Daniel Turbine Flow Meters - Series 1200 Sizes 1" - 2" with Universal Mounting Box

Daniel Turbine Flow Meters - Series 1200 Sizes 1" - 2" with Universal Mounting Box
Operation and maintenance manual
Part Number 3-9008-512, rev. E
June 2013
DanielTM Series 1200 turbine meter
1" thru 2" sizes
Safety signal words and symbols
Pay special attention to the following signal words, safety alert symbols and statements:
Safety alert symbol
This is a safety alert symbol. It is used to alert you to potential physical injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Warning indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
Caution indicates a hazardous situation which, if not avoided, could result in minor or moderate
injury.
Notice is used to address safety messages or practices not related to personal injury.
Important safety instructions
Daniel Measurement and Control, Inc. (Daniel) designs, manufactures and tests products to
function within specific conditions. Because these products are sophisticated technical
instruments, it is important that the owner and operation personnel must strictly adhere both to
the information printed on the product and to all instructions provided in this manual prior to
installation, operation, and maintenance.
Daniel also urges you to integrate this manual into your training and safety program.
BE SURE ALL PERSONNEL READ AND FOLLOW THE INSTRUCTIONS IN THIS
MANUAL AND ALL NOTICES AND PRODUCT WARNINGS.
Failure to follow the installation, operation or maintenance instructions for a Daniel
product could lead to serious injury or death from explosion or exposure to dangerous
substances.
To reduce this risk:
•
•
•
Comply with all information on the product, in this manual, and in any local and
national codes that apply to the product.
Do not allow untrained personnel to work with this product.
Use Daniel parts and work procedures specified in this manual.
Product owners (Purchasers):
•
•
•
•
•
•
•
•
Use the correct product for the environment and pressures present. See technical data or
product specifications for limitations. If you are unsure, discuss your needs with your
Daniel representative.
Inform and train all personnel in the proper installation, operation, and maintenance of
this product.
To ensure safe and proper performance, only informed and trained personnel should
install, operate, repair and maintain this product.
Verify that this is the correct instruction manual for your Daniel product. If this is not the
correct documentation, contact Daniel at 1-713-827-6314. You may also download the
correct manual from: http://www.daniel.com
Save this instruction manual for future reference.
If you resell or transfer this product, it is your responsibility to forward this instruction
manual along with the product to the new owner or transferee.
ALWAYS READ AND FOLLOW THE INSTALLATION, OPERATIONS,
MAINTENANCE AND TROUBLESHOOTING MANUAL(S) AND ALL PRODUCT
WARNINGS AND INSTRUCTIONS.
Do not use this equipment for any purpose other than its intended service. This may result
in property damage and/or serious personal injury or death.
Product operation personnel:
•
•
•
•
•
•
•
•
•
•
To prevent personal injury, personnel must follow all instructions of this manual prior to and
during operation of the product. Follow all warnings, cautions, and notices marked on, and
supplied with, this product.
Verify that this is the correct instruction manual for your Daniel product. If this is not the
correct documentation, contact Daniel at 1-713-827-6314. You may also download the
correct manual from: http://www.daniel.com
Read and understand all instructions and operating procedures for this product.
If you do not understand an instruction, or do not feel comfortable following the instructions,
contact your Daniel representative for clarification or assistance.
Install this product as specified in the INSTALLATION section of this manual per applicable
local and national codes.
Follow all instructions during the installation, operation, and maintenance of this product.
Connect the product to the proper pressure sources when and where applicable.
Ensure that all connections to pressure and electrical sources are secure prior to, and during,
equipment operation.
Use only replacement parts specified by Daniel. Unauthorized parts and procedures can
affect this product's performance, safety, and invalidate the warranty. "Look-a-like"
substitutions may result in deadly fire, explosion, release of toxic substances or improper
operation.
Save this instruction manual for future reference.
Notice
THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES ONLY,
AND WHILE EVERY EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY, THEY ARE NOT TO
BE CONSTRUED AS WARRANTIES OR GUARANTEES, EXPRESSED OR IMPLIED, REGARDING THE
PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY. ALL SALES ARE
GOVERNED BY DANIEL’S TERMS AND CONDITIONS, WHICH ARE AVAILABLE UPON REQUEST. WE
RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR SPECIFICATIONS OF SUCH
PRODUCTS AT ANY TIME.
DANIEL DOES NOT ASSUME RESPONSIBILITY FOR THE SELECTION, USE OR MAINTENANCE OF
ANY PRODUCT. RESPONSIBILITY FOR PROPER SELECTION, USE AND MAINTENANCE OF ANY
DANIEL PRODUCT REMAINS SOLELY WITH THE PURCHASER AND END-USER.
TO THE BEST OF DANIEL’S KNOWLEDGE THE INFORMATION HEREIN IS COMPLETE AND
ACCURATE. DANIEL MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT
TO THIS MANUAL AND, IN NO EVENT, SHALL DANIEL BE LIABLE FOR ANY INCIDENTAL,
PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF
PRODUCTION, LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING
WITHOUT LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF THIRD PARTIES.
PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION ONLY
AND MAY BE TRADEMARKS/REGISTERED TRADEMARKS OF THESE COMPANIES.
Warranty and limitation of liability
1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein, Daniel Measurement &
Control, Inc. (“Daniel”) warrants that the licensed firmware embodied in the Goods will execute the programming
instructions provided by Daniel, and that the Goods manufactured by Daniel will be free from defects in materials or
workmanship under normal use and care and Services will be performed by trained personnel using proper
equipment and instrumentation for the particular Service provided. The foregoing warranties will apply until the
expiration of the applicable warranty period. Goods are warranted for twelve (12) months from the date of initial
installation or eighteen (18) months from the date of shipment by Daniel, whichever period expires first.
Consumables and Services are warranted for a period of 90 days from the date of shipment or completion of the
Services. Products purchased by Daniel from a third party for resale to Buyer (“Resale Products”) shall carry only
the warranty extended by the original manufacturer. Buyer agrees that Daniel has no liability for Resale Products
beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If
Buyer discovers any warranty defects and notifies Daniel thereof in writing during the applicable warranty period,
Daniel shall, at its option, correct any errors that are found by Daniel in the firmware or Services or repair or replace
F.O.B. point of manufacture that portion of the Goods or firmware found by Daniel to be defective, or refund the
purchase price of the defective portion of the Goods/Services. All replacements or repairs necessitated by
inadequate maintenance, normal wear and usage, unsuitable power sources or environmental conditions, accident,
misuse, improper installation, modification, repair, use of unauthorized replacement parts, storage or handling, or
any other cause not the fault of Daniel are not covered by this limited warranty, and shall be at Buyer’s expense.
Daniel shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be
agreed upon in writing in advance by Daniel. All costs of dismantling, reinstallation and freight and the time and
expenses of Daniel’s personnel and representatives for site travel and diagnosis under this warranty clause shall be
borne by Buyer unless accepted in writing by Daniel. Goods repaired and parts replaced by Daniel during the
warranty period shall be in warranty for the remainder of the original warranty period or ninety (90) days, whichever
is longer. This limited warranty is the only warranty made by Daniel and can be amended only in a writing signed by
Daniel. THE WARRANTIES AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE. THERE ARE NO
REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, AS TO
MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT
TO ANY OF THE GOODS OR SERVICES. Buyer acknowledges and agrees that corrosion or erosion of materials
is not covered by this warranty.
2. LIMITATION OF REMEDY AND LIABILITY: Daniel shall not be liable for damages caused by delay in
performance. The remedies of buyer set forth in this agreement are exclusive. In no event, regardless of the form of
the claim or cause of action (whether based in contract, infringement, negligence, strict liability, other tort or
otherwise), shall Daniel’s liability to buyer and/or its customers exceed the price to buyer of the specific goods
manufactured or services provided by Daniel giving rise to the claim or cause of action. Buyer agrees that in no
event shall Daniel’s liability to buyer and/or its customers extend to include incidental, consequential or punitive
damages. The term “consequential damages” shall include, but not be limited to, loss of anticipated profits, revenue
or use and costs incurred including without limitation for capital, fuel and power, and claims of buyer’s customers.
This page intentionally left blank.
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
TABLE OF CONTENTS
1.0
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1
General.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
Description.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2.0
SPECIFICATIONS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3.0
INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
General.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Flow Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3
Installation and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4
Pickoff Coils and Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-1
3-3
3-6
4.0
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
General.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
Pre-start Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-1
4-1
5.0
MAINTENANCE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
General.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
Maintenance Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
Disassembly Procedures Internal Components. . . . . . . . . . . . . . . . . . . . . . . . . .
5.4
Reassembly of Internal Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
Field Retrofitable Dual Pickoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-1
5-2
5-9
5-9
6.0
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1
General.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7.0
PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
TABLE OF CONTENTS
i
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
Figures
3-1
3-2
7-1
7-2
7-3
Typical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UMB Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UMB Assembly (All Sizes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Meter Assembly (1") - Stainless Steel Bearing Internals.. . . . . . . . . . . . . . . . . . . . . . . .
Meter Assembly (1-1/2" and 2") - Stainless Steel Bearing Internals.. . . . . . . . . . . . . . .
3-3
3-7
7-2
7-4
7-6
Tables
6-1
7-1
7-2
7-3
ii
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UMB Assembly (All Sizes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Numbers (1") - Stainless Steel Bearing Internals. . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Numbers (1-1/2" and 2") - Stainless Steel Bearing Internals. . . . . . . . . . . . . . . . . .
6-1
7-3
7-5
7-7
TABLE OF CONTENTS
DANIEL™ SERIES 1200 TURBINE METER
1.0
INTRODUCTION
1.1
General
JUNE 2013
This manual is designed to assist in the installation and operation of the Daniel™ Series 1200
Turbine Flowmeter. To assure proper installation and startup it is important to read this manual in
its entirety.
