Standard and Extended Velocity Range T5 Flare Gas Transducers
Contents
1. x Psi Rod Welding Boss Side View Washer and Nut to Secure hw aay H l a Threaded Rod 7 E ii 3 MRS E ca ay _ Velding Boss Side View N 3 Remember to orient the boss in the jig to maintain the proper contour location to the pipe for installation Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 11 Chapter 1 Installing Pipe Nozzles 1 2 5 Installing the Second Welding Boss cont 4 Place the spacer flange on top of the welded nozzle and then mount the second end of the alignment plate on top of the spacer flange Bolt into position using the remaining bolts Spacer Flange Welded Nozzle End View Top View 5 The second welding boss should now be positioned over the second nozzle location scribe marks Align the boss scribe marks with the pipe scribe marks then tighten all nuts securely 6 Check the boss alignment again then tack weld the boss in each of the four grooves between the boss scribe marks 7 After tacking check the boss alignment once more If the boss is misaligned by 0 02 in 0 5 mm or more remove the boss by grinding off the welds and reinstall 8 Remove the threaded rod and the jig Leave the alignment plate bolted to the first nozzle with the spacer flange sandwiched between them 12 Standard and Extended V2. N S ZH OS SO PORRE nda ano BORD AA aus XONINDIZI XSPOZXILVLOVMIX E ZAWA ZI 0 09 0 D 0f quid 3 Sr 3n0 180 Sh ees DA QL oi P Xa 9 Z II DE7 ITONV IO de MSN WH VOISITIO 20 nnm nes ps 081 2000 IHOWAIS gI ONISNIS 3UNLONYLSVYANI 35 gt gt QVaH 3390gSNV3L Ad JXJHM X3 44 1N 00 99 89 LL1L YO XA 44 39 00 99 99 S1 SYSEWNN luvd 8 SI ZI LL 8 ILON 33S GIMUVA ATININVAYId HOG GIOY YO 3AVYONT Z S6Z ZSL v6Z 2SZ ONIMVYO OL 3343383 9 g90 ZS 8 190 Z2SZ SNIMVYO OL M34389 S 090 ZSL 6S0 7S ONIMYYO OL 3933393 8S0 ZSL X LS0 CSL QNIMYYO OL 3934393 E CCE CSL PNIMVYO OL 343438 7 LEE CSL QNIMVHO OL MI4dY L SALON o 2 r j C f s j _ __ 0 a n a Transducer Arrangement dwg 752 063 rev L Figure 22 Standard and Extended Velocity Range T5 Flore Gos Tronsducers Installation Guide 56 Chapter 4 Specifications Chapter 4 Specifications Table 3 T5 Transducer Specifications Transducer T5 Specification Designation Hazardous area applications flare gas hydrocarbon gases saturated steam Holder Type Holder Ratings Operating Frequency Standard 100 kHz Optional 50 kHz and 200 kHz Pressure Range 0 to 2700 psig Electrical Rating 200 V peak to peak 5 mA Ambient Temperature Range Europe 40 to 140 F 40 to 60 C North America 40 to 140 F 40 to 60 C Process Temperature Range 364 to 500 F 220 to 26
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4. Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 57 Chapter 3 Installing Transducer Assemblies 3 3 Mounting the Bias 90 Insertion Mechanism Transducer Assembly cont 6 Line up the flange holes and bolt the packing gland to the isolation valve a bim Us E Packing Tool p gt a 7 Using the packing tool tighten the packing nut again so the nut is recessed WARNING 38 THE PACKING MATERIAL MUST BE SECURELY PACKED BEFORE THE ISOLATION VALVE IS OPENED Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 3 4 Inserting the Bias 90 Transducer into the Pipe 1 Before youopen the isolation valve carefully check the following the barrel is pulled up as far as it can go all bolts are secure the transducer head 1s recessed in the packing gland Barrel Packing Gland ST cia ami C Im x E WARNING FOLLOW ALL APPLICABLE SAFETY CODES AND PRACTICES BEFORE OPENING THE ISOLATION VALVE 2 Open the isolation valve Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 39 Chapter 3 Installing Transducer Assemblies 3 4 Inserting the Bias 90 Transducer into the Pipe cont 3 Placing your hands on top of the barrel push the barrel transducer down into the pipe so that the barrel flange and the packing gland fl
5. 2 Check the spacing between the holes on the alignment plate The dimensions should correspond to the bias spacing dimension on the welding boss O oO 6 O 4 5 in Bias 9 in Spacing Bolt location shown for 150 rating 3 2 in Bias 6 4 in Spacing Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 3 Chapter 1 Installing Pipe Nozzles 1 2 2 Selecting and Marking the Pipe for Nozzle Locations CAUTION Correct nozzle alignment is critical to the successful operation of the flowmeter therefore all marking positioning and welding operations must be carried out with the utmost attention to accuracy Unless otherwise stated dimensional positioning of the nozzles must be held to a tolerance of 1 16 in 1 6 mm relative to each other and with respect to the pipe centerline The angular tolerance must be held to 1 All hole cutting in process piping must be performed using hot tapping equipment WARNING BE SURE TO ADHERE TO ALL APPLICABLE SAFETY REGULATIONS 1 For optimum performance you should select a location that has at least 20 pipe diameters of straight undisturbed pipe upstream and 10 pipe diameters of straight undisturbed pipe downstream from the point of measurement Undisturbed pipe means avoiding sources of turbulence such as flanges elbows and tees avoiding swirl and avoiding disturbed flow profiles Never install the flowmeter downstream of control valves espec
6. EE _ PT_ _T _ _ 0 9 VIENI __ IEETIETTLOE 1 DOWNSTREAM TRANSDUCER PORT STANDARD ASSEMBLY 46 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies UPSTREAM TRANSDUCER PORT 3 INCH 150 LB RF WELDING NE CK FLANGE 3 INCH SCH 80 PIPE NOZZLE 2 PLACES REF ONLY a a Zitti dtt TUTUP es iti K a n RECOVERY ANGLE BOLT NUT SPACER GASKET S RECOVERY ANGLE WEDGE GASKET DOWNSTREAM TRANSDUCER PORT 3 INCH 150 LE RF FULL OPENING ISOLATION BALL VALVE 2 PLACES REF ONLY EX TENDED RANGE ASSEMBLY Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 47 Chapter 3 Installing Transducer Assemblies 3 7 Mounting the Tilted 45 Insertion Mechanism Transducer Assembly cont 3 For the Standard Velocity Range application the upstream and downstream nozzle designations are interchangeable The system is bi directional For the Extended Velocity Range application the system is not bi directional Note which valve is designated upstream and downstream on the pipe Identify the upstream and downstream insertion mechanism assemblies The downstream assembly is labeled with a ring marked Downstream located at the end of the assembly near the junction box See the figure below 4 Proceed with either the upstream or downstream assembly 5 Lift the insertion mechanism
7. 13 Upstream Transducer Mark Aligned with Cover Plate Line 44 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 7 Upon completion of the above steps remove the cover plate locking collar and guide plate from the transducer assemblies 8 Place the remaining bolts into the flanges and tighten securely 9 Placeatagon the isolation valve stating the following DO NOT OPERATE CLOSE WHEN TRANSDUCER IS INSERTED INTO PIPE 10 Refer to your Startup Guide or User s Manual to make transducer electrical connections 3 7 Mounting the Tilted 45 Insertion Mechanism Transducer Assembly 1 Lift the gasket and insert the packing tool into the packing nut Turning the packing tool clockwise tighten the packing material so that the barrel will stay up without support Packing Tool Gasket Barrel Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 45 Chapter 3 Installing Transducer Assemblies 3 7 Mounting the Tilted 45 Insertion Mechanism Transducer Assembly cont 2 Check and make sure the isolation valves are securely installed with gaskets and hardware then place a gasket on the face of each isolation valve UPSTREAM x TRANSDUCER PORT SS GASKET 3 INCH 150 LB RF WELDING NECK FLANGE 2 PLACES REF ONLY 3 INCH SCH 60 PIPE NOZZLE 2 PLACES REF ONLY E Zini ee daodaieolaniendeeiaiola _
8. BNC head of the transducer extends slightly past the ground screw bosses as shown below n Figure 14 Torquing Reducer into NPT Port 3 Ifthe BNC head extends too far into the junction box it will make the assembly more difficult by reducing the amount of area needed to properly store the excess cable If the BNC head is not positioned approximately where it is pictured in the image above loosen the compression fitting and adjust the transducer Tighten the compression fitting after this is completed 4 Torque the cable gland provided coming from the electronics main housing into the other 3 4 NPT port until there are at least 5 threads of engagement Figure 15 Torquing the Cable Gland 52 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 3 8 Connecting an XAMP cont With the transducer and the cable gland assembled the junction box should now resemble Figure 16 below Figure 16 Assembled Transducer and Cable Gland 5 First connect the right angle male BNC plug to the exposed BNC cable from the cable gland assembly as shown in Figure 17 below gt gt alle Figure 17 Connecting BNC Plug to Cable Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 53 Chapter 3 Installing Transducer Assemblies 3 8 Connecting an XAMP cont 6 Connect the female BNC plug of the XAMP to the male BNC transducer
