Manual Flocometer

Training Handbook Clamp-on Ultrasonic Flowmeter Installation Module FU060BBEB

Editor The following training handbook is produced by Endress+Hauser Flowtec AG. Changes and extracts are subject to the permission of the editor. To contact the editor please use address below. Copyright This document is protected by copyright. The use outside of E+H or the right to c opy the document is only permitted with written permission of Endress+Hauser Flowtec. For further information and permissions please contact: Endress+Hauser Flowtec AG Training Manager Kägenstrasse 7 4153 Reinach BL Switzerland

E-Mail: [email protected] Prerequisite of the trainee Before attempting this learning module it is expected that the trainee has successfully finished the training module FU010B to FU050B. If necessary this knowledge has to be built up first. Objective of this learning module The participant understands… …the relevant parameters to install an ultrasonic flowmeter …the parameters which have the greatest influence on a successful installation …how to verify a successful installation …where to install the meter to have the greatest chance of success

Additional documents Power Point Presentation FU060BPEB Assessment document FU060BAEB Installation Video CD 044D/06/en/11.07 (also available via internet) Installation_93P_small_sensor.WMV

Changes REV B Completely up-dated, fully replaces REV A

Training Handbook FU060BBEB

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Content 1.

Selecting an Installation Location ......................................................................................................................4 1.1. 1.2. 1.3. 1.4. 1.5.

2.

General Requirements.........................................................................................................................................4 Inlet and Outlet requirements for Clamp-on Ultrasonic Meter..............................................................................4 Insufficient Inlet and Outlet run Information .......................................................................................................4 Sensor Radial Location.........................................................................................................................................5 Electronics Installation Location ..........................................................................................................................5

Transmitter Programming .................................................................................................................................6 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9.

Outer Diameter (circumference)..........................................................................................................................6 Liquid Sound Velocity .........................................................................................................................................6 Number of Traverses ...........................................................................................................................................6 Sensor Type ........................................................................................................................................................7 Pipe Wall Thickness ............................................................................................................................................7 Pipe Wall Thickness ............................................................................................................................................7 Pipe Sound Velocity.............................................................................................................................................7 Pipe Liner and Thickness.....................................................................................................................................7 Temperature .......................................................................................................................................................7

3.

Transmitter Programming Steps ........................................................................................................................8

4.

Installation of Mounting Post...........................................................................................................................10 4.1. 4.2.

1 Traverse Installation of Mounting Post............................................................................................................10 2 Traverse Installation of Mounting Post............................................................................................................11

5.

Installation Sensor Holders..............................................................................................................................12

6.

Installation of P sensor 6 MHz (small) .............................................................................................................13

7.

Installation Verification ...................................................................................................................................14


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1. Selecting an Installation Location 1.1.

General Requirements The specification of ANY flowmeter is based on an ideal installation. Installation guidelines for any technology exist. They should be looked at as a MINIMUM requirement. Particular installation requirements of a Ultrasonic clamp-on meter: The meter must be installed with sufficient straight pipe up- and down-stream The pipe must remain completely full of liquid during measurement The programming • • •

1.2.

Inlet and Outlet requirements for Clamp-on Ultrasonic Meter Clamp-on ultrasonic meter, installation location is critical for a successful installation. It is critical that the meter be installed in a location where the flow will have a flow profile that is fully developed. To insure the flow is fully developed it is required that the meter have a straight metering section before and after the meter. The length of this straight section will depend on what flow disturbances that is before the metering section. If several flow disturbances are before the meter, the disturbances requiring the greatest straight run is the determining distance.

1.3.

Insufficient Inlet and Outlet run Information The WRC in England Source of Influence (% reading) at separation conducted an independent disturbance distances of study of 3 manufactures of ultrasonic clamp on meters. 5D 10 D 20 D They determined the single most determining factor of Single bend -3 to -8 -2 to -6 -1 to -4 accuracy of a clamp-on Gate valve -2 to -3 -2 to -3 0 to -1 ultrasonic flow meter was flow (2/3 open) profile and the straight run length before the meter. In the Reducer (2:1) -1 to -3 0 to -2 0 table the effects can be seen as Expander (1:2) -3 to -5 -2 to -4 0 to -2 a range on the accuracy. A range is used since the radial Double bend -5 to -7 -3 to -6 -4 to -5 position around the pipe will also have an effect. It is important to note that all the add uncertainty is negative. This means in practice if the up stream requirements can not be met, then the highest flow value at constant conditions when the sensor are radial moved around the pipe is most li kely the best value to the true value, however most likely still under registering the flow.


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1.4.

Sensor Radial Location A vertical installation is the preferred method of installation. This is the best installation to avoid partially filled pipes and it avoids placing the sensors where solid particles or entrained gas can accumulate and disturb the flow measurement. If the sensors must be installed in a horizontal pipe avoid the top and bottom of the pipe. Try to place the sensors directly on the sides or at least 15° from the top or bottom of the pipe. This is done to avoid accumulating gas at the top and solid build up at the bottom of the pipe, both of which can disturb the flow measurement.