1.2
Description
The Series 1200 Turbine Flowmeter is a volumetric flow metering and transmitting device used
extensively in the petroleum industry for the accurate measurement of liquid hydrocarbons. The
meter’s simple configuration assures higher flow rates, extended flow range and sustained
performance capability. This meter is specifically designed for pipeline and loading rack service
where a vital characteristic is repeatability.
INTRODUCTION
1-1
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
This page intentionally left blank.
1-2
INTRODUCTION
DANIEL™ SERIES 1200 TURBINE METER
2.0
JUNE 2013
SPECIFICATIONS
This meter is designed for use within the guidelines of API Standards, Chapter 5.3, formerly
Standard 2534 (The Measurement of Liquid Hydrocarbons by Turbine Meter Systems) and the test
procedures of API Standards, Chapter 4 (Prover Systems).
PERSONAL INJURY AND/OR EQUIPMENT DAMAGE
Do not exceed specifications listed below.
Failure to heed this warning could result in serious injury and/or damage to the equipment.
Approvals:
Electrical
UL and ULC: Class I, Division 1, Groups C & D
DEMKO 03 ATEX 130946X
IECEx UL 11.0031X
Environmental
NEMA 4
Metrology
NTEP 90-118
NMi TC7573
ATEX certification
Standard Temperature
INMETRO certification
Certification number
and marking
Applicable norms
ABNT NBR IEC 60079-0:2008
ABNT NBR IEC 60079-1:2009
Temperature range
-40°C # to # +60°C
SPECIFICATIONS
2-1
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Conditions for safe use (X)
- The joint between the Universal Mounting Box cover and
housing is a flat joint and has a flame path of 9,52 mm in
length and clearance of less than 0,0381 mm.
- The joint between the Universal Mounting Box housing
and Sensor housing is a spigot joint which has a radial
length of 3,18 mm, an axial length of 13,61 mm and a
clearance of 0,059 mm.
- Device is to be remote-mounted when the process
temperature is outside of the ambient temperature range.
Ratings
The maximum working pressure for the Series 1200 Turbine Meter is based on the temperature/
pressure rating of the ANSI B16.5 flanges. The following chart lists the maximum working
pressure of both 304 stainless steel and carbon steel flanges at 100° and 180° Fahrenheit (the
maximum operating temperature for the standard meter). For maximum working pressures at
intermediate temperatures, and for other materials, refer to ANSI B16.5.
Pressure/Temperature
150# ANSI / -20 to 100°F
Stainless Steel
(-29° to 38°C)
150# ANSI / 180°F (82°C)
300# ANSI / -20 to 100°F
275 psig WP
239 psig WP
(-29° to 38°C)
300# ANSI / 180°F (82°C)
720 psig WP
624 psig WP
Pressure
ANSI pressure/temperature rating corresponding to flanges used.
150# ANSI: 285 PSI
300# ANSI: 740 PSI
Ambient Temperature
-40 to 140°F (-40° to 60°C) (Tamb is an electrical specification)
CS flange minimum temperature is -20°F (-29°C)
Process Temperature
-20° to 180°F (-29° to 82°C)
Pressure Drop
three psi (20.7 kPa) at maximum flow rate (based on gasoline,
meter only)
2-2
SPECIFICATIONS
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Mechanical Connections
Standard: 150 or 300 # ANSI R.F. flanges
Meter Performance
Linearity: ± 0.25% (Linearity of ± 0.15% optional on 1-1/2" and 2" sizes)
Repeatability: ± 0.02%
Pickoff Type
Single or dual, non-wetted, reluctance pickoffs
Preamplifier Type
Dual Channel preamplifier
Preamplifier Performance
Inputs
Supply voltage: 10-30 Vdc
Sensor Type: Reluctance
Type: Sine Wave
Amplitude: 40 mV peak to peak minimum
Outputs
Powered Pulse Output
Type: Square Wave
Frequency Range: 0 to 5 kHz
Amplitude: 0 to 5 V
1000 Ohm internal pull-ups, 20 mA, max.
Variable Voltage Output
Type: Square Wave
Frequency Range: 0 to 5 kHz
Amplitude: 0 to Supply Voltage
1000 Ohm internal pull-ups, 70 mA, max.
Open Collector Output (Per Channel)
Type: Square Wave
Frequency Range: 0 to 5 kHz
SPECIFICATIONS
2-3
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Max. Voltage: 30 Vdc
Max. Current: 125 mA
Max. Power: 0.5 Watts
Transmission Distance
Pickoff Only (without preamp): Belden 88442 or equivalent up to 20 ft. (6.1 meters)
With Preamp: 3,000 ft. (914 meters)
Materials of Construction
Meter Body: SS
Internal Components: Aluminum/SS
Bearings: Stainless Steel
UMB Housing: Aluminum
2-4
SPECIFICATIONS
DANIEL™ SERIES 1200 TURBINE METER
3.0
INSTALLATION
3.1
General
JUNE 2013
This section contains specific instructions for receipt and installation of the meter.
3.2
Flow Considerations
A properly designed flow system will do two basic things towards maintaining the linearity of the
turbine meter. It will properly condition the incoming flow such that it is homogeneous
throughout its cross section and it will provide proper back pressure so that cavitation will not
originate inside the meter.
