Emerson Process Management 3-9008-701 manual

Operating and maintenance instructions Part Number: 3-900 8-701, Rev. J January 2015 Compac t Prov er[...]

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Da n i el cus to m er s er v i ce Email • Custo mer S er vice: tech .ser vi ce@em er son pro cess .com • Cust omer Support: danie l.cst.suppor t@emerson.c om • Asia -Pacific: danielap .suppor t@emerson.com • Eur op e: Dani elE MA . C ST @E m er son P roce ss. com Location Te l e p h o n e n u m b e r Fa x n u m b e r Nor th America/L atin A[...]

Sign al w ord s and symbols Pay speci al atten tion to the following sign al words, sa fe t y alert s ymbols and state men ts: Impor tant Impor tant is a state me nt the us er needs to know and conside r . Tip Tip provides information or suggestions fo r improved e fficie ncy or best results. Note Note is a “ gene ral by-the-way” conten t not e[...]

Impor t ant sa f et y instruc tions Daniel Me asure ment and Control, Inc. (Danie l) designs, manu factures and tests products to func tion within specific conditions. Becaus e these produc ts are sophisticated technical instruments, it is impor tant that the owner and opera tion personnel strictl y adhere both to the inf ormation printed on the pr[...]

Product O peration Pe rsonnel: • T o preve nt pe rsonal in jur y , personne l must f ollow all instructions of this m anual pri or to and during operation of the pro duc t. • Follow all warnings, cautions, and notices m arked on, and supplied with, this produc t. • V erif y t hat this is the correct instruc tion manual for your Daniel product[...]

No tic e THE CONTENTS OF THIS PUBLICA TIO N ARE PRESENTED FOR INFORMA TIONAL PUR POSES ONL Y , AND WHILE E VERY EFFORT HAS B EEN MADE T O ENSURE THEIR ACCURA CY , THE Y ARE NOT T O BE C ONST RUED AS W ARRANTIES OR GU ARANTEES , EXPRE SSED OR IMPLIED , RE GARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICAB ILIT Y . ALL SALES A[...]

W arrant y and Limitations 1. LIMITED W ARRANT Y : Subject to t he limitations con tained in Section 2 he rein , Dan iel Me asureme nt & Control, Inc. ("Danie l") warrants that the lice nsed firmware embo died in t h e Goods will execute the programming inst ruc tions provided by Daniel, and that the Goods manufac tured by Daniel will[...]

Operating and maintenance in structions Table of Contents 3-9008-701 Rev J January 2015 Table of Contents 9 Co ntents D aniel c ust omer se r vice ................................................................................... 3 • Sign al words and symbols .............................................................................. 4 • Im[...]

10 Table of Contents Table of Cont ents Operating and mainte nance instructions January 2015 3-9008-701 Rev J 4.5 Optical c onv ersion kit ................................................................................ 6 7 4.6 Detector Switc h R epl ace me nt ..................................................................... 68 Section 5: Troub[...]

Operating and maintenance in structions List of Tables 3-9008-701 Rev J January 2015 List of Tables 11 List o f T ables T able 1-1 Hydraulic ..... ........... .............. ........... ........... .............. ........... .............. ............ .............. . .... . 7 T able 1-2 Standard compact prover set-up data .................. .....[...]

12 List of Tables List of Tables Operating an d maintenance instructions January 2015 3-9008-701 Rev J[...]

Operating and maintenance in structions List of Figures 3-9008-701 Rev J January 2015 List of Figures 13 List o f Figures Figure 1-1 Outline drawings - Compact prover .................. .............. .............. ............ .............. ...... 4 Figure 1-1 Outline drawings - Compact prover (Continued)......................... ........... ...[...]

14 List of Figures List of Figures Operating an d maintenance instructions January 2015 3-9008-701 Rev J Figure 5-2 Prover wiring diagram (single phase power) ............ .............. .............. .............. .......... 76 Figure 5-3 Prover wiring diagram (three phase power) ............. .............. .............. .............. .......[...]

Operating and ma intenance instru ctions Section 1: Introdu ction 3-9008-701 Rev J January 20 15 General 1 11 12 13 14 15 16 Sec t ion 1: Introduc tion 1.1 General This manual is designed to provide in form atio n and guidance to pe rsonnel res ponsible for the operation and mainte nance o f the Compac t Prove r . The content o f this manual is int[...]