1.5.

Electronics Installation Location With the Ultrasonic Clamp-on meters, the electronics are always a remote version. Thus the location for mounting the electronics must be within the cable length ordered. Each electronics can either be wall or pipe mounted. The appropriate ambient condition within specification must be adhered followed.


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2. Transmitter Programming In order to install the ultrasonic sensors, the relative information concerning the application must be programmed into the transmitter. After this information is programmed into the transmitter via the display or FieldTool/FieldCare, the transmitter will then output the proper sensor distance. Applicator can also be used as an alternative. It is very important this information be as accurate as possible as the accuracy of the system is strongly dependent on these variables.

2.1.

Outer Diameter (circumference) The diameter of the pipe can be determined by measurement (preferred) , reading the diameter printed on the pipe, or using a pipe dimensions reference book. Alternatively, the circumference could also be entered. The value can be determined just as the diameter. If the diameter is inputted the circumference is automatically calc ulated and vice versa. The last entered value is the value used for sensor distance.

2.2.

Liquid Sound Velocity The Prosonic Flow transmitter already contains an extensive list of liquids which the sound velocity i s already preprogrammed. If liquid be measured is not listed then the sound velocity will need to be entered manually. This can be done by selecting the option “others” and then entering sound velocity. The sound velocity of other liquids can be determined by r eferences (books, internet, etc…), using the liquid sound velocity sensors (DDU 18), or a trial a nd error method (this is taught in Advance Hands-on Training).

2.3.

Number of Traverses The number of traverses will determine if the sensors are mounted on opposite sides of the pipe, in a 1 traverse installation or on the same side of the pipe i n a 2 traverse installation. The main factor for deciding the number of traverses is the size of the pipe and the easy of installation. Generally a 2 traverse installation is always the easiest form of installation. If signal strength is low, changing to a 1 traverse installation can improve the signal strength. The following table can be used as a guideline.


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2.4.

Sensor Type The sensor type is printed on the name plate. The corrected sensor should have been selected in the selection process (see training module “Selection and Sizing”)

2.5.

Pipe Wall Thickness The pipe wall thickness can be determined by measurement (preferred with DDU19) , reading the diameter printed on the pipe, or using a pipe dimensions reference book.

2.6.

Pipe Wall Thickness The pipe wall thickness can be determined by measurement (preferred with DDU19) , reading the diameter printed on the pipe, or using a pipe dimensions reference book.

2.7.

Pipe Sound Velocity The pipe sound velocity is in almost every circumstance preprogrammed into the Prosonic Flow transmitter through the selection of the pipe material. In the rare case it can be measured using the DDU 19 sensor.

2.8.

Pipe Liner and Thickness If the pipe is lined, the liner ma terial and thickness need to be determined. Often this is only possible by referring to reference material or consulting the pipe manufacturer.

2.9.

Temperature The normal process temperature is required. The temperature influences the speed of sound of the measured liquid and the pipe, thus it influences the sensor position. After a suitable sensor location is found the transmitter is programmed to determine the sensor spacing


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3. Transmitter Programming Steps It is highly recommended to refer to the Installation Vi deo (CD 044D/06/en/11.07) available on the internet to understand the installation sequence. If access to video is not available, the following can be used as an outline for installation. Begin the programming of the Prosonic Flow meter by pushing the "E"-button. This button is used to initiate the programming sequence, and later for confirming selections. The plus and minus buttons are used to access the va rious selection options. After entering into programming, select "quick set-up" or "sensor set-up". Text displayed will depend on the Prosonic Flow device employed. After entering the set-up routine, confirm again, that you wish to enter the sensor set-up. The first programming change requires an access code. Enter the model number (The model number of the device serves as the default access code). Then enter the liquid being measured. Various options are available: if your particular liquid is not listed, simply choose t he option "others". The temperature for normal operations is then to be entered. If temperature varies during operations, enter an average temperature value. The sound velocity of the liquid is then displayed for the normal operating temperature. If you have c hosen “others” earlier, you will need to enter the liquid sound velocity. The material of the pipe in which the li quid is being conveyed should then be entered. Select the appropriate material. The sound velocity of the pipe is then displayed. You now have the choice of entering either the outer pipe circumference or outer pipe diameter. After entering one of the values, the other value is automatically calculated. The outer pipe diameter can often be found printed on the pipe, along with the pipe wall thicknes If the pipe diameter cannot be found, we suggest measuring the circumference of the pipe and entering that value. Now enter the pipe wall thickness. If this is unknown, it is possible to estimate the value.