Linearity can be defined as the total range of deviation of accuracy, expressed as a curve,
between minimum and maximum flow rates. The ideal accuracy curve of a volumetric meter,
such as the turbine, is a straight line denoting a constant meter factor.
Cavitation is the formation and collapse of vapor-filled cavities that result from a sudden
decrease and increase in pressure.
MECHANICAL EQUIPMENT DAMAGE
Provide unobstructed upstream piping.
Turbine meter performance depends on the incoming fluid being devoid of swirls and excessive
turbulence. These conditions can be avoided by providing unobstructed piping upstream of the
meter. Pipe fittings such as elbows and tees, and piping components such as valves and strainers
should be located far enough upstream to allow dissipation of any flow disturbance before it
reaches the meter. Use of flow straighteners greatly influence meter performance.
INSTALLATION
3-1
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
Specific Gravity
Turbine meter performance is affected by specific gravity and may influence performance. The
effect of specific gravity on the turbine meter may be evidenced when specific gravity drops
below 0.70. As specific gravity decreases, the lift forces on the turbine blade decreases. Likewise
as velocity decreases, lift forces decrease. These reduced lift forces are overtaken by bearing
friction as low rates are approached. Subsequently, linearity deteriorates at low flow rates while
measuring low density fluids.
To compensate for separate meter factors at low flow rates electronic monitoring equipment is
used. This has been proven to enhance the overall measuring accuracy at the load rack. As low
flow startup and shutoff flow rate is encountered, an established meter factor for that rate is
applied. During the time that the high flow rate is used to load the bulk of the measured volume,
a meter factor established for high flow rate is applied.
Viscosity
Turbine meters are viscosity sensitive in that as the metered fluid increases in viscosity, meter
linearity begins to suffer. This effect on linearity is primarily due to a change in the fluid's
velocity profile and skin friction between the fluid and the rotor blades.
Seasonal Changes
For optimal performance in loading rack applications, where fuel oils are metered and where
there is a large temperature swing from summer to winter, it is recommended that a new meter
factor be established as seasons change. This is recommended since temperature affects the
viscosity of fuel oil and viscosity affects turbine meter performance.
Generally speaking, viscosities of 3 centipoise or less give no cause for concern. Above this
viscosity, all influential factors should be considered. By properly anticipating the flow system's
viscosity, maximum flow rate, flow range and desired linearity, the user can properly apply the
turbine meter to the required application.
3-2
INSTALLATION
DANIEL™ SERIES 1200 TURBINE METER
3.3
JUNE 2013
Installation and Equipment
Figure 3-1, Typical Installation has been provided as a guide in establishing optimum
performance of the meter. Prior to installation consider the general information listed below.
Figure 3-1. Typical Installation
1.
Note the direction of flow indicated on the plate near the inlet flange and install
accordingly.
2.
New Installations - Lines should be flushed thoroughly to rid piping of potentially
damaging foreign material such as welding bead, pipe scale, etc. before the meter is
placed into service.
A spool piece installed in place of the meter is recommended for this procedure.
When installing this equipment, bolting must conform to the requirements of ASME B16.5
paragraph 5.3 and to the material requirements of ASME B16.5 Table 1B. Gaskets must
conform to the requirements of ASME B16.20.
INSTALLATION
3-3
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
It is the customer's responsibility to ensure that piping or other attachments connected to the
Product do not place adverse stresses on the Product.
The design of the Product has not been assessed for the effects of traffic, wind or earthquake
loading.
It is the customer's responsibility to provide fire prevention measures and equipment per local
regulations.
PERSONAL INJURY AND/OR EQUIPMENT DAMAGE
Install and use the Daniel Series 1200 Turbine Meter only per noted instructions and
specifications.
Use of this equipment for any purpose other than its intended purpose may result in property
damage and/or serious personal injury or death.
The Product has been designed with a minimum of 1.5mm (.059 inches) corrosion allowance.
The customer should implement a periodic inspection and maintenance program to ensure that no
part of the Product's pressure-retaining components has corrosion or erosion exceeding this
amount. (The design engineer may choose to select a different corrosion allowance, but it should
be identified and published.)
3.
Products to be measured.
MECHANICAL EQUIPMENT DAMAGE
Always use a flushing medium that is compatible with the metallurgy of the meter and its
internal components and similar to the product for which the meter is intended.
Using water as a flushing medium may result in damage to the internal components of the
turbine meter.
4.
3-4
Always install the meter downstream of pumps
INSTALLATION
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Valves
The metering system should have a flow rate control valve located at a convenient distance
downstream of all measurement equipment. The function of the control valve is to limit and
maintain system pressure on the meter. This avoids cavitation.
When a loading rack meter is being calibrated with a displacer type prover (using a piston or
sphere) a back pressure valve should also be used downstream of the proving device. This valve
can be a simple manual valve that is partially closed. A minimum pressure of 12 to 15 PSI (83 to
103 kPa) should be maintained downstream of the prover.
1.
2.
3.
4.
Valves should be capable of rapid, smooth opening and closing with positive shut-off.