9. as near as possible to the horizontal plane 1 e 3 o clock and 9 o clock for horizontal pipe Note Ifyou cannot find a proper location please consult with GE Sensing Flow Application engineering 16 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 3 2 Selecting and Marking the First Nozzle Location cont 3 At the 3 o clock position center punch the pipe to mark the position for the center of the first nozzle Side View 4 Spray this area with a marking dye product Using a metal edge scribe a vertical and a horizontal line 6 in long that intersect at the center punch mark Side View Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 17 Chapter 1 Installing Pipe Nozzles 1 3 3 Determining and Marking the Second Nozzle Location 1 The position for the second nozzle is typically a distance equal to one pipe outside diameter along the pipe and located on the opposite side of the pipe i e 180 around Spray this area with a marking dye product For installation other than 45 the distance is equal to the OD times the tangent of the install angle 2 Due to the possible variation in outside diameter of the pipe measure the outside diameter of the pipe at four location between the nozzle centers Calculate the average outside diameter based on these measurements D1 D2 D3 D4 Side View 3 Using
10. flow 28 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 2 Installing the Isolation Valve Flow Direction F A A Nut Side Marking on Bolt Spacer Nozzle Face Marking on 6 Wedge Valve Face Marking on Figure 4 Putting the Mounting Bolts Bolt Spacers Wedge and Gaskets in Place 3 With the Nozzle Face marking facing the pipe and the Valve Face marking facing outward hold the gasket wedge gasket in line with the insertion hole and oriented in the required direction see Figure 4 above 4 While one person holds the gaskets and wedges in place another person should line up the valve assembly mounting holes with the bolts already installed push the valve assembly against the gasket wedge gasket and install the washers and nuts to secure the valve assembly to the spoolpiece see Figure 5 below Figure 5 Mounting the Valve Assembly Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 29 Chapter 2 Installing the Isolation Valve 2 3 Tilted 45 Installation for extended range gas flow velocity of up to 120 m s 394 ft s for 3 inch valves applications cont 5 Insert the two adjustment screws into the threaded holes on the wedge see Figure 6 below and use them to adjust rotate the wedge until the scribe line is evenly positioned between the two bolts Adjustment Screw x il Adjustment Screw Figure 6 Inserting the Adju
11. passes as required Allow to cool then remove the threaded rod washer nut and jig Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 3 6 Installing the Second Welding Boss and Nozzle Install the second welding boss and nozzle at the required position as described in nstalling the First Welding Boss and Installing the First Nozzle The completed installation should appear as shown below NOZZLE 2PLACES WELDING BOSS Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 25 Chapter 1 Installing Pipe Nozzles 1 3 7 Hot Tapping the Pipe Note Hot tapping tilted 45 installation is possible only for the standard range 100 m s 328 ft s flow gas application For the extended range 120 m s 394 ft s application only the 4 pipe size can be hot topped WARNING HOT TAPPING SHOULD BE PERFORMED ONLY BY QUALIFIED PERSONNEL FOLLOW ALL APPLICABLE CODE AND SAFETY PRACTICES DURING THESE PROCEDURES For 3 in Flanges 1 Install 3 in ANSI flanged isolation valves on both nozzles full bore and 8 in face to face 150 RF or 11 125 in for 300 RF with gasket and 5 8 in or 3 4 in diameter studs and nuts for 150 or 300 flange rating respectively Orient valve handles to minimize interference 2 Hot tap holes in the pipe using a hot tap machine equipped with a 3 4 in 19 05 mm drill bit Then use a coupon retainin
12. 0 C North American Certifications D Class I Division 1 Group C D Explosion proof Class II Class III Division 1 Group E F G CUS European International x H 2 G Ex d IIC T6 T2 Gb T code dependent on Process Temperature Certifications Flameproof Tamb 40 to 140 F 40 to 60 C KEMA OLATEX2045X IECEx KEM09 0009X Standards used EN 60079 0 2012 EN 60079 1 2007 IEC 60079 0 2011 IEC 60079 1 2007 Ed 6 North American Certifications IP66 TYPE 4X Weatherproof K DI 200Vpp SmA C US European International IP 66 Certifications Weatherproof C Standard and Extended Velocity Range T5 Flore Gos Transducers Installation Guide 57 Chapter 4 Specifications no content intended for this page proceed to next page 58 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Warranty Warranty Fach instrument manufactured by GE Sensing is warranted to be free from defects in material and workmanship Liability under this warranty is limited to restoring the instrument to normal operation or replacing the instrument at the sole discretion of GE Sensing Fuses and batteries are specifically excluded from any liability This warranty is effective from the date of delivery to the original purchaser If GE Sensing determines that the equipment was defective the warranty period 1s one year from delivery for electronic or mechanical failures one year from del
13. 4 studs for a 3 300 flange Welding Boss Nozzle aa Threaded Rod with Washer and Nut Figure 2 Components for Nozzle Installation Kit Check the marking on the end of the welding boss The pipe OD and the mounting angle are engraved on the boss as shown below Mounting Angle Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 15 Chapter 1 Installing Pipe Nozzles 1 3 2 Selecting and Marking the First Nozzle Location CAUTION Correct nozzle alignment is critical to the successful operation of the flowmeter therefore all marking positioning and welding operations must be carried out with the utmost attention to accuracy Unless otherwise stated dimensional positioning of the nozzles must be held to a tolerance of 1 16 in 1 6 mm relative to each other and with respect to the pipe centerline the angular tolerance must be held to 1 All hole cutting in process piping must be performed using hot tapping equipment 1 For optimum performance you should select a location that has straight run pipeline at least 20 pipe diameters of straight undisturbed pipe upstream and 10 pipe diameters of straight undisturbed pipe downstream from the point of measurement Undisturbed pipe means avoiding sources of turbulence such as valves flanges elbows avoiding swirl and avoiding disturbed flow profiles TOP VIEW 2 PLACES 2 We recommend that you install the nozzles on a diameter
14. 5 Flare Gas Transducers Installation Guide 35 Chapter 3 Installing Transducer Assemblies 3 3 Mounting the Bias 90 Insertion Mechanism Transducer Assembly 1 Lift the gasket and insert the packing tool into the packing nut Turning the packing tool clockwise tighten the packing material so that the barrel will stay up without support Gasket Packing 2 Check and make sure the isolation valves are securely installed with gaskets and hardware then place a gasket on the face of each isolation valve Gasket Upstream Transducer location amp A 36 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 3 For the Standard Velocity Range application the upstream and downstream nozzle designations are interchangeable The system is bi directional For the Extended Velocity Range application the system is not bi directional Note which valve 1s designated upstream and downstream on the pipe Identify the upstream and downstream insertion mechanism assemblies The downstream assembly is labeled with a ring marked Downstream located at the end of the assembly near the Junction box See the figure below 4 Proceed with either the upstream or downstream assembly 5 Lift the insertion mechanism by the barrel and place the insertion mechanism on the isolation valve Downstream Transducer Assembly Identification Ring on Extended Range version