2 Mechanical description Section 1: Introduc tion Opera ting and mainten ance instructio ns January 2015 3-9 008-701 Rev J • Mete r F ac tor: Correction factor (multiplier) for me ter re adout 1.3 Mechanical description The basic outline of the c o mpact prove r and its compone nt parts are shown in Figure 1-1 . The compact prove r consists of a [...]

Operating and ma intenance instru ctions Section 1: Introdu ction 3-9008-701 Rev J January 20 15 Mechanic al descripti on 3 the measu rement pis ton by mea ns of th e d etec to r shaft. The passa ge of the fl ag through the slotted op tical switches de fines the dis plac ed volume (ba se volume) o f the prov er . For detailed informa tion on th e O[...]

4 Mechanical description Section 1: Introduc tion Opera ting and mainten ance instructio ns January 2015 3-9 008-701 Rev J Figure 1-1 Outline drawings - Compact prover T ypical 8”, 12”, 18”, 24”, 34” and 40” NE C T ype T ypical 8”, 12”, 18”, 24”, 34” and 40” A T E X T y pe[...]

Operating and ma intenance instru ctions Section 1: Introdu ction 3-9008-701 Rev J January 20 15 Mechanic al descripti on 5 Figure 1-1 Outline drawings - Compact prover (Continued) Ty p i c a l 1 2 ” M i n i N E C Ty p e Ty p i c a l 1 2 ” M i n i AT E X Ty p e[...]

6 Technical data Section 1: Introduc tion Opera ting and mainten ance instructio ns January 2015 3-9 008-701 Rev J 1.4 T ec hnical data Materi als of c onstruc tion: Standar d: 17-4 stainless st eel flow tube with h ard c hrome plating, carbon steel pipe and fl anges Standar d maximum working pressure : 8" to 24" Siz e: 150 lb. AN SI  [...]

Operating and ma intenance instru ctions Section 1: Introdu ction 3-9008-701 Rev J January 20 15 Technical data 7 34” and 40" Siz e : 20 to 120.F (-7 to 49.C) Standar d ambien t tempe rature range : -4.F to 104.F (-20.C to 40.C) Consult factor y for othe r ch anges. Impor tant T emperatur e span diffe rential between tie rods and flow tube n[...]

8 Technical data Section 1: Introduc tion Opera ting and mainten ance instructio ns January 2015 3-9 008-701 Rev J Note s: 1. T empera ture and pres sure tap on the outlet flange (1” di a.) can be supplied upon reques t. 2. Fluid visc osit y ranges up to 10,000 ce ntist ok es. 3. Considerations f or mete r t ype and pulse output qualit y should b[...]

Operating and ma intenance instru ctions Section 1: Introdu ction 3-9008-701 Rev J January 20 15 Technical data 9 5. For more in form ation on pulse qu alit y and compact prov ers, re fe re nce API Ch apte r 4.2. 6. For c ert ified dimensional drawing s, plea se con tac t the fac tor y . 7. Upstream multiplie r s are appro xima te . Actual values c[...]

10 Technical data Section 1: Introduc tion Opera ting and mainten ance instructio ns January 2015 3-9 008-701 Rev J Note s: 1. Consul t the factory for opti onal v oltages no t listed. 2. The opera ting comp ute r must be c onnected to a power sourc e se parate fr om that of the prove r to av oid varianc e in signal caused by line load charge and d[...]

Operating and ma intenance instru ctions Section 1: Introdu ction 3-9008-701 Rev J January 20 15 Technical data 11 Equipme nt f or Hazar dous Locations PED - siz es 12 ” Mini, 12”, 18” and 34”, Britis h Stand ards Institute A TE X - 8" through 34", DEMK O 03 A TE X 0322369 (Option 1 designs only) Ex d e ia m IIB T4 Certif ications[...]

12 Technical data Section 1: Introduc tion Opera ting and mainten ance instructio ns January 2015 3-9 008-701 Rev J[...]

Operating and main tenance instr uctions Section 2: Instal lation and set-up 3-9008-701 Rev J January 20 15 Installation 13 21TOP (14) Sec t ion 2: Installa tion and set -up 2.1 Installation The compa ct prove r ma y be installed perm ane ntly in a proc ess line or used a s a port able unit. The prove r is intended f or abov e ground use and should[...]