When used for intermittent flow, valves should be fast acting and shock-free.
Bypass lines should be equipped with blind or positive shut-off devices.
Shut-off or control valves should be located downstream of the meter.
Flow Straightening
The Series 1200 Turbine Meter in sizes one and a half inches through four inches is supplied
with an integral flow conditioning plate as standard. For best performance it is recommended that
an upstream and downstream spool equal to a minimum of five pipe diameters be utilized. The
Series 1200 one-inch meter is not installed with an integral flow conditioning plate and it is
recommended that an upstream spool equal to a minimum of twenty pipe diameters and a
downstream spool equal to a minimum of five pipe diameters be used for best performance.
Strainers
A strainer of proper size should be installed upstream of the meter to protect it from the
introduction of foreign material which might damage the meter. Recommended mesh size: 80
mesh.
Strainer Monitoring:
1.
Recommended procedures dictate that regular, scheduled cleaning of the strainer basket
should be conducted to prevent filling and rupturing of the screen.
2.
Pressure gauges installed on both sides of the strainer will indicate differential pressure
across the strainer. High-pressure differential caused by filling of the basket with foreign
material can cause strainer basket rupture resulting in possible meter damage.
INSTALLATION
3-5
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
3.4
Pickoff Coils And Electrical Connections
A.
Pickoff Coils
The Series 1200 Turbine has the capacity for single or dual pickoff coils mounted 90° electrically
out of phase. Each pickoff produces a low level sine wave signal, which varies in amplitude (V)
and frequency (Hz) proportional to the velocity of the turbine blades. This signal information is
coupled to the input terminals of the preamplifier.
B.
Electrical Connections
Pickoff input signal connections are made at terminal strip connection TB2 for Channel A and
TB3 for Channel B. Power supply and output signal connections are made at terminal strip TB1.
Reference Figure 3-2.
C.
Induced Interference
The Turbine meter should be located as far as possible from any electrical equipment such as
motors, solenoids or relays which could induce an interference signal into the turbine meter
pickoff coil. High amplitude interference introduced into the preamplifier can result in
interference with the flow signal.
Interference Check - Upon installation of the turbine meter and preamplifier, the presence of an
interference signal can be detected by performing the following check.
1.
Connect a suitable readout device to the preamp output terminal strip TB1 (number 3 for
channel A or number 5 for channel B).
2.
Apply +12 Vdc power to the preamp at terminal strip TB1 (number 1).
3.
If an output is indicated on the readout at a no-flow condition, induced interference is
present.
4.
Duplicate the checking process if dual pickoffs are being used. Use output terminal strip
TB1 number 3 or 5 as selected for pickoff output.
Interference may be reduced or eliminated by changing the location of the meter or by rotating
the meter in the pipeline in progressive steps while simultaneously checking the output for the
lowest possible signal reading.
3-6
INSTALLATION
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Figure 3-2. UMB Wiring
D.
Accessory Hookup
General considerations: It is important that the appropriate service manual be referenced before
attempting to use accessories or instrumentation with the Series 1200 Turbine. If service manuals
for instrumentation were not received at the time of purchase or delivery, please contact the
factory or nearest Daniel Measurement and Control Sales and Service Office.
INSTALLATION
3-7
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
This page intentionally left blank.
3-8
INSTALLATION
DANIEL™ SERIES 1200 TURBINE METER
4.0
OPERATION
4.1
General
JUNE 2013
This section contains the operating procedures for the Series 1200 Turbine Meter. Reference
Section 3.4 for general flow considerations that may effect meter performance. The Series 1200
Turbine Meter is a volumetric flow measuring and transmitting device that produces an output
signal proportional to the rate-of-flow of the liquid being measured. The primary output is a
single or dual high resolution signal that is amplified and shaped by an integral amplifier
mounted within an explosion proof housing. This square-wave pulse can be fed directly to
remote totalizing counters, digital readout devices or control instrumentation, or a locally
mounted electronic register.
4.2
Pre-start Checks
Inspect all electrical connections to assure compliance to electrical codes and safety regulations.
All bolts used to secure the meter in line should be inspected to assure that proper mounting
procedures have been followed and that flange connections are leak free.
Evaluate the system setup to assure that all components are in the proper sequence for accurate
product measurement: isolation valve, strainer, flow straightener, meter, downstream section,
control valve, etc.
4.3
Operation
Flow and pressure information is stamped on the nameplate located on the outside of the meter.
PERSONAL INJURY AND/OR EQUIPMENT DAMAGE
Never subject the meter to flow or pressure ranges above those specified in Section 2
Specifications, or those stamped on the meter.
Exceeding the meter specifications could result in serious injury and/or damage to the
equipment.
OPERATION
4-1
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
1.
Back pressure at the outlet of the meter must be sufficient for proper operation. Consider
the following equation when determining back pressure for the meter.
2.
Pb = 2 ªp + 1.25 pe
Where
3.