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If a lined pipe is being used, the material of the liner will need to be entered along with the thickness of the liner. If the pipe is not lined, simply choose “none”. The sensor type is required; this can be found printed on the sensor itself. The transmitter will prompt the number of traverses. The number of traverses determines if the sensors are to be mounted on opposite sides of the pipe, in a one-traverse installation, or on the same side of the pipe in a 2-traverse installation. For pipes smaller than 80mm, one traverse is suggested. For pipes in the size range of 80 mm to 600mm, 2 traverseinstallation is suggested. And for pipes larger than 600 mm, one traverse is suggested. The length of the sensor cable will now need to be entered. Now, all the parameters for installation have been programmed into the transmitter, and the mechanical installation can begin.


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4. Installation of Mounting Post Depending on the selected number of traverse in the transmitter programming one of the two possible procedures will be required:

4.1. 1 Traverse Installation of Mounting Post It is highly recommended to refer to the Installation Vi deo (CD 044D/06/en/11.07) available on the internet to understand the mechanical installation of the 1 traverse mounting post. If access to video is not available, the following can be used as an outline. For a one-traverse installation, the transmitter will display a sensor distance and wire length. The instrument is delivered with two wires with a flat cable shoe on one end, and a variable-length cable shoe on the other end. Adjust the cable shoes to correspond with the wire length indicated from the transmitter. The distance should be measured from the center of each cable shoe. Securely tighten the screw on the variable cable shoe, so that the cable shoes are firmly positioned at the proper distance. Tighten one of the mounting posts firmly to the side of the pipe, and leave the other post loose, so it can slide along the pipe. Place the flat cable shoe on each mounting post. Then take the other end with the variable-length cable shoe and run each wire around opposite sides of the pipe. Place the cable shoe on the mounting post, so that the screw is on the outside, and thus accessible to be loosened later. Slide the free mounting post, so the cables are pulled tight. Then secure the post to the pipe. Loosen the screw on the cable shoe, and detach from the mounting post. The mounting posts for one-traverse installation are now in place..


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J. Metcalfe/MTU

4.2. 2 Traverse Installation of Mounting Post It is highly recommended to refer to the Installation Vi deo (CD 044D/06/en/11.07) available on the internet to understand the mechanical installation of the 2 traverse mounting post. If access to video is not available, the following can be used as an outline. To position the mounting posts for the two-traverse installation, the ruler supplied in the delivery will be needed.

After programming the application parameters, the transmitter will indicate a "letter" and "number", corresponding to two holes, drilled into the ruler. The mounting posts will feed through these holes for proper positioning. Tighten the mounting posts to the pipe, making sure the posts are at the same radial position on the pipe. The ruler can then be removed.


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J. Metcalfe/MTU

5. Installation Sensor Holders Secure the sensor holders to the mounting post. Make sure they are facing in the correct direction as shown. After the sensor holders are fastened to the pipe, apply coupling gel to the face of the sensor. Approximately 1 mm thickness is required for the surface area, which will be in contact with th e pipe. The coupling gel provides a good acoustic coupling between the sensor and the pipe. Now the sensors can be placed into the holders. They only slide into the holders in a particular orientation, where a groove in the sensor aligns with a guide rail in the holder. Push the sensor firmly onto the pipe, compressing the internal spring. Then turn the sensor covers, so that the closed arrow aligns with the arrow on the sensor holder. Remove the protective caps from sensor and sensor cable, and firmly secure the sensor cable to the sensor. The mechanical installation is now complete


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6. Installation of P sensor 6 MHz (small) The 6 MHz P sensor installation can begin by i nstalling the mounting plate. Unlike the other sensors this can be done before knowing the sensor d istance. For smaller pipes DN15-32 a U-bolt is used for securing the mounting plate to the pipe for pipes sizes DN40-65 a band is used. After the sensor distance is determined, the freely adjustable sensor must be adjusted to the proper sensor distance. This must be done precisely as sensor distance on such small pipes can have a large influence on the overall accuracy of the system. The sensor distance is m easured from the points shown on the graphic. This needs to be done with the supplied callipers (Vernier). Finally coupling media can be applied to the transmitting portion of the sensor (raised portion at the sensor spacing location) and the sensor attached to the mounting plate. See video “Installation_93P_small_sensor.WMV” for procedure.

S e n s o r s p a c i n g


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7. Installation Verification To verify successful installation, check the signal strength from the transmitter under "measured values". This va lue should not undercut exceed 50 decibels. If it is below this minimum, the installation should be improved if possible. Also check the measured sound velocity of the liquid. This should be within 3% of the sound velocity of liquid, entered into the transmitter in the initial programming sequence. After confirming that installation is successful, the Prosonic Flow meter is ready to measure.

Verification

Parameter Liquid Sound Velocity Measured versus programmed

+/- 3%

Signal Strength


> 50 decibels (dB)

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Manual Flocometer

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