with the angular movement
of the stator and torsion element and their movement in relation to the stop
posts which protrude through the stator. Additionally, solids can build up at
the mechanical seal which may affect its ability to maintain leak-free
operation.
The user must establish cleaning procedures and cleaning fluids.
Clean-In-Place (CIP) is strongly recommended as the cleaning procedure
of choice. In addition to CIP, the user may choose the flushing option in
order to direct cleaning fluid to the internal components to enhance the
cleaning process. The third choice for cleaning is to manually clean the
internal components. This is not a recommended practice due to the
damage that can be caused on the torsion element when exposed to this
manual cleaning.
The clean-in-place procedure can be accomplished with high flow rate
cleaning fluid or steam.
NOTE: The cleaning fluid must be compatible with the seal. Steam
Temperature should not be higher than the temperature rating of the
viscometer.
In some instances, the instrument installation can be plumbed with 2 three-
way valves with the cleaning fluid introduced and drained through the side
ports of these valves.
The flushing option, available in the TT100, is offered in either or both
endcaps. When in use, the cleaning fluid is introduced towards the internal
components through directional spray nozzles. This cleaning procedure
should be accomplished with the measuring chamber void of any process
fluid and the cleaning fluid at a pressure of approximately 30-40 psi and a
flow rate of 3-10 gpm.
Refer to Section 5 - Maintenance for clean-in-place or flushing
procedures.

In-Line Viscometer Description
1-10 P/N M/97-520
Component Identification
The following paragraphs provide a brief description of each component
within the TT100 In-Line Viscometer. Refer to Figure 1-5 for the
component location within the viscometer.
Torque Sensor Assembly
The Torque Sensor Assembly contains the torsion element, armature, and
field coil. These components generate an electrical signal proportional to
the viscous drag of the process fluid which is sent to the torque sensor
electronics enclosure for signal processing.
Sensing Endcap
The Sensing Endcap contains the torque sensor assembly and all related
components.
Stator
The Stator, which is mounted on the torsion element, applies torque
generated by viscous drag to the torsion element. The dimensions of the
stator, in conjunction with the rotor, are critical to the accuracy of the
viscometer. Many different stator sizes are available which provide
different viscometer measurement ranges.
Stop Posts
The stop posts limit stator/torsion element movement to prevent torsion
element damage.
Inlet/Outlet
The Inlet and Outlet are provided with an appropriate connection type and
allows process fluid to enter or exit the viscometer. Either connection may
be used to allow process fluid to enter or exit the viscometer.
Rotor
The Rotor is a hollow cylinder which constantly rotates around the stator,
driven by the motor. The rotation of the rotor moves process fluid in the
measuring annulus which results in viscous drag on the stator. Rotors are
available that contain additional surface holes to allow a faster turnover of
process fluid in the measuring annulus. Different rotor sizes are also
available.

TT100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
P/N M/97-520 1-11
Drive Endcap
The Drive Endcap supports the rotor, mechanical seal, drive shaft, bearings
and bearing housing, motor, and all related mechanical components.
Motor Cable
The Motor Cable supplies electrical power to the motor from the motor
control enclosure, or directly from a power source.
Gearbox
The Gearbox reduces rotational speed and allows the drive shaft to rotate
slower than the motor. The rotational speed of the drive shaft is determined
by Brookfield Engineering Laboratories, Inc. based upon customer
viscosity range requirements.
Drive Motor
The Drive Motor is an electric motor which provides a constant rotational
speed to the gear box, drive coupling, and viscometer drive shaft. The
drive motor is usually a single-speed synchronous motor but is also
available in a controlled variable speed induction motor for custom
applications.
Drive Coupling
The Drive Coupling connects the viscometer drive shaft to the
gear box. The drive coupling contains a rubber cushion (or bronze cushion
for high temperature applications) to isolate the viscometer from motor
vibration.
Bleed Screw
The Bleed Screw is used to vent air from the viscometer which may be
trapped within the measuring chamber.
Measuring Chamber
The Measuring Chamber is the area in which process fluid viscosity is
measured. Process fluid may flow through it in either direction.
Measuring Annulus
The Measuring Annulus is the space between the stator and rotor. Process
fluid is continuously sheared within the measuring annulus which creates
viscous drag on the stator.

In-Line Viscometer Description
1-12 P/N M/97-520
Sensing Cable
CAUTION
Changing the length of the sensing cable will affect viscometer calibration.
Refer to Appendix A and contact Brookfield Engineering Laboratories for
more information.
The Sensing Cable carries the electrical signal that is proportional to the
viscous drag of the process fluid. The signal is sent to the torque sensor
electronics enclosure for processing. The Sensing Cable also carries an
excitation current from the torque sensor electronics enclosure to the
torque sensor assembly.
Torsion Element
The Torsion Element, which is part of the torque sensor assembly, senses
the torque from the viscous drag on the stator. The twist or deflection of the
torsion element is proportional to the torque applied to it.
Heat Baffle
The Heat Baffle, which is sometimes referred to as an insulator, dissipates
heat from the viscometer that has been transferred from the process fluid.
The transfer of heat to the baffle protects the field coil from high
temperatures.
Torque Sensor Electronics Enclosure
The Torque Sensor Electronics Enclosure contains a circuit board which
processes the signal from the torque sensor assembly and generates a linear
electrical signal (4 - 20 mA) proportional to the viscosity of the process
fluid in the measuring annulus. The circuit board also provides an
excitation current to the field coil.
The 4 - 20 mA signal can be:
• Observed on a readout display
• Transmitted to a personal computer for process monitoring and
control
• Recorded for process control records