4-2
Pb =
minimum back pressure, pounds per square inch gauge (psig)
ªp =
pressure drop through the meter at the maximum operating flow rate for the liquid
being measured, pounds per square inch (psi)
pe =
equilibrium vapor pressure of the liquid at the operating temperature, pounds per
square inch absolute (psia), gauge pressure plus atmospheric pressure
Care should be taken to protect the Series 1200 housing and components from external
impact of any kind. Note temperature limitations in Section 2 when selecting meter
location.
OPERATION
DANIEL™ SERIES 1200 TURBINE METER
5.0
JUNE 2013
MAINTENANCE
Reference Figure 7-2 and 7-3 Exploded Parts Drawings.
Item numbers reference actual engineering drawings and are not meant to be consecutively
numbered.
5.1
General
The Series 1200 Turbine is designed to operate for extended periods of time without evidence of
wear or loss of precision. All meter adjustments were completed at the factory during liquid
calibration and should not require field setup. However, should inspection of internal
components be required or should field requirements change, information contained in this
document must be read and understood before attempting any maintenance procedure.
If the Series 1200 Turbine is found to be in need of repair, it is recommended the user contact the
nearest Daniel Measurement and Control Sales or Service Office. It is important that servicing be
performed by trained and qualified service personnel.
5.2
Maintenance Considerations
1.
Label all parts or place parts in labeled containers during disassembly.
2.
Use no metal clamping devices in direct contact with any meter part or surface.
3.
Rotor blades determine proper flow measurement and should be handled with extreme
care. Bending or altering the blades in any way can effect meter accuracy.
MAINTENANCE
5-1
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
5.3
Disassembly Procedure - Internal Components
All Sizes
Before removing the meter from the system the following precautions must be taken:
Disconnect all power to the meter.
PERSONAL INJURY AND/OR EQUIPMENT DAMAGE
Disconnect power to the meter.
Failure to disconnect power to the meter could result in serious personal injury and/or damage
to the equipment.
Relieve all line pressure.
PERSONAL INJURY AND/OR EQUIPMENT DAMAGE
Relieve all pressure at this time.
Failure to relieve line pressure at this time could result in serious personal injury and/or
damage to the equipment.
5-2
MAINTENANCE
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Disassembly Internal Components Size 1"
The internals of the 1” Series 1200 turbine meter are secured by means of a sleeve and C-ring.
The internals are supported by both up-and downstream hangers, which locate against a lip in the
turbine body.
The up and downstream hangers are identical. Each hanger has two hanger blades. When
assembled these hold between them a short shaft supporting the rotor assembly. The rotor
includes two small ball-bearing assemblies and a spacer. The ball bearing assemblies are a loose
fit in recesses in the rotor.
During disassembly it is possible to separate the rotor, bearings, spacer and shaft. These parts
are VERY SMALL and care should be taken not to lose any item.
Remove the C-clip at the inlet flange using
pliers.
Remove the sleeve. You may need to GENTLY tap the
internals from the downstream end using a soft punch
to start the process.
MAINTENANCE
5-3
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
Carefully remove the upstream stator. This is a onepiece assembly. NOTE: The shaft and rotor assembly
may come with this. The bearings, shaft and rotor will
fall out of the meter body if tipped.
View of the upstream stator, upstream
bearing, spacer and shaft as an
assembly.
METER PERFORMANCE CAN BE AFFECTED
Handle the rotor with care.
Improper handling of the rotor assembly may cause distortion to the rotor blades.
5-4
MAINTENANCE
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
The complete
internals of the
meter without the
sleeve and C-clip.
Meter internals
assembled ready for
re-assembly. It is
recommended that
the re-assembly of
the meter is
accomplished by
inserting the
internals as a single
assembly as shown.
The rotor has a “U” etched on the upstream side of the rotor. Be sure to re-assemble the
internal assembly with the rotor correctly oriented.
MAINTENANCE
5-5
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
Disassembly Internal Components Size 1-1/2" and 2"
The internals of the Series 1200 turbine meter (sizes 1-1/2" and above) are retained by means of
patented self-centering support fins, which are engaged by the compression of the flow
conditioning plate against the support fins.
Series 1200 turbine meter shown with nut driver in
place to begin disassembly.
Remove the nut, washer and flow conditioning plate
from the center bolt.
Lightly tap the center bolt on the end with a soft-faced
mallet to loosen the compression on the support fins.
Push the shaft in approximately flush with the support
fins and lift the fins slightly to remove them from their
engagement in the groove in the flowtube.
5-6
MAINTENANCE
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Gently remove the internals from the flowtube.
METER PERFORMANCE CAN BE AFFECTED
Handle the rotor with care.
Improper handling of the rotor assembly may cause distortion to the rotor blades.
This figure shows the internals after the initial
disassembly.
MAINTENANCE
5-7
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
After laying the support fins aside, remove the nut
from the downstream (rotor) end of the internal bullet.
The rotor assembly includes the rotor, two stainless
steel ball bearing assemblies and a spacer between the
ball races. The ball races are a loose fit in recesses on
the rotor hub and may fall out. Be careful not to lose
any small parts!
Remove the downstream stator and rotor from the bolt.
5-8
MAINTENANCE
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
The internals fully disassembled.
