Flow Meter Tokico 2 Inch Calibration: K-Factor Programming for Boiler Diesel Transfers

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Flow Meter Tokico 2 Inch Calibration: K-Factor Programming for Boiler Diesel Transfers

Quick Answer: A Tokico 2 inch diesel flow meter needs the K-factor from the meter plate or the original calibration sheet loaded into the batch controller or PLC. Most Tokico positive displacement models for diesel run between 10 and 100 pulses per litre. Check the totalizer after a 200 litre proving run and correct the K-factor if the error exceeds 1 percent.

Boiler diesel transfer is not pure custody transfer, but poor calibration still causes burner trips and tank inventory errors. Silver Instruments supports plants that run Tokico 2 inch flow meters on diesel day tanks, boiler feed lines, and generator fuel loops. We receive questions from marine engineers in Singapore, palm oil mills in Indonesia, and textile plants in Vietnam. The main issue is always the same: the K-factor value in the PLC does not match the actual meter output over time.

What the K-Factor Means on a Tokico 2 Inch Meter

The K-factor is the number of pulses the flow meter sends per unit volume. On a Tokico 2 inch (DN50) positive displacement meter, a typical diesel K-factor might be 23.540 pulses per litre or 89.1 pulses per gallon depending on the register and gearing. The value is specific to each meter. Two identical Tokico 2 inch meters can have different K-factors because of machining tolerances and viscosity effects.

Never copy a K-factor from a similar meter on another boiler line. That shortcut creates a hidden error. We have seen a waste oil recycler in Malaysia run a Tokico 2 inch unit with the K-factor from a different skid. The diesel inventory showed a 4 percent error. The burner consumed more fuel than the PLC totalizer reported.

Field Programming Sequence for Diesel Boiler Transfer

Most sites wire the Tokico 2 inch meter to a PLC, a flow computer, or a batch controller. You need three things before starting: the meter serial number, the K-factor on the calibration plate, and the pulse output type. Some Tokico models use an open collector output, while others use a reed switch. Check the signal type before you set the input card.

Step 1. Stop the boiler fuel transfer pump and isolate the line. Step 2. Record the current K-factor from the controller memory. Step 3. Compare that value with the metal plate on the meter body. Step 4. Enter the new K-factor in pulses per litre if the unit is metric, or pulses per gallon for imperial. Step 5. Run a known volume through the meter, for example 200 litres from a calibrated tank or prover. Step 6. Read the totalizer and calculate the error. If the error is above 1 percent, adjust the K-factor using the formula: new K-factor = current K-factor x display volume / actual volume.

In practice, a proving run of 200 litres works well because it is large enough to reduce valve timing errors but small enough to perform during a shift. Some plants in the Philippines use a 55 gallon drum as a quick check. That test is acceptable if the drum is clean and the scale or sight glass is marked correctly.

Common K-Factor Mistakes on Boiler Diesel Lines

One mistake is entering the K-factor in the wrong unit. A customer in Thailand entered pulses per gallon into a controller set for pulses per litre. The diesel total was wrong by 3.785 times. The boiler operator discovered the issue

Another mistake is forgetting to compensate for temperature. Diesel volume changes by about 0.09 percent per degree Celsius. If the meter runs at 40 degrees Celsius and the calibration was done at 15 degrees Celsius, the volume difference is real. For boiler transfer this error may be acceptable below 1 percent. For larger temperature swings, set the flow computer to correct to 15 degrees Celsius using the diesel density table. Typical gas oil viscosity is 2.5 to 5.5 cSt at 40 degrees Celsius.

Pulse Output and Wiring Notes

A Tokico 2 inch meter with a reed switch output can miss pulses at high frequency if the PLC input filter is set too slow. Most engineers skip this part. Set the input filter to 10 microseconds or less for pulse duty. If the meter has an open collector output, use a pull-up resistor of 1 kilo ohm to 4.7 kilo ohm. This prevents pulse loss on long cable runs from the boiler house to the control room.

We have seen sites where the pulse cable ran next to a variable frequency drive for the forced draft fan. The drive induced noise into the pulse signal. The controller counted extra pulses. The diesel transfer total was higher than actual. Always route pulse cable away from power cable. Use shielded twisted pair and ground the shield at one end only.

Silver Instruments Replacement and Calibration Support

Silver Automation Instruments supplies new diesel flow meters, calibration services, and spare parts for boiler fuel systems. If your Tokico 2 inch meter has mechanical wear or a damaged register, you can replace it with an oval gear flow meter for diesel from our range. These meters provide pulse output and accept K-factor programming in a PLC or panel meter.

Send us your operating pressure in bar, diesel temperature in degrees Celsius, pipe size in DN, and flow range in litres per minute. We will recommend a meter body and pulse output that matches your boiler transfer line. We serve customers in Southeast Asia, the Middle East, Latin America, and Africa.

Tel: +86-25-68650347
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FAQ

Question: What K-factor should I use for a Tokico 2 inch diesel flow meter?
Answer: Use the exact value from the meter plate or the original calibration certificate. Do not copy from another meter.

Question: How often should I check the K-factor on a boiler diesel meter?
Answer: Check the totalizer against a known volume every 6 months or after any mechanical repair. If the error is above 1 percent, reprogram the K-factor.

Question: Can I use the same K-factor for diesel and heavy fuel oil?
Answer: No. Viscosity changes the slip and the meter output. Use the K-factor for the actual fuel and operating temperature.

Question: Why does my Tokico 2 inch meter totalize more than the tank level shows?
Answer: Check for electrical noise, a wrong pull-up resistor, or a K-factor in the wrong unit. Also check for air in the diesel line before the meter.

Question: What is the typical flow range for a Tokico 2 inch diesel meter?
Answer: Many 2 inch positive displacement meters handle 20 to 200 litres per minute for diesel. Check the model plate for the exact range and pressure drop.

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