14 Installation Section 2: Instal lation and set-u p Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J Impor tant: It is the custome r's re sponsibility to inst all this equipmen t in a system th at provide s adequat e over -p res su re pr otec tio n. Impor tant: Lines shou ld be flushed thor oughly t o rid p iping of po[...]

Operating and main tenance instr uctions Section 2: Instal lation and set-up 3-9008-701 Rev J January 20 15 Set-up 15 Figure 2-1 T ypical prov er installati on 2.2 Set -up 2.2.1 Supplying e lec trical power t o the compact prove r Refer en ce T able 1-3 for stand ard v oltage and ampera ge inf ormation. Option al v oltage and ampera ge inf orm atio[...]

16 Connection of the op erating computer Section 2: Instal lation and set-u p Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J the motor star ting swi tch will be neces sar y for this conv ersion. Be sure to follow all applicable electrical codes f or the area o f installa tion. 2.2.2 Connection of the ope ra ting c ompute r[...]

Operating and main tenance instr uctions Section 2: Instal lation and set-up 3-9008-701 Rev J January 20 15 Connection of the operating computer 17 Figure 2-2 Double chronometr y[...]

18 12 or 24V DC Interface Board Section 2: Instal lation and set-u p Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J 2.2.3 12 or 24V DC In te r face Bo ard Ther e ar e t wo ( 2) d ifferent st yles of i nter f ace boards: 12V DC and 12/24V DC. See Figure 2-3 and 2-4. The power requir ed for the inter face board is supplied t[...]

Operating and main tenance instr uctions Section 2: Instal lation and set-up 3-9008-701 Rev J January 20 15 12 or 24V DC Interface Board 19 Figure 2-3 12V Prov er interface board J1: T o optical as se mbly (pin 6 not u sed) J2: T o co ntr ol co nn ec t ion J3: T o water draw h ardware kit J4: T o r un valve J5 : Fo r e x t ern al co ntr o l o f S 1[...]

20 12 or 24V DC Interface Board Section 2: Instal lation and set-u p Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J Figure 2-4 12/24V Prov er interface board J1: T o optical a sse mbly (pin 6 no t us ed) J2: T o co ntr ol co nn ec t ion J3: T o water draw h ardware kit J4: T o r un valve J5 : Fo r e x ter na l cont r ol of[...]

Operating and main tenance instr uctions Section 2: Instal lation and set-up 3-9008-701 Rev J January 20 15 Charging the Pneumatic Spring Plenum 21 2.2.4 Ch arging the Pne um atic Spring Ple num The pneuma tic spring ple num must be ch arged for prope r opera tion. The prov er is shipped from the fac tor y with an empt y spring plenum for saf ety. [...]

22 Charging the Pneumatic Spring Plenum Section 2: Instal lation and set-u p Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J Figure 2-5 T ypical nitrogen adjust panel[...]

Operating and main tenance instr uctions Section 2: Instal lation and set-up 3-9008-701 Rev J January 20 15 Base vol ume cer tificat ion 23 Figure 2-6 Connection diagram 2.3 Base volume cer t ification The prove r base v olume has bee n ce r tified at the factor y using the volumetric displac eme nt method (water draw) per API guidelines. Th e ba s[...]

24 Calibration integrity seal installation procedure Section 2: Instal lation and set-u p Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J 2.4 Calibration integrit y seal installation procedure Purpose : The purpose is to pro vide a proc edure for e nsu ring the calibrated v olume int egrit y of the compact prove r . The opt[...]

Operating and main tenance instr uctions Section 2: Instal lation and set-up 3-9008-701 Rev J January 20 15 Calibration integrity seal installation procedure 25 Step 1 Once the se al nut is se cure ly tight ened in pl ace (see Figure 2A); insert the braided wire through the hole in t he nut as sho wn in Figure 2B. Step 2 Wrap the braided wire aroun[...]

26 Calibration integrity seal installation procedure Section 2: Instal lation and set-u p Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J[...]

Operating and ma intenance instru ctions Section 3: Operat ion 3-9008-701 Rev J January 20 15 General operational theory 27 Sec tion 3: O pe ra tion 3.1 General operational theor y The operational sequenc e of the compact prove r is as f ollows: 1. The mea suremen t piston is normally in t he upstream (standby) position, with the poppet valv e ope [...]

28 General operational theory Section 3: Operati on Operating and maintenance instruction s January 2015 3-9 008-701 Rev J Figure 3-1 Standby position Figure 3-2 In itial motion[...]

Operating and ma intenance instru ctions Section 3: Operat ion 3-9008-701 Rev J January 20 15 General operational theory 29 Figure 3-3 Proving Figure 3-4 End of proving run[...]

30 Operating instructions Section 3: Operati on Operating and maintenance instruction s January 2015 3-9 008-701 Rev J Figure 3-5 Piston return ing to upstream position 3.2 O perating instructions The compact prove r should be connected to the process line, similar to Figure 2 -1 , eithe r upstre am or downstre am of the met er unde r test . Electr[...]

Operating and ma intenance instru ctions Section 3: Operat ion 3-9008-701 Rev J January 20 15 Operating instructions 31 * R = 5.88 for Pr ov ers shipped bef ore Janu ar y 1, 2006 Figure 3-6 Spring plenum T able 3-1 Spring plenun ‘R’ values Prov er size R 8” 3.5 12” Mini 3.2 12” 3.2 18” 5 24” 5* 34” 3.7 40” 4.45[...]

32 Operating instructions Section 3: Operati on Operating and maintenance instruction s January 2015 3-9 008-701 Rev J If the plenum pressure is gre at er than the calcul a ted va lue , the ex ce ss pres sure mu st be v en ted from the plenum. If the plenum pres sure is less than the calculated value , the supply bottle will need to furnish the nec[...]

Operating and ma intenance instru ctions Section 3: Operat ion 3-9008-701 Rev J January 20 15 Operating instructions 33 Figure 3-7 Hydraulic system 7. V ent all air from the syst e m using the hand valves locat ed on the inlet and outlet flanges of the f low tub e. Slowl y close the process fl uid dive r ter valv e (double block and bleed) and open[...]

34 Operating instructions Section 3: Operati on Operating and maintenance instruction s January 2015 3-9 008-701 Rev J If the proce ss flow is to be le f t running through the pro ve r , be sure t o lea ve the h ydraulic syste m motor running. The hydraulic pump wil l go into by-pas s mode and hold the piston upstream. The motor will draw minimal c[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Seal Leak Chec k 35 Sec tion 4: Maint en ance 4.1 Seal Leak C heck For fa ctor y part number of seal Le ak Detector Kit, see S ection 7: Par ts list , Part s. Refer en ce Figure 4-1 and Figure 4-2 . Figure 4-1 Leak detector kit MAINTENANC E HAZARD Ensure[...]

36 Seal Leak Chec k Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J Impor tant: It is ESSENTIAL that the liquid and prover te mpera tures remain stable during the leak check procedure as thermal expansion or contrac tion will gi ve incorrect resu lts. The kit shown in Figure 4-1 is d e s i g n ed to o p[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Base volume determination 37 5. Plac e the me asure ment pist on in the upstr eam po sition f or simple a ttachme nt o f the indicat or rod. The me asure m en t piston ma y be mo ved up stre am by activating the hydraulic syst em. 6. The indicator rod is[...]

38 Certification techniques Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J be dete rmined to ha ve an exact volume of 15. 00123 or 14.99712 gallons. Thes e t ypes of numbers are typical and nece ssary . The particular v olume used is determined by the physical location of the met er unde r test, e ithe[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Certification techniques 39 • Certif ication Data Sheet for rec ording data. Re f er to Figur e 4-6 f or example da ta shee t. Refer to Sec tion 4.3 for explan ation of symbols. Note s: 1. T empe ratur e transmitte rs are not r ecomme nded. 2. F ac tor[...]

40 Certification techniques Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J Figure 4-3 Compact prov er wate r draw asse mbly t ypical NEC style (non -explosion proof)[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Certification techniques 41 Figure 4-3 Compact prover wate r draw assembly (continued) T ypical Ex -proof style[...]

42 Water draw procedure: (Reference Figure 4-4 and notes on page 47) Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J Figure 4-4 W ater dra w system 4. 2 . 2 Water d r aw p r o ced u r e: ( Referen ce F i g ur e 4 - 4 a n d n otes o n page 4 7) 1. Isolate the pro ve r from operational lines u s ing doubl[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Water draw procedure: (Reference Figure 4-4 and notes on page 47) 43 4. Supply appropria te ope rational v oltage (+12 or 24 VDC) to the prove r interface board at rece ptacle J-2, pins 2 (-) and 4 (+). Ref erence Sect ion 2.4 to verif y p ro per vo lt a[...]

44 Water draw procedure: (Reference Figure 4-4 and notes on page 47) Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J Be sure this proc edure plac es the mea sure men t pist on and flag in to the full downstre am position. 10. The mea surement pist on must no w be placed in to the start position for the [...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Water draw procedure: (Reference Figure 4-4 and notes on page 47) 45 Figure 4-5 T est measur e temperature stabilization 15. Slide optical a ssembly c ov er back to expose the sec ond optical v olume switch and the ends of the invar rods . Measure and re[...]

46 Water draw procedure: (Reference Figure 4-4 and notes on page 47) Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J nece ssar y , to ma intain the w ate r lev el in the te st mea sure near the z e ro mark. When th e flag exits th e seco nd optical volume swit ch, the sol enoi d valve (SV) will c lose a[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Water draw procedure: (Reference Figure 4-4 and notes on page 47) 47 level in the test mea sure near the z ero mark. Whe n the flag ent ers the fir st optical volume switc h, the sole noid valv e (SV) will clos e . 31. Fully ope n valve W3 to drain the t[...]

48 Water draw procedure: (Reference Figure 4-4 and notes on page 47) Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J Figure 4-6 T ypical volumetric determinatio n data s heet[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Certification Data Sheet and Calculations 49 Figure 4-7 T ypical prover control panel assembly (12” sho wn) 4.3 Cer tification Data Sheet and Calculations 4.3.1 D ata Sheet Entrie s The follo wing is a ste p-by-ste p proc edure f or using th e V olumet[...]

50 Calculations Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J 7. T est Mea sure Scale R ea ding: Actual measureme nt rec orded from the calibrated section of the test mea sure. This is a + or — reading from the z ero mark. 4.3.2 Calcula tions The following formula will be used in the process of calc[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Calculations 51 Td is the Sensor Moun ting T emperature reco rded from the water draw proc edure. Eir is the linear c oeffic ien t of expansion f or the Inv ar R ods. This value is ba sed on the tempe ra ture units used and will be 0.0000008/ F or 0.0000[...]

52 Seal Replacement Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J mea sured in kPa, the Modulus of el astici t y for stainless stee l will be 196,500,574.5, 206,842,710 f or carbon stee l, and 200, 000,000 f or 2205duplex stainle ss stee l. t is the wall thickness of the flow tube. Be sure to us e ide[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Measurement Piston and Flow Tube 53 1. Disasse mble the op tical and hydraulic syst ems f ollowing the appropri ate disa sse mbly instruc tions. See Sec tion 4.4.2 and Section 4.4.3 respectively . 2. Slide a piece of pla stic tubing, approximately 2 feet[...]

54 Measurement Piston and Flow Tube Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J 3. Plac e the piece s of guide condu it (us ed in disas se mbly) through the upstream fl ange and flow tube . 4. Lubricat e the poppet valve o-ring and fit it on to the groove in the poppet valv e . It is recomme nded th[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Measurement Piston and Flow Tube 55 5. If th e p opp et val ve has b een remo ved f ro m t he m easur ement pis to n, in st al l i t at th is time. T orque the poppe t bolts. NO TE: F or high tempe ra ture 2 piece poppets, the 3/8-24 s crew requires 24 f[...]

56 Measurement Piston and Flow Tube Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J 10. Sl ide the measur ement pisto n into th e flow tube up to t he upst ream seal . Lubri cate th e upstream se al with light oil. If the upstream seal is installed correctl y , the seal should slip into the flow tube wh[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Measurement Piston and Flow Tube 57 22. Follow the appropria te a ssembly proc ed ures f or installation of the hydraulic se al suppor t, hydraulic c ylinder , optical seal suppor t , and optical asse mbly . See Sec tion 2.4 , Sec tion 4.4.2 and Sec tion[...]