5.4
Reassembly of Internal Components
In all cases reassembly is the reverse of disassembly. Caution must be taken at all times to protect
the rotor blades from rough handling as blade position is critical to meter performance.
The rotor has a “U” etched on the upstream side of the rotor. Be sure to reassemble the internal
assembly with the rotor correctly oriented.
Torque the retaining nuts to 25 in. lbs.
5.5
Field Retrofitable Dual Pickoff
(Reference Figure 7-1)
In the event that a second pickoff is required for equipment originally supplied with a single
pickoff, or should field service or replacement of existing pickoffs be necessary, the following
procedure is recommended.
MAINTENANCE
5-9
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
All Sizes
1.
Disconnect all power to the meter.
PERSONAL INJURY AND/OR EQUIPMENT DAMAGE
Disconnect power to the meter.
Failure to disconnect power to the meter could result in serious personal injury and/or damage
to the equipment.
2.
Remove retaining screws (item 16) and cover (item 22) of the UMB housing assembly.
3.
Disconnect terminal connects at TB1, TB2, and TB3.
4.
Loosen retaining screws of preamplifier board (item 19) and lift out.
5.
Care should be taken not to jar or disrupt terminal board components.
6.
Remove retaining plate (item 26) and screw, (item 16).
7.
Insert second pickoff (item 24) into the pickoff cavity of the UMB and secure with
retaining plate (item 26) and screw, (item 16).
8.
Mount the preamplifier board in its original position and secure using spring loaded
retaining screws.
9.
Attach electrical output wiring from both pickoffs to terminal connection TB2 and TB3.
10.
Attach electrical output wiring from electrical accessories (conduit wiring) to terminal
connection TB1, number 3 for channel A, and number 5 for channel B.
11.
Secure all electrical wiring.
12.
Return UMB cover and secure using original retaining screws.
5-10
MAINTENANCE
DANIEL™ SERIES 1200 TURBINE METER
6.0
TROUBLESHOOTING
6.1
General
JUNE 2013
This information has been provided as an aid in basic troubleshooting. Disassembly procedures
have been outlined in Section 5.3 of this manual. If the Series 1200 Turbine is found to be in
need of repair, it is recommended the user contact the nearest Daniel Measurement and Control
Sales or Service Office. It is important that servicing be performed by trained and qualified
service personnel.
Table 6-1. Troubleshooting
Condition
Probable Cause
Correction
No output pulses from
amplifier module
Input voltage to amplifier below
minimum required for operation
Apply correct voltage (10 30 VDC)
Damaged or shorted pickoff
(Resistance across leads should
be 600-900 Ohm)
Replace pickoff
Damaged amplifier module
Replace amplifier module
Receiver unit not operating
Refer to instruction manual
on defective unit
Meter rotor not turning
Troubleshoot internal
assembly
Defective rotor bearing
Return rotor assembly to
factory for replacement or
repair
Rotor damaged by foreign
material passing through meter
Return rotor assembly to
factory for replacement or
repair
Foreign material on rotor blades
Check and clean blades
Rotor blades are bent
Return to factory for
replacement or repair
Defective accessory equipment
Troubleshoot equipment
Turbine meter rotor not
turning
Inaccurate readout
TROUBLESHOOTING
6-1
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
This page intentionally left blank.
6-2
TROUBLESHOOTING
DANIEL™ SERIES 1200 TURBINE METER
7.0
JUNE 2013
PARTS LIST
This section contains the necessary parts required to make up any standard unit covered in this
manual. Recommended spare or replacement parts have been denoted by an asterisk.
Item numbers reference actual engineering drawings and are not meant to be consecutively
numbered.
When ordering, the following information must be supplied.
•
•
•
•
Serial number
Part number
Part description
Quantity required.
PARTS LIST
7-1
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
Figure 7-1. UMB Assembly (All Sizes) (Reference Table 7-1)
7-2
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Table 7-1. UMB Assembly (All Sizes) (Reference Figure 7-1)
*
**
Item
Number
Description
Part Number
Quantity
Required
13*
O-ring (Viton®-A)
1500093-022
1
16**
Screw (Hex Socket Head)
151496
9
17
UMB Housing
899-00-100-00
1
18
Insulator
799-00-424–01
1
19*
Dual Channel Preamp
230-00-300-00
1
21*
Gasket
CA-375Z-259-XXA
1
22
UMB Cover
899-00-101-00
1
24*
Pickoff
899-00-201-00
1 or 2
26
Clamp
799-00-424–00
1
Recommended Spare Parts
All item 16 - Torque 55 in. lbs., min.
Viton® is a registered trademark of E.I. du Pont de Nemours and Company.
ATEX REPAIR NOTE:
Special Conditions for Safe Use: The joint between the Universal Mounting Box cover and housing
is a flat joint and has a flame path of 9.52mm in length and clearance of less than .0381mm. The
joint between the Universal Mounting Box housing and Sensor housing is a spigot joint which has
a radial length of 3.18mm, a axial length of 13.61mm and a clearance of .059mm.