15. 61010 1 2001 Overvoltage Category II Pollution Degree 2 Other standards used e EN 50014 1997 A1 A2 e EN 50018 2000 following the provisions of the 2004 108 EC EMC 2006 95 EC Low Voltage and 94 9 EC ATEX Directives Where products were initially assessed for compliance with the Essential Health and Safety Requirements of the ATEX Directive 94 9 EC using earlier harmonized standards a subsequent review has determined that technical knowledge is unaffected by the current harmonized standards listed above The units listed above and any ancillary equipment supplied with them do not bear CE marking for the Pressure Equipment Directive as they are supplied in accordance with Article 3 Section 3 sound engineering practices and codes of good workmanship of the Pressure Equipment Directive 97 23 EC for DN lt 25 A Za Ga Billerica November 2011 Issued Mr Gary Kozinski Certification amp Standards Lead Engineer N CE TOV GE Sensing ATEX COMPLIANCE We GE Infrastructure Sensing Inc 1100 Technology Park Drive Billerica MA 01821 4111 U S A as the manufacturer declare under our sole responsibility that the product Type T5 Ultrasonic Flow Transducer to which this document relates in accordance with the provisions of ATEX Directive 94 9 EC Annex Il meets the following specifications CE Ex aao LATE SE aore 1180 KEMA01ATEX2045X 40 C to 60 C Furthermore the following additional requiremen
16. GE Measurement amp Control Flow Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide I 916 117 Rev C imagination qt work April 2013 GE Measurement amp Control Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 916 117 Rev C April 2013 www ge mcs com 2013 Gen shes ctric Co cee ny All rights r i Techni x subject to change witho ie sn no content intended for this page proceed to next page Contents Certification and Safety Stotements vi Special Conditions for Safe USe vil Chapter 1 Installing Pipe Nozzles LI WWF OCU CTO Aes indire e 1 12 BI S 907IPSCONOHOR astiene 1 1 2 1 Identifving and Checking the Nozzle Installation Kit Components 2 1 2 2 Selecting and Marking the Pipe for Nozzle LocationS 4 1 2 3 Installing the First Welding BoSS 8 24 alno herr i NO oere AE adelaide 9 1 2 5 Installing the Second Welding BoSSs 11 1 26 installing the Second Nozz 8 u u u s s acces Oa EE ERRENA SaR E ARE ERNER 13 Lo we WADING VIG Pipe ii sa susu eee eee bayu ee ee ees 14 1 2 8 Cold Tapping th PIPE saint ein
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18. Proceed to complete the root pass and subsequent filler passes as required Allow to cool Remove all nuts and bolts the alignment plate jig spacer flange and threaded rod The completed installation should appear as shown below Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 13 Chapter 1 Installing Pipe Nozzles 1 2 7 Hot Tapping the Pipe WARNING HOT TAPPING SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL FOLLOW ALL APPLICABLE CODE AND SAFETY PRACTICES DURING THESE PROCEDURES For 3 in Flanges 1 Install 3 in ANSI flanged isolation valves on both nozzles full bore and 8 in face to face 150 RF or 11 125 in for 300 RF with gasket and 5 8 in or 3 4 in diameter studs and nuts for 150 or 300 flange rating respectively Orient valve handles to minimize interference 2 Hot tap holes in the pipe using a hot tap machine equipped witha 3 4 in 19 05 mm drill bit Then use a coupon retaining hole saw to cut a hole with a diameter of 2 36 in 60 mm minimum to 2 875 in 73 mm maximum For 2 in Flanges 1 Install 2 in ANSI flanged isolation valves on both nozzles full bore and 7 in face to face 150 RF or 8 50 in for 300 RF with gasket and 5 8 in diameter studs and nuts Orient valve handles to minimize interference 2 Hot tap holes in the pipe using a hot tap machine equipped witha 3 4 in 19 05 mm drill bit Then use a coupon retaining hole saw to cut a hole w
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20. a roll of polyester film or equivalent cut a strip of film at the width and length as follows IMPORTANT Ensure that the sides of the film are cut parallel to each other Width equal to the average outside diameter calculated in Step 1 above Length equal to 4 times the outside diameter of the pipe Average O D 18 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 3 3 Determining and Marking the Second Nozzle Location cont 4 Wrap the strip of film around the pipe with one edge running along the vertical scribe line at the first nozzle location Make sure the strip overlaps squarely around the pipe and mark the overlap position of the strip This equals the circumference of the pipe Overlap Mark Side View 5 Remove the strip of film and fold it as shown below to determine the position which is diametrically opposite the overlap position when the film is reapplied to the pipe Overlap Mark Fold to Here 6 Mark the outside of the fold for reference Mark the Edge Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 19 Chapter 1 Installing Pipe Nozzles 1 3 3 Determining and Marking the Second Nozzle Location cont 7 Place the strip of film on the pipe again this time line up the overlap mark with the horizontal and vertical scribe lines Ag
21. ain make sure you wrap the strip of film squarely around the pipe Overlap Mark Side View First Edge 8 The new position of the center of the second nozzle is now identified as the intersection of the fold line and the second edge of the strip of film Center punch this location prior to removing the strip of film Fold Mark Punch Here Second Edge Side View 9 Remove the film 10 Scribe vertical and horizontal lines each 6 in long to intersect at the center punch mark Scribe Lines Side View 20 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 3 4 Installing the First Welding Boss 1 Before welding the first boss you must add another scribe line known as the oblique center line The oblique center line compensates for the slope or oblique of the boss The oblique center line is offset from the true center vertical scribe line marked earlier by a distance of X which is dependent on the pipe outside diameter as follows a7 2 X D 2 tan sin d D where D pipe outside diameter d welding boss outside diameter 1 660 in Table 2 below shows values of X for various pipe sizes Table 2 X Values for Various Pipe Sizes oD Dimensions 6 in 150 mm 6 625 in 0 106 in 2 69 mm 8 in 200 mm 0 081 in 2 06 mm 10 in 250 mm 0 064 in 1 62 mm 12 in 300 mm 0 054 in 1 37 mm 14 in 350 mm 0 049 in 1 24
22. an isolation valve onto a nozzle for applications using the flare gas insertion mechanism 2 1 Bias 90 Installation for standard or extended range applications 2 1 1 For3 inch Flanges Install 3 inch ANSI flanged isolation valves on both nozzles full bore and 8 in face to face 150 RF or 11 125 in For 300 RF with a gasket and 5 8 in or 3 4 in diameter studs and nuts for 150 or 300 flange rating respectively Orient the valve handles to minimize interference Note This installation of the isolation valve may have been accomplished already during the hot tapping operation 2 1 2 For 2 inch Flanges Install 2 in ANSI flanged isolation valves on both nozzles full bore and 7 in face to face 150 RF or 8 1 2 in for 300 RF with a gasket and 5 8 in diameter studs and nuts Orient the valve handles to minimize interference Note This installation of the isolation valve may have been accomplished already during the hot tapping operation 2 2 Tilted 45 Installation for standard range gas flow velocity up to 100 m s 328 ft s applications 2 2 1 For 3 inch Flanges Install 3 inch ANSI flanged isolation valves on both nozzles full bore and 8 in face to face 150 RF or 11 125 in For 300 RF with a gasket and 5 8 in or 3 4 in diameter studs and nuts for 150 or 300 flange rating respectively Orient the valve handles to minimize interference Note This installation of the isolation valve may have been accomplish
23. ange meet You may have to twist the barrel to get it moving Place hands here 1 n as I AZ aol E QS l 4 For this bias 90 configuration orient the alignment marks on each barrel flange so that they are facing each other The alignment mark is scribed on the top and outside of the flange It will also be marked with paint 40 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 5 Place two bolts into the flange in holes opposite each other but not in the hole with the scribe mark Hand tighten Note DO NOT insert the remaining bolts until instructed to do so in the following section 6 Install the second insertion mechanism by repeating the steps in the two previous sections After the second mechanism is installed proceed to the following section 3 5 Aligning the Transducers for applications with gas flow velocity up to 100 m s 1 Useastraightedge to line up the alignment marks 2 Place the remaining bolts into the flanges and tighten securely 3 Place a tag on the isolation valve stating the following DO NOT OPERATE CLOSE WHEN TRANSDUCER IS INSERTED INTO PIPE 4 Refer to your Startup Guide or User s Manual to make transducer electrical connections 5 This applies to both upstream and downstream assemblies equally Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 41 Ch
24. apter 3 Installing Transducer Assemblies 3 6 Aligning the Transducers for applications with gas flow velocity 120 m s Note The downstream transducer is pre set at the factory in the barrel of the downstream insertion mechanism to shift the signal direction 6 away from the upstream transducer signal 1 Verify that the downstream transducer is located on the right when a person is looking up against the flow see Figure 8 below Contact a representative or the factory if the port locations do not follow this convention Upstream Transducer Downstream Transducer Sa Figure 8 Mounting the Transducer Assemblies 2 Slide the end slot of the guide plate around the upstream transducer and rotate the plate until the side slot is around the downstream transducer see Figure 9 below Align the transducer mark on the upstream barrel with the guide plate mark Moderately tighten the upstream barrel bolts to maintain the alignment Upstream Guide Plate Transducer Downstream Transducer Figure 9 Installing the Guide Plate 42 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 3 Place the cover plate on top of the guide plate and slide it as far as possible until it is positioned around the upstream transducer as shown in Figure 10 below Then tighten the screws to secure it Upstream Cover Plate Transducer Figure 10 Installing the Cov
25. boss that is welded onto the pipe If necessary remove the washer and nut from the threaded rod Threaded Rod Welded Boss 2 Slide the nozzle over the threaded rod and align the contoured end of the nozzle so it matches the pipe arc Then slide the jig over the threaded rod fitting the jig into the welding boss Jig Threaded Rod Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 23 Chapter 1 Installing Pipe Nozzles 3 Align the jig and nozzle bolt holes and tighten the assembly in place using the washer and nut Washer and Nut Bolt Holes The jig boss and nozzle combination is designed to provide a 0 094 in 2 4 mm root gap between the beveled edge of the nozzle and the outside diameter of the pipe If the 0 094 in 2 4 mm clearance does not exist all around the nozzle must be removed and ground appropriately to provide the required clearance If the root gap is larger than the 0 094 in 2 4 mm dimension then suitably sized washers may be inserted between the jig and the nozzle in order to reduce the root gap dimension WARNING ONLY QUALIFIED PERSONNEL SHOULD WELD BOSSES AND NOZZLES USING A SUITABLE ASME IX 24 QUALIFIED WELDING PROCEDURE Tack weld the nozzle to the pipe at four diametrically opposed points each tack being approximately 0 6 in 15 mm in length Allow to cool for 30 seconds between tacks Proceed to complete the root pass and subsequent filler
26. by the barrel and place the insertion mechanism on the isolation valve Downstream Transducer Assembly Identification Ring on Extended Range Version 6 Line up the flange holes and bolt the packing gland to the isolation valve 48 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 3 7 Mounting the Tilted 45 Insertion Mechanism Transducer Assembly cont 7 Using the packing tool tighten the packing nut again so the nut is recessed WARNING THE PACKING MATERIAL MUST BE SECURELY PACKED BEFORE THE ISOLATION VALVE IS OPENED 3 7 1 Inserting the Tilted 45 Transducer into the Pipe 1 Before you open the isolation valve carefully check the following the barrel is pulled as far up as it can go all bolts are secure the transducer head is recessed in the packing gland Bolts Barrel Packing Gland Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 49 Chapter 3 Installing Transducer Assemblies WARNING FOLLOW ALL APPLICABLE SAFETY CODES AND PRACTICES BEFORE OPENING THE ISOLATION VALVE 2 Open the isolation valve 3 Placing your hands at the end of the barrel push the barrel transducer into the pipe so that the barrel flange and the packing gland flange meet You may have to twist the barrel to get it moving Place hands here 4 Place the bolts into the flange joining the barrel flang
27. d to supply eight 5 8 studs with two nuts each or 3 4 studs with two nuts each 5 8 studs fora2 150 flange a 2 300 flange or a 3 150 flange and 3 4 studs for a 3 300 flange Once you are familiar with each component verify that the welding bosses and alignment plate shipped are for the required spacing and pipe size as described in the following steps Gy Welding Boss Nozzle Jig Spacer Flange Threaded Rod with Washer and Nut Alignment Plate Figure 1 Components for Nozzle Installation Kit 2 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 2 1 Identifying and Checking the Nozzle Installation Kit Components cont 1 Check the marking on the end of the welding boss The pipe O D and the bias dimension or spacing are engraved on the boss as shown below Typically a for flow velocity up to 100 m s 328 ft s the 10 in spacing is used on pipes 18 in 450 mm and larger the 9 in spacing is used on pipes 16 in 400 mm or on larger pipes when attenuating gases are present and b for up to 120 m s 394 ft s flow velocity the 6 4 in spacing is used on pipes 14 in 356 mm or larger Note Bias dimension refers to the distance between the center of the nozzle location and the center line of the pipe 3 4 in Bias 6 4 in Spacing 4 5 in Bias 9 in Spacing 5 in Bias 10 in Spacing Bias Dimension or Spacing
28. e 1 Screw the threaded rod into the boss that is welded onto the pipe If necessary remove the washer and nut from the threaded rod Threaded Rod Welding Boss 2 Insert the pipe section of the jig the key cut section into the pipe section of the nozzle and fasten the assembly using four nuts and bolts Nozzle Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 9 Chapter 1 Installing Pipe Nozzles 1 2 4 Installing the First Nozzle cont 3 Slide the jig nozzle assembly over the threaded rod fitting the jig into the key cut end of the welding boss while aligning the contoured end of the nozzle to the pipe arc ms ao Threaded Rod T Jig id 3 1 I ii di il Podi ss I Ii i i di sE 3 3 i 3 Nozzle I 3 I LT il RI i V 7 tui 3 il l Welding Boss End View 4 Align the nozzle scribe marks with the pipe scribe marks and tighten the assembly in place using the 1 in washer and nut If slight misalignment occurs between the nozzle scribe marks and pipe scribe marks loosen the four bolts holding the jig and nozzle assembly and rotate the nozzle for the best alignment Once it is aligned retighten the four bolts Washer and Nut iy Ad End View 5 The jig boss and nozzle combination is designed to provide a 0 094 in 2 4 mm
29. e to the packing gland flange 5 Tighten the bolts securely 50 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 3 7 1 Inserting the Tilted 45 Transducer into the Pipe cont 6 Install the second insertion mechanism by repeating the steps in the previous sections Confirm that the downstream transducer assembly is in the downstream port and the upstream assembly is in the upstream port 7 Placeatagon the isolation valve stating the following DO NOT OPERATE CLOSE WHEN TRANSDUCER IS INSERTED INTO PIPE 8 Refer to your Startup Guide or User s Manual to make transducer electrical connections 9 This applies to both upstream and downstream assemblies equally Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Sil Chapter 3 Installing Transducer Assemblies 3 8 Connecting an XAMP The following section explains how to correctly install and assemble an XAMP into a transducer junction box It applies to all three possible junction box options refer to drawing 752 063 Figure 22 on page 56 despite one junction box being used as an example in the steps below 1 Place a 3 4 NPT compression fitting on the stem of the transducer closest to the BNC end 2 Torque the fitting into one of the 3 4 NPT ports of the junction box with at least 5 threads engaged Once the fitting is torqued into place ensure that the
30. ed already during the hot tapping operation 2 2 2 For 2 inch Flanges Install 2 in ANSI flanged isolation valves on both nozzles full bore and 7 in face to face 150 RF or 8 1 2 in for 300 RF with a gasket and 5 8 in diameter studs and nuts Orient the valve handles to minimize interference Note This installation of the isolation valve may have been accomplished already during the hot tapping operation Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 27 Chapter 2 Installing the Isolation Valve 2 3 Tilted 45 Installation for extended range gas flow velocity up to 120 m s 394 ft s for 3 inch valves Note The upstream valve and transducers are installed without wedges per normal installation procedures To install the downstream valve assembly onto the spoolpiece the following items are required see Figure 3 below Adjustment Screws Bolt S 6 Wedge 0000 olt Spacer L g 0000 O 0000 Bolt Spacer Tae Gaskets I Figure 3 Parts Used to Install a Valve Assembly Note A 150 RF installation is shown 1 Insertthe four bolts into the flange holes 2 With the Nut Side marking facing the pipe place the split bolt spacer pieces behind the flange over the bolts with the thin ends corresponding to what will be the thickest side of the other wedge see Figure 4 on the next page Note The wedge positions are based on the need to tilt the transducer 6 against the
31. elocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 2 6 Installing the Second Nozzle 1 4 5 Insert the Jig into the second nozzle and position this assembly over the boss and under the alignment plate Insert the threaded rod Alignment Plote Jig Pim Ja Flange Nozzle End View The jig boss and nozzle combination is designed to provide a 0 094 in 2 4 mm root gap between the beveled edge of the nozzle and the outside diameter of the pipe If the 0 094 in 2 4 mm clearance does not exist all around the nozzle must be removed and ground appropriately to provide the required clearance If the root gap is larger than the 0 094 in 2 4 mm dimension then suitably sized washers may be inserted between the jig and the nozzle in order to reduce the root gap dimension Secure the alignment plate by replacing the two sets of four bolts on both ends of the plate and the washer and nut on the threaded rod Line up the nozzle scribe marks with the pipe scribe marks and tighten all the nuts Make sure the nozzle is still in alignment WARNING ONLY QUALIFIED PERSONNEL SHOULD WELD BOSSES AND NOZZLES USING A SUITABLE ASME IX QUALIFIED WELDING PROCEDURE ALL APPLICABLE SAFETY CODES SHOULD BE OBSERVED Tack weld the nozzle to the pipe at four diametrically opposed points each tack being approximately 0 2 in 5 mm in length Allow to cool for 30 seconds between tacks
32. en 14 be TEJA WS GUO einen een 14 1 3 1 Identifying and Checking the Nozzle Installation Kit Components 15 1 3 2 Selecting and Marking the First Nozzle Locotion 16 133 Determining and Marking the Second Nozzle Locotion 18 1 3 4 Installing the First Welding BoSS 2 Eee osi u us E REI 2 1 3 6 Installing the Second Welding Boss and Nozzle ccc eee eee e eee eens 25 1 3 7 Hot Tapping the PIpe 26 L38 ColdTapping ihe POOR E EEEE A EE EEEREN ENRERE ArI pu pagasqa 26 Chapter 2 Installing the Isolation Valve 2 1 Bias 90 Installation for standard or extended range opplicotions 27 Alt O J lil WI uu uuu z neretto 27 A FOr lili ie iii a 22 Tilted 45 Installation for standard range gas flow velocity up to 100 m s 328 ft s applications 27 2270 POF 119 RNO 2c age hace as nage een es pues homed oa dh eeecuede dna neaeescunededsaeeaas net 2 2 2 2 For2inchF qngeS 27 23 Tilted 45 Installation for extended range gas flow velocity up to 120 m s 394 ft s for 3 inch valves 28 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide li C
33. enance procedures on the equipment Qualification of Personnel Make sure that all personnel have manufacturer approved training applicable to the auxiliary equipment Personal Safety Equipment Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment Examples include safety glasses protective headgear safety shoes etc Unauthorized Operation Make sure that unauthorized personnel cannot gain access to the operation of the equipment Standard and Extended Velocity Range Flare Gas Transducer Installation Guide V Preface Environmental Compliance Waste Electrical and Electronic Equipment WEEE Directive GE Sensing amp Inspection Technologies is an active participant in Europe s Waste Electrical and Electronic Equipment WEEE take back initiative directive 2002 96 EC The equipment that you bought has required the extraction and use of natural resources for its production It may contain hazardous substances that could impact health and the environment In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources we encourage you to use the appropriate take back systems Those systems will reuse or recycle most of the materials of your end life equipment in a sound way The crossed out wheeled bin symbol invites you to use those systems If you need more information on the collection reuse and
34. ential to the proper completion of the instructions Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the equipment Failure to follow these instructions carefully may cause unreliable performance e Caution paragraphs provide information that alerts the operator to a hazardous situation that can cause damage to property or equipment Warning paragraphs provide information that alerts the operator to a hazardous situation that can cause injury to personnel Cautionary information is also included when applicable Safety Issues WARNING Itis the responsibility of the user to make sure all local county state and national codes regulations rules and laws related to safety and safe operating conditions are met for each installation Auxiliary Equipment Local Safety Standards The user must make sure that he operates all auxiliary equipment in accordance with local codes standards regulations or laws applicable to safety Working Area WARNING Auxiliary equipment may have both manual and automatic modes of operation As equipment can move suddenly and without warning do not enter the work cell of this equipment during automatic operation and do not enter the work envelope of this equipment during manual operation If you do serious injury can result WARNING Make sure that power to the auxiliary equipment is turned OFF and locked out before you perform maint
35. er Plate 4 Slide the locking collar down the downstream transducer to the cavity on top of the guide plate align the 6 mark on the top of the collar with the line on the transducer see Figure 11 below Then tighten the collar set screws until it is secure around the transducer Downstream Transducer Line on Transducer Tube Collar 6 Mark et Figure 11 Locking Collar 6 Mark Aligned with Line on Transducer Tube Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 43 Chapter 3 Installing Transducer Assemblies 3 6 Aligning the Transducers for applications with gas flow velocity 120 m s cont 5 Check to see if the 0 mark on the side of the collar is aligned with the line on the guide plate If they are not aligned then loosen the nuts on top of the barrel and rotate the barrel transducer assembly until the two lines are aligned see Figure 12 below Then retighten the nuts Downstream Transducer Nuts on Barrel Collar 0 Mark Guide Plate Line Figure 12 Locking Collar 0 Mark Aligned with Guide Plate Line 6 Check to see if the line on the upstream transducer tube is aligned with the line on the cover plate If they are not aligned loosen the nuts on top of the barrel and rotate the barrel transducer assembly until the two lines are aligned see Figure 13 below Retighten the nuts Upstream Transducer Upstream Transducer Line Cover Plate Line Figure
36. g hole saw to cut a hole with a diameter of 2 36 in 60 mm minimum For 2 in Flanges 1 Install 2 in ANSI flanged isolation valves on both nozzles full bore and 7 in face to face 150 RF or 8 50 in for 300 RF with gasket and 5 8 in diameter studs and nuts Orient valve handles to minimize interference 2 Hot tap holes in the pipe using a hot tap machine equipped with a 3 4 in 19 05 mm drill bit Then use a coupon retaining hole saw to cut a hole with a diameter of 1 81 in 46 mm minimum to 1 89 in 48 mm maximum 1 3 8 Cold Tapping the Pipe Note Cold tapping is the same as the hot top procedure for a standard range 100 m s 328 ft s flow gas meter Cold tapping can be performed only before the isolation valve is installed except for the 4 in pipe size This is due to the tilted downstream transducer insertion mechanism and valve assembly WARNING COLD TAPPING SHOULD BE PERFORMED ONLY BY QUALIFIED PERSONNEL FOLLOW ALL APPLICABLE CODE AND SAFETY PRACTICES DURING THESE PROCEDURES For 3 in Flanges 1 Cold tap holes in the pipe using a hot tap machine equipped with a 3 4 in 19 05 mm drill bit Then use a coupon retaining hole saw to cut a hole with a diameter of 2 7 8 in 73 mm 26 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 2 Installing the Isolation Valve Chapter 2 Installing the Isolation Valve Note The following information demonstrates how to install
37. gers e Installation Instructions Install per manual 916 117 C amp CERT ATEX D Rev August 2004 Customer Support Centers U S A The Boston Center 1100 Technology Park Drive Billerica MA 01821 U S A Tel 800 833 9438 toll free 978 437 1000 E mail sensing ge com Ireland Sensing House Shannon Free Zone East Shannon County Clare Ireland Tel 353 6161470291 E mail gesensingsnnservices ge com An ISO 9001 2008 Certified Company www ge mcs com en about us quality html www ge mcs com 2013 General Electric Company All rights reserved Technical content subject to change without notice 916 117 Rev C
38. head as shown in Figure 18 below Figure 18 Female Plug to Male BNC Head 7 Wrap the extra length of cable around the perimeter of the junction box such that the BNC heads do not rest on other cables or on each other An image of this can be seen in Figure 19 below Figure 19 BNC Heads 54 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 3 8 Connecting an XAMP cont 8 Place the XAMP body into the Junction box resting the puck gently on the cables below it Ensure that the cables of the XAMP rest naturally according to the slant at which they exit the epoxy to reduce stress and strain on the Joint The XAMP should remain still and the cap of the junction box should rotate freely around the XAMP Figure 20 Junction Box Cap 9 Place the lidof the junction box over top of the XAMP and tighten the lid until the unit is closed and secure Engage the set screw to prevent it from being tampered or removed Figure 21 Set Screw of Junction Box To disconnect or uninstall the XAMP from the assembly users can reverse the procedures above Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 55 Chapter 3 Installing Transducer Assemblies Si no 907 Ny 1 ONIAVYO SIHL NOLLUNMOINI AVLI 90728 cen ase LT ee NP IR SES e YIONOSNYYL ZLL SL 9 ININZONVUNV TV83N39 sue cool sorse Mib in sana sasa
39. ially butterfly valves If you cannot find a proper location please consult with GE Sensing Flow Application engineering 2 Usea center finder device to locate the center of the pipe EYEBALLING IS NOT ADEQUATE FOR ACCURATE FLOW MEASUREMENT 3 Lightly punch two marks approximately 16 in apart on the top of the pipe running along the centerline The two nozzle locations will fall between the two center punch marks Top View 4 Spray the area between the two punch marks on the top of the pipe with a marking dye product Using a metal edge scribe a line between the two punch marks 4 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 2 2 Selecting and Marking the Pipe for Nozzle Locations cont Scribe Line Top View 5 Along the new scribe line mark off a 10 in length or 9 in or 6 4 in depending on spacing and scribe two perpendicular lines at least 10 in in length as shown 10 9 or 6 4 3 3 5 or 4 8 Top View 6 Along each perpendicular scribe line lightly punch a mark at a distance of 5 in or 4 5 in or 3 2 in from the center line depending on the bias Keep in mind that the distance along the arc of the pipe L from the pipe centerline is slightly greater These marks pinpoint the centers for the nozzles Refer to Table 1 on page 7 for arc distances for the most commonly used pipe sizes If your pipe size is
40. ide Chapter 3 Installing Transducer Assemblies 3 2 2 Mounting the Insertion Mechanism cont 2 Visually inspect the transducer Make sure the top compression fitting is not loose IMPORTANT The stop ring at the end of the barrel is supposed to be loose DO NOT tighten the compression fitting or you could change the transducer alignment Top Compression Fitting Four Bolts Stop Ring 3 Remove the four bolts that fasten the barrel to the packing gland Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 55 Chapter 3 Installing Transducer Assemblies 3 2 2 Mounting the Insertion Mechanism cont 4 Retract the barrel from the packing gland so that the transducer head is recessed in the packing gland You will hear the stop ring click when the transducer is fully recessed Compression Fitting hand tight 34 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies 5 Visually inspect the mechanism Make sure the transducer is recessed in the packing gland Again make sure the top compression fitting is secure and hand tight Bias 90 Assembly with 90 Head Transducer recessed In packing gland i 7 Ve Tilted Diameter Assembly with 180 Head ae DA a N TAN Ts N HO WT wi ih N cl v Transducer recessed in packing gland Standard and Extended Velocity Range T
41. ing for Installation e Mounting the Insertion Mechanism e Inserting the Transducer into the Pipe e Aligning the Transducers WARNING THE MANUAL INSERTION MECHANISM SYSTEM IS FOR LOW PRESSURE APPLICATIONS 80 PSIG 6 5 BAR absolute OR LESS USE THE APPROPRIATE SAFETY PRECAUTIONS WHEN INSERTING OR WITHDRAWING THE INSERTION MECHANISM 3 2 1 Preparing for Installation Before you begin you should find an area where you can place the insertion mechanism upright without placing any weight on the transducer e g a bench with a cutout large enough to slide the transducer through You will need the following items for installation a packing tool may be shipped with the electronics a gasket to place on the isolation valve a straight edge ruler scale e atag to place on the isolation valve bolts Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Jl Chapter 3 Installing Transducer Assemblies 3 2 2 Mounting the Insertion Mechanism 1 Before mounting the mechanism to the isolation valve you should familiarize yourself with its components see the figure below junction box barrel packing gland transducer Note Explosion proof boxes are not mounted on the end of the transducer when shipped Junction Box Packing Gland Transducer Transducer 90 head shown 180 head shown 32 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Gu
42. ith a diameter of 1 81 in 46 mm minimum to 1 89 in 48 mm maximum 1 2 8 Cold Tapping the Pipe The procedure for cold tapping a pipe is the same as the hot tapping procedure however a valve is not necessary during the process The hot tap medium can be applied directly to the nozzle Valves will be added after the tapping is complete 1 3 Tilted 45 Installation This procedure contains the following instructions e Identifying and checking the nozzle installation kit components e Selecting and marking the first nozzle location e Determining and marking the second nozzle location e Installing the first welding Boss e Installing the first nozzle Installing the second welding boss and nozzle e Hot tapping the pipe 14 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 3 1 Identifying and Checking the Nozzle Installation Kit Components The nozzle kit consists of various components which you must identify and check as described in the following sub sections The Nozzle Installation Kit contains the materials listed below Use Figure 2 below to help identify each component 2 Nozzles if purchased 2 Welding bosses 1 Threaded rod 1 in diameter washer and nut IMPORTANT You will need to supply eight 5 8 studs with two nuts each or 3 4 studs with two nuts each 5 8 studs fora2 150 flange a 2 300 flange or a 3 150 flange and 3
43. ivery for sensor shelf life If GE Sensing determines that the equipment was damaged by misuse improper installation the use of unauthorized replacement parts or operating conditions outside the guidelines specified by GE Sensing the repairs are not covered under this warranty The warranties set forth herein are exclusive and are in lieu of all other warranties whether statutory express or implied including warranties or merchantability and fitness for a particular purpose and warranties arising from course of dealing or usage or trade Return Policy If a GE Sensing instrument malfunctions within the warranty period the following procedure must be completed 1 Notify GE Sensing giving full details of the problem and provide the model number and serial number of the instrument If the nature of the problem indicates the need for factory service GE Sensing will issue a RETURN AUTHORIZATION NUMBER RAN and shipping instructions for the return of the instrument to a service center will be provided 2 If GE Sensing instructs you to send your instrument to a service center it must be shipped prepaid to the authorized repair station indicated in the shipping instructions 3 Upon receipt GE Sensing will evaluate the instrument to determine the cause of the malfunction Then one of the following courses of action will then be taken Ifthe damage is covered under the terms of the warranty the instrument will be repaired at no c
44. mm 2 Scribe the oblique center line on the pipe at the prescribed distance from the true center line The oblique center line should be marked on the side of the true center line that 1s closer to the second nozzle location __Obli LI True Center Line a E Side View Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 21 Chapter 1 Installing Pipe Nozzles 1 3 4 Installing the First Welding Boss cont 3 Position the welding boss such that the four scribe lines on the welding boss are lined up with the horizontal scribe mark and the oblique center line on the pipe Make sure you orient the boss as shown below Horizontal Scribe Mark Side View 4 Clamp the boss in place using a pipe strap or equivalent so that it cannot move during tack welding 5 Check the boss alignment then tack weld the carbon steel boss to the pipe in each of the four grooves between the boss scribe marks 6 Remove the clamp and check the alignment again If the boss is misaligned by 0 02 in 0 5 mm or more remove the boss grind off the welds and reinstall 22 Standard and Extended Velocity Range Flore Gos Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 3 5 Installing the First Nozzle IMPORTANT It is essential that the nozzle is set up and fixed in position using the jig and 1 in threaded rod provided prior to welding the nozzle 1 Screw the threaded rod into
45. not shown in Table 1 use the equation in the figure on page 6 to calculate the arc distance Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 1 Installing Pipe Nozzles 1 2 2 Selecting and Marking the Pipe for Nozzle Locations cont IMPORTANT For 3 2 in bias the downstream port must be located on the right when a person is looking up against the flow see the figure below This convention is mandatory for the 6 4 in spacing and is optional not required for the 10 in or 9 in spacing Downstream Port Location for 3 2 in bias Punch Marks L Arc Length along pipe surface lt C Calculate L as follows L 3 142xRxA 180 Where A Sin 1 S R R Radius in inches S Bias in inches End View 6 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 2 2 Selecting and Marking the Pipe for Nozzle Locations cont Table 1 Calculated Arc Distances for Commonly Used Pipes 4 5 in Bias 16 in 400 mm 4 779 in 18 in 450 mm 4 713 in 24 in 600 mm 4 613 in 30 in 750 mm 4 571 in 36 in 900 mm 4 549 in 42 in 1050 mm 4 536 in 3 2 in Bias 30 in 750 mm 3 225 in 7 Scribe a horizontal centerline 6 in long through each nozzle center location point parallel to the original centerline Scribe Lines Top View Standard and Extended Velocity Range T5 Fla
46. onnection the transducer must be mounted into a certified metal enclosure with type of protection flameproof enclosure D complying with EN 60079 1 2007 and IEC 60079 1 2007 Ex d IIC Measures must be taken to ensure a good electrical contact and to prevent the threads from self loosening The compression fitting 1s suitable for temperatures 60 C to 250 C vi Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Preface Special Conditions for Safe Use The user installer must take care that during operation with process temperatures lower than 40 C and higher than 60 C the service temperature of the Ultrasonic Flow Transducers stays within 40 C to 60 C A minimum distance of 8 inches 20 cm shall be maintained between the process pipe and the compression gland The compression gland is suitable for operating temperatures to 250 C With process temperatures up to 260 C the user installer shall take care e g by measuring the temperature at this spot that the temperature stays below the operating temperature of the compression gland To avoid electrical shock be sure the transducer is mounted to a metal electrically grounded pipe system To avoid an ignition hazard protect the transducer from impact or friction Where the process temperature is below 25 C or exceeds 60 C do not insulate the transducers or junction box The temperature class is based on the process temperature as sh
47. ontents Chapter 3 Installing Transducer Assemblies 2l 5 2 5 5 5 4 5 5 3 6 3 3 8 JI O o ETSE iscritte er EE E vans aeepusunsosescageneuernsesaranegeeuseecoe Ane 31 Inserting Transducers Using a Low Pressure Insertion Mechanism Common Steps 31 3 2 1 Preparing for Instollation 51 3 2 2 Mounting the Insertion Mechqnism 32 Mounting the Bias 90 Insertion Mechanism Transducer Assembly 36 Inserting the Bias 90 Transducer into the PIDe 39 Aligning the Transducers for applications with gas flow velocity up to 100 m s 41 Aligning the Transducers for applications with gas flow velocity 120 m s 42 Mounting the Tilted 45 Insertion Mechanism Transducer Assembly 45 3 7 1 Inserting the Tilted 45 Transducer into the Pipe 49 Connecting an XAMP i 2 ee nnn EDERE eee eect nnn eee tee e enn Area 52 Chapter 4 Specifications Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Preface Information Paragraphs Note paragraphs provide information that provides a deeper understanding of the situation but is not ess
48. ost to the owner and returned e If GE Sensing determines that the damage is not covered under the terms of the warranty or if the warranty has expired an estimate for the cost of the repairs at standard rates will be provided Upon receipt of the owner s approval to proceed the instrument will be repaired and returned Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 59 Warranty no content intended for this page proceed to next page 60 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide GE DECLARATION sensing OF CONFORMITY DOC 0028 Rev E We GE Sensing 1100 Technology Park Drive Billerica MA 01821 USA declare under our sole responsibility that the Models T3 T5 T8 T11 T14 and T17 Wetted Ultrasonic Flow Transducers Models BWT p n 533 322 and p n 533 323 Buffered Ultrasonic Flow Transducers to which this declaration relates are in conformity with the following standards e IEC 60079 0 2009 e IEC 60079 1 2007 e EN 60079 0 2012 e EN 60079 1 2007 e EN 50281 1 1 1998 e 2 G ExdllC T6 Gb T3 KEMAO6ATEX0052 T5 KEMAOLATEX2045xX T8 KEMAOZATEX2283x T11 KEMAO2ATEX2252 T14 KEMAO4ATEX2054X T17 KEMAOIATEX2045xX BWT 533 322 533 323 KEMAO1ATEX2051 IEC Ex KEM09 0010 DEKRA Certification B V Ultrechtseweg 310 Arnhem The Netherlands NoBo 0344 e EN 61326 1 2006 Class A Table 2 Industrial Locations e EN 61326 2 3 2006 e EN
49. own in the product part number EE as shown below Part Numbers T5 BB CC DD EE FF EX 30 Right Angle 30 CC 05 Oblique 174 cc Frequency os soke DD Tube length in inches specified per application 220 C to 100 C Standard and Extended Velocity Range Flare Gas Transducer Installation Guide vii Preface vili Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles Chapter 1 Installing Pipe Nozzles 1 1 Introduction Before the T5 transducers can be installed into the pipe you will need to install pipe nozzles Nozzles may be installed as part of a fabricated spoolpiece or by using the hot or cold tap process with a GE Sensing Nozzle Installation Kit IMPORTANT This procedure only applies if you are using a Nozzle Installation Kit If you are tapping the pipe without using a Nozzle Installation Kit refer to the supplied drawings in your shipment This procedure is written and illustrated for installations on horizontal pipes however the procedure is the same for vertical pipe installations This section describes how to install nozzles in the following configurations 1 Bias 90 Installation a Standard spacings of 10 and 9 with both transducers facing straight at each other are for gas velocity up to 100 m s 328 ft s applications This is the standard velocity range b Shorter spacing of 6 4 with only the do
50. re Gas Transducers Installation Guide 7 Chapter 1 Installing Pipe Nozzles 1 2 3 Installing the First Welding Boss 1 Each welding boss has four scribe marks indicating the center of the bias Take one welding boss and line up its scribe marks with the horizontal and perpendicular scribe marks on the pipe as shown below Make sure you position the boss on the pipe so that the contoured end of the boss matches the pipe arc the shorter side of the boss should be closer to the original scribed pipe centerline Scribed Horizontal Centerline Welding Boss Scribed Pipe Centerine Scribed Vertical Centerline Nozzle Location Top View 2 Clamp the boss in place using a pipe strap or equivalent so that it cannot move during tack welding 3 Check the boss alignment again then tack weld the boss in each of the four grooves between the boss scribe marks Make sure you keep the boss contour flush with the pipe contour during the entire tacking operation The boss is constructed of carbon steel 4 Check the alignment again If the boss is misaligned by 0 02 in 0 5 mm or more remove the boss grind off the welds and reinstall 8 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 2 4 Installing the First Nozzle CAUTION Itis essential that the nozzles are set up and fixed in position using the jig and alignment plate provided prior to welding the nozzl
51. recycling systems please contact your local or regional waste administration Visit http www gesensing com environment weee htm for take back instructions and more information about this initiative Certification and Safety Statements To maintain DEKRA certification the transducer is provided with a ATEX and IECEx certified compression fitting and or adapter of either thread M25 X 1 5 material brass or NPT material 316 SS both with tube size of 0 50 O D For example Tyco part number 496SSGL34Ex ATEX certified under BASEEFA 08ATEX0327X and IECEx BAS08 0107X Peppers adapter part number ARB NP O7S5NPT M20 ATEX certified under SIRA09ATEX1322X or SIRA09ATEX4323X and IECEx SIR09 0121X and reducer Capri part number 740724 ATEX certified under LCIO8ATEX6085X and IECEx LC018 0035X or equivalent parts ATEX IECEx certified enclosure Type Ex d IIC For example International Metal Engineering PTE Limited IME Type 8080 8075 8066 or 7080 certified under SIRA 07ATEX1331U and IECEx SIR 07 0111U or equivalent that complies with EN 60079 0 2012 IEC 60079 0 2011 and EN 60079 1 2007 IEC 60079 1 2007 For example Cortem SL 26 1N certified under CESI 03 ATEX032U or equivalent A certified metric to NPT adapter material brass may be used in addition to the compression fitting in applicable configurations Both fitting and adapter to comply with EN 60079 0 2012 IEC 60079 0 2011 and EN 60079 0 2012 IEC 60079 1 2007 for Ex d IIC For electrical c
52. root gap between the beveled edge of the nozzle and the outside diameter of the pipe If the 0 094 in 2 4 mm clearance does not exist all around the nozzle must be removed and ground appropriately to provide the required clearance If the root gap is larger than the 0 094 in 2 4 mm dimension evenly all around the nozzle then suitably sized washers may be inserted between the jig and the nozzle in order to reduce the root gap dimension WARNING ONLY QUALIFIED PERSONNEL SHOULD WELD BOSSES AND NOZZLES USING A SUITABLE ASME IX QUALIFIED WELDING PROCEDURE ALL APPLICABLE SAFETY CODES SHOULD BE OBSERVED 10 Standard and Extended Velocity Range Flare Gas Transducer Installation Guide Chapter 1 Installing Pipe Nozzles 1 2 4 Installing the First Nozzle cont 6 Tack weld the nozzle to the pipe at four diametrically opposed points each tack being approximately 0 2 in 5 mm in length Allow to cool for 30 seconds between tacks 7 Complete the root pass and subsequent filler passes as required 8 Allow to cool then remove the threaded rod washer nut and jig 1 2 5 Installing the Second Welding Boss 1 Bolt the jig to one end of the alignment plate using four bolts Alignment Plate ht Va ED lt Zzzz ui Jig dela Side View 2 Screw the threaded rod into the second boss Insert the bolt boss assembly into the Jig key cut grooves and secure with the washer and nut on top
53. stment Screws 6 When the wedge is positioned correctly use wrenches to tighten the hardware and secure the components then remove the adjustment screws Figure 7 The Valve Wedges and Gaskets Installed Note The upstream valve and transducers are installed without the wedge and bolt spacers per normal installation procedures 30 Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide Chapter 3 Installing Transducer Assemblies Chapter 3 Installing Transducer Assemblies 3 1 Introduction Transducers and their holder assemblies are installed into a meter body The meter body is a section of pipe that contains the ports where the transducer assemblies will be mounted The meter body may be prefabricated or created by installing ports on the existing pipe Transducers can be inserted into the pipes using a number of holder methods Low pressure insertion mechanism Barrel holder e Flanged holder Note This manual will describe the low pressure insertion mechanism type only For other types please see the GE Transducer Installation Guide 3 2 Inserting Transducers Using a Low Pressure Insertion Mechanism Common Steps Note The Insertion Mechanism is designed for manual non assisted transducer insertion into operating or low pressurized pipes The mechanism uses an isolation valve and a packing gland for sealing Inserting the transducers into the pipe consists of the following Prepar
54. ts and specifications apply to the product e Having been designed in accordance with EN 60070 0 and EN 60079 1 the product meets the fault tolerance requirements of electrical apparatus for category d e The productis an electrical apparatus and must be installed in the hazardous area in accordance with the requirements of the EC Type Examination Certificate The installation must be carried out in accordance with all appropriate international national and local standard codes and practices and site regulations for flameproof apparatus and in accordance with the instructions contained in the manual Access to the circuitry must not be made during operation e Only trained competent personnel may install operate and maintain the equipment e The product has been designed so that the protection afforded will not be reduced due to the effects of corrosion of materials electrical conductivity impact strength aging resistance or the effects of temperature variations e The product cannot be repaired by the user it must be replaced by an equivalent certified product Repairs should only be carried out by the manufacturer or by an approved repairer e The product must not be subjected to mechanical or thermal stresses in excess of those permitted in the certification documentation and the instruction manual e The product contains no exposed parts which produce surface temperature infrared electromagnetic ionizing or non electrical dan
55. wnstream transducer rotated 6 into the flow is for extended range gas velocity up to 120 m s 394 ft s applications 2 Tilted 45 Installation a Standard transducer face to face spacings with both transducer body axes concentric and parallel to each other are for gas velocity up to 100 m s 328 ft s applications This is the standard velocity range b Shorter transducer face to face spacing of approximately 7 85 with only the downstream transducer tilted 6 into the flow is for extended range gas velocity up to 120 m s 394 ft s applications 1 2 Bias 90 Installation This procedure contains the following instructions identifying and checking the nozzle installation kit components selecting and marking the pipe for nozzle locations e installing the first welding boss e installing the first nozzle e installing the second welding boss e installing the second nozzle hot tapping the pipe Standard and Extended Velocity Range T5 Flare Gas Transducers Installation Guide 1 Chapter 1 Installing Pipe Nozzles 1 2 1 Identifying and Checking the Nozzle Installation Kit Components The Nozzle Installation Kit contains the materials listed below Use Figure below to help identify each component e 2 Nozzles if purchased e 62 Welding Bosses 61 Jig e 1 Alignment Plate 9 in 10 in or 6 4 in spacing Spacer Flange e 1 Threaded Rod 1 in diameter washer and nut IMPORTANT You will nee
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