58 Measurement Piston and Flow Tube Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J 4. Re mov e the tie rod nut s securing the outlet flange assembly . 5. Re mov e the outlet flange and then all bu t the lower t wo tie rods. 6. Using a hoist, suppor t the flow tube. T ake care to k ee p the flow tube le[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Measurement Piston and Flow Tube 59 5. T est fit of the rulon ride rs on the mea suremen t piston . T rim any exc es s lengt h so tha t there will be a 1/16” (2 mm) gap be t ween the ends of e a ch rider . Re move the riders from the piston and lay the[...]

60 Optical Seal Support Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J 17. T orque the tie rod nuts to the values specified in T able 4-2 for the proper prov er size . T orque all the tie rod nuts in a ‘cri ss-cros s ’ pa tte rn. 18. It is recommended th at the leak check procedure be pe r formed a[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Optical Seal Su pport 61 7. Re mov e the three (3) socket he ad screws from the optical seal support that hold it to the inlet flange. Re m ove the se al suppor t and o -ring by carefully sliding it off the detector shaf t. Inspec t for we ar or damage .[...]

62 Optical Seal Support Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J Figure 4-10 Opti cal seal support assembly - 24” ( built after January 1, 2006) and 34” As se mb l y Ref er en c e Figure 4-9 and Figure 4-10 1. On the smalle r diame te r end o f the optical se al suppor t, install the small op[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Hydraulic Cylinder and Hydraulic Seal Support 63 8. After achie ving prope r alignme n t of the op tical sy stem , install the o-ring and the co ve r tube . The cov er should be po siti oned with the boss on the side . 9. Install the brace from the suppo[...]

64 Hydraulic Cylinder and Hydraulic Seal Support Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J 3. Disconnect t he Nitrogen supply line from the hydraulic c ylinder . 4. Drain the hydraulic fluid from the hydraulic cylind er b y disconnec ting the pressure hose from the hydraulic pump. If the fluid is [...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Hydraulic Cylinder and Hydraulic Seal Support 65 Figure 4-12 T ypical hydr aulic cylinder assembl y 12. Re move the h ydraulic lines from the downstream flange of the hydraulic cy linder . 13. Re mov e the downstre am flange of the hydrau lic cylinder . [...]

66 Hydraulic Cylinder and Hydraulic Seal Support Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J 18. Check the bu shing in the actuat or se al support for cle aranc e on the actuat or rod. Correct cle arance is .002 to .005 inch (.0 51 to .127 mm). If cl earanc e is exc e ssive , con sult the factory fo[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Optical conversion kit 67 13. Install th e four nuts on the hydraulic c ylinder tie rods. D ouble check the o -rings on each end o f the hydrau lic cylinder tube t o mak e sure they are in pl ace. Tigh ten t he nuts eve nly to bring the hydraulic cylinde[...]

68 Detector Switch Replacement Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J design ha s been simplified from the old de sign. V o lume re- certification is no longer necessar y when repl acing a volume switch on the ‘plug st y l e’ or the ‘pin-and -socket’ optical as semblies. See Section 4.6[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Detector Switch Replacement 69 1. Disc onnect electrical powe r to the unit . 2. Re mov e the suppor t bracke t at the outboard e nd of the det ector shaft dust cov er . 3. Remove t he dus t cover . 4. Carefully cut the wire ties holding the plug for the[...]

70 Detector Switch Replacement Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J 8. Adjust the switch po sition so tha t the detector pa sse s through the c ent e r of the switc h. If necessary , loos en the be aring housing and slide it along the shaf t while adjusting the switc h po sition . It may be n[...]

Operating and ma intenance instru ctions Section 4: Maint enance 3-9008-701 Rev J January 20 15 Detector Switch Replacement 71 12. Upon c ompletio n of v olume c ertification s ee Section 2.4 . If the switch r epl ace men t proc edure ha s been performed correctly , the repl ace men t switch will be within 0.001 inches (.0254 mm) from the origin al[...]

72 Detector Switch Replacement Section 4: Mainten ance Operating and maintenance instructions January 2015 3-9 008-701 Rev J[...]

Operating and main tenance instru ctions Section 5: Trou bleshooting 3-9008-701 Rev J January 20 15 General 73 Sec t ion 5: T roubleshoo ting 5.1 General Should the e lectrical system o f the c ompact prove r requi re repa ir , the f ollowing two sections contain solutions and information to he lp solve problems that ma y be encoun tered. If these [...]

74 Interface Signal s Section 5: Troubleshooting Operati ng and maintenance instructions January 2015 3-9 008-701 Rev J inte rface board whene ve r the flag is within e ither o f the op tic volu me switc hes. This sign al is prese nt between pins 2(-) and 7(+) of J -2. Figure 5-1 is a timing di agram th at sho ws the inte r face signal ope rati on [...]

Operating and main tenance instru ctions Section 5: Trou bleshooting 3-9008-701 Rev J January 20 15 Measurement Piston Movement 75 5.3 Measurement P iston Mo veme nt Piston does not mo ve upstre am: (No hydraulic pre ssure) 1. Check to be sure the hydraulic system motor is running. If so, check the hydraulic con trol valv e oper ation b y disc onne[...]

76 Measurement Piston Movement Section 5: Troubleshooting Operati ng and maintenance instructions January 2015 3-9 008-701 Rev J in the full upstrea m position. Be sure to ch eck the saf et y barriers for proper r esistanc e. If the barrier re sistance is acc eptable , the cause m ay be in the op tical as sembly wirin g or upstream switch. Figure 5[...]

Operating and main tenance instru ctions Section 5: Trou bleshooting 3-9008-701 Rev J January 20 15 Measurement Piston Movement 77 Figure 5-3 Prover wiring diagram (three phase power)[...]

78 Measurement Piston Movement Section 5: Troubleshooting Operati ng and maintenance instructions January 2015 3-9 008-701 Rev J Figure 5-4 Prov er wiring diagr am (A TE X internal)[...]

Operating and main tenance instru ctions Section 5: Trou bleshooting 3-9008-701 Rev J January 20 15 Measurement Piston Movement 79 Figure 5-5 Prov er wiring diagr am (A TE X ex ternal)[...]

80 The auto plenum adjust panel Section 5: Troubleshooting Operati ng and maintenance instructions January 2015 3-9 008-701 Rev J 5.4 The auto plenum adjust p anel Compact prover ple num adjustmen t panels can hav e either A C or DC power solenoids. Someti mes th ese s ole noids will no t work c orrectly or at all. The probl em ty pically lies in t[...]

Operating and main tenance instru ctions Section 5: Trou bleshooting 3-9008-701 Rev J January 20 15 The auto plenum adjust panel 81 Correction procedure : Dete rmine which t y pe of compute r output is being used and c ompared this to the wiring at the relays. 1. If necessar y , refer to the prover’s wiring diagram . 2. If +24V DC is common to bo[...]

82 The auto plenum adjust panel Section 5: Troubleshooting Operati ng and maintenance instructions January 2015 3-9 008-701 Rev J Figure 5-6 DC powered solenoids[...]

Operating and main tenance instru ctions Section 5: Trou bleshooting 3-9008-701 Rev J January 20 15 The auto plenum adjust panel 83 Figure 5-7 AC pow ered solenoids[...]

84 The auto plenum adjust panel Section 5: Troubleshooting Operati ng and maintenance instructions January 2015 3-9 008-701 Rev J[...]

Operating and ma intenance inst ructions Section 6: Specia l tools and equipment 3-9008-701 Rev J January 20 15 Tool list 85 Sec tion 6: Speci al tools and equipme nt 6.1 T ool list The following list of par ts will aid the qualifie d technician in repair of the compac t prover: 1. Hea v y Dut y non -marking Str ap Wr enc h, McMast er -Carr par t n[...]

86 Tool list Section 6: Special tool s and equipment Operating and maintena nce instructions January 2015 3-9 008-701 Rev J T abl e 6-1 T ool size requirement Tie rod nut socket siz e Hydraulic tie rod nut socket Hydraulic cyl in d er piston nut socket si ze Allen screw for hydra u lic gland Allen screw for o pti cal gland 8” 150# 1-5/8” 9/16?[...]

Operating and ma intenance inst ructions Section 6: Specia l tools and equipment 3-9008-701 Rev J January 20 15 Tool list 87 T able 6-2 T orque values f or pipe flange stud/nut sets Prover siz e Nut size T orque requ irement 150 300 600 Ft -l bs N-m Ft - lb s N-m Ft -lbs N-m 8 5/8” 75 1 0 2 6 58 86 58 8 12m 5/8” 95 129 3/4” 120 163 7/8” 215[...]

88 Tool list Section 6: Special tool s and equipment Operating and maintena nce instructions January 2015 3-9 008-701 Rev J[...]

Operating and ma intenance inst ructions Section 7: Parts list 3-9008-701 Rev J January 20 15 General 89 Sec tion 7: Par ts list 7.1 General This section con tains those p ar ts required t o prope rly main tain and se r vice a standar d c ompact prove r . Ref ere nce those drawings applicable to the specific prove r size and con figuration. See Fig[...]

90 Replacement Parts List Section 7: Parts list Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J T able 7-1 Par ts list Item Description Qt y 8” 12 Mini” 12” 18” 24” 34” 40” 1 Compl ete seal kit*1 Buna-N SK08 SK12 SK12 SK18 SK24-07 SK34 C/F pre 2006 1S K 2 4 FKM SK08-22 SK12-022 S K12-022 SK18-022 SK 24-022- 07[...]

Operating and ma intenance inst ructions Section 7: Parts list 3-9008-701 Rev J January 20 15 Replacement Parts List 91 11 Piston cup seal 2 157388 157365 157365 157373 1 57393 1500137 158993 12 Hydraulic O -ring 1 157386-022 157084-022 157084-022 157011 -022 157081-022 1500131 159602-022 13 Optic al O-ring 1 157360-022 157360-022 157360-022 157360[...]

92 Replacement Parts List Section 7: Parts list Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J 415/50/3 A T EX 1 1500266 1500266 1500266 1500268 (1) 1500268 1 500272 C/F 23 Hydraulic pump 1 157925 157925 157925 15 7925 (2) 157983 (1) 15 7983 158916 158916 24 Hyd. con trol valv e solenoid (V/Hz) 110/60 NEC 1 158263 158263 1[...]

Operating and ma intenance inst ructions Section 7: Parts list 3-9008-701 Rev J January 20 15 Replacement Parts List 93 36 Ret a i ni n g r i n g 1 156561 156559 156 559 156553 156452 1500133 C/F 37 Seal Backup washer 1 N/A N/A N/A N/ A 911-24-029- 01 911-34-029- 01 911-40-029- 01 38 Seal backup washer 1 N/A N/A N/A N/ A 911-34-025- 00 911-34-025- [...]

94 Replacement Parts List Section 7: Parts list Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J Gallons 911-24-325- 12 Liters pre 2006 1 911-08-325- 16 921-12-325- 16 911-12-325- 16 911-18-325- 16 911-24-325- 16 911-34-325- 16 911-40-325- 16 Lite r s 911-24-325- 17 N/S Wate rd r a w ki t 115V , °F , NEC 1 911-12-372- 01 91[...]

Operating and ma intenance inst ructions Section 7: Parts list 3-9008-701 Rev J January 20 15 Replacement Parts List 95 Figure 7-1 Spare par ts diagram (flow tube)[...]

96 Replacement Parts List Section 7: Parts list Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J Figure 7-2 Spare parts diagram (Flow tube) (continued)[...]

Operating and ma intenance inst ructions Section 7: Parts list 3-9008-701 Rev J January 20 15 Replacement Parts List 97 Figure 7-3 Spare parts diagram (Mechanical components)[...]

98 Replacement Parts List Section 7: Parts list Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J Figure 7-4 Spare parts diagram (Electrical components)[...]

Operating and ma intenance inst ructions Section 7: Parts list 3-9008-701 Rev J January 20 15 Replacement Parts List 99 T able 7-2 Compac t prov er model code[...]

100 Replacement Parts List Section 7: Parts list Opera ting and mainten ance instructi ons January 2015 3-9 008-701 Rev J T able 7-3 Compac t prover model code (c ontinued)[...]

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P/N 3-9008-701 Rev J 2015 Daniel Measuremen t and Control, Inc . 11100 Brittmoore Park Drive Houston, TX 77041 USA T+1 713-467-6000 F+1 713-827-4805 USA Toll Free 1 888-356-9001 Daniel Measuremen t Services, Inc. T +1 713-827-6314 www.Daniel.com Europe: Stirling, Scotland, UK T + 44-1786-433400 Middle East: Africa: Dubai, UA E T +971-4-811-8100 Asi[...]