PARTS LIST
7-3
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
Figure 7-2. Meter Assembly (1") - Stainless Steel Bearing Internals (Reference Table 7-2)
7-4
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Table 7-2. Part Numbers (1") - Stainless Steel Bearing Internals (Reference Figure 7-2)
PARTS LIST
Item
Number
Description
1" Part Number
Quantity
Required
1
Clip
1-504-05-520
1
2
Sleeve
797-10-500-60
1
3
Hanger Blade
798-10-080-00
4
4
Hanger Hub
798-10-008-00
2
5
Shaft
798-10-018-00
1
6
Bearing
1505024
2
7
Spacer
798-10-073-00
1
8
Rotor
798-10-019-00
1
14
O-Ring
1500093-022
1
7-5
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
Figure 7-3. Meter Assembly (1-1/2" and 2") - Stainless Steel Bearing Internals
(Reference Table 7-3)
7-6
DANIEL™ SERIES 1200 TURBINE METER
JUNE 2013
Table 7-3. Part Numbers (1-1/2" and 2") - Stainless Steel Bearing Internals
(Reference Figure 7-3)
Item
Number
Description
1-1/2" Part Number
2" Part Number
Quantity
Required
1
Nut
151687
151687
1
2
Washer
151891
151891
1
3
Flow Conditioning Plate
798-14-301-01
798-16-301-01
1
4
Hanger Blade
798-14-070-00
798-16-070-00
3
5
Hanger Hub
798-14-308-00
798-16-308-00
1
6
Rotor
798-14-019-00
798-16-019-00
1
7
Down-Stream Cone
798-14-013-00
798-16-013-00
1
12
O-Ring
1500093-022
1500093-022
1
26
Bearing
155195
155195
2
27
Spacer
798-14-073-00
798-14-073-00
1
PARTS LIST
7-7
JUNE 2013
DANIEL™ SERIES 1200 TURBINE METER
This page intentionally left blank.
7-8
PARTS LIST
Daniel Measurement and Control, Inc.
Returned Material Authorization
Repair Form for Used Equipment
Including Decontamination/Cleaning Statement
A Return Material Authorization (RMA) number must be obtained prior to returning any equipment
for any reason. Download the RMA form on the Daniel Measurement and Control, Inc. Support
Services web page by selecting the link below.
http://www2.emersonprocess.com/EN-US/BRANDS/DANIEL/SUPPORT-SERVICES/Pages/Support-Services.aspx
1. Return Material Authorization (RMA) Number ____________________________________
2. Equipment to be returned:
Model Number _________________________ Serial Number _______________________
3. Reason for return: ___________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
________________________________________________________________________
Decontamination/Cleaning Fluids Process
A.
List each substance in which the equipment was exposed. Attach additional documents if necessary.
Common
Name
B.
CAS# if
available
Used for Hazardous
Waste (20 CFR 261)
[ ] Yes
[ ] No
[ ] Yes
[ ] No
[ ] Yes
[ ] No
[ ] Yes
[ ] No
[ ] Yes
[ ] No
[ ] Yes
[ ] No
EPA Waste Code
if used for hazardous waste
Circle any hazards and/or process fluid types that apply:
Infectious
Cyanides
Carcinogen
Radioactive
Sulfides
Peroxide
Explosive
CorrosiveOxidizer
Reactive-Air
Pyrophoric
Flammable
Reactive-Water
Poison Gas
Poison
Reactive-Other (list)
Other hazard category (list):
C.
Describe decontamination/cleaning process. Include MSDS description for substances used in decontamination and
cleaning processes. Attach additional documents if necessary.
Shipping Requirements
Failure to comply with this procedure will result in the shipment being refused.
1. Write the RMA number on the shipping package.
2. Inside the package include one copy of this document and all required Material Safety Data
Sheets (MSDS)
3. Outside of the package attach one copy of this document and all required Material Safety Data
Sheets (MSDS).
THIS EQUIPMENT, BEING RETURNED “FOR REPAIR,” HAS BEEN COMPLETELY
DECONTAMINATED AND CLEANED. ALL FOREIGN SUBSTANCES HAVE BEEN
DOCUMENTED ABOVE AND MSDS SHEETS ARE ATTACHED.
By:
(Signature)
Title:
(Print name)
Date:
Company:
Phone:
Fax:
Emerson Process Management
Daniel Measurement and Control, Inc.
11100 Brittmoore Park Drive
Houston, TX 77041
T+1 713-467-6000
F+1 713-827-4805
www.emerson.com
Copyright© 2013
Daniel Measurement and Control, Inc. and Daniel Measurement Services, Inc. Divisions of Emerson Process Management reserve the right
to make changes to any of its products or services at any time without prior notification in order to improve that product or service and to
supply the best product or service possible.
Daniel Measurement Services, Inc. offers both on-call and contract maintenance service designed to provide single-source
responsibility for all Daniel products. The sales and service offices of Daniel Measurement and Control, Inc. are located throughout the
United States and in major countries overseas. For the location of the sales or service office nearest you, telephone the number below
or visit the Daniel Measurement and Control, Inc. website.
T+1713-827-6314
F+1713-827-4805
www.emerson.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement