maintenance manual for turbine flow meter
Contents
1. Model Lwav 07 07 707 07 07 Explanation 4 4mm normal flow range0 04 0 25m h wide flow range0 04 0 4m h 6 6mm normal flow range0 1 0 6m7 h wide flow range0 06 0 6m7 h 10 10mm normal flow range0 2 1 2m h wide flow range0 15 1 5m h 15 15mm normal flow range0 6 6m h wide flow range0 4 8m h 20 20mm normal flow range0 8 8m h wide flow range0 4 8m h 25 25mm normal flow range1 10m h wide flow range0 5 10m h DN 32 32mm normal flow rangel1 5 15m h wide flow range0 8 15m h mm 40 40mm normal flow range2 20m h wide flow range1 20m h 50 50mm normal flow range4 40m h wide flow range2 40m h 65 65mm normal flow range7 70m h wide flow range4 70m h 80 80mm normal flow range10 100m h wide flow range5 100m h 100 100mm normal flow range20 200m h wide flow range10 200m h 125 125mm normal flow range25 250m h wide flow range13 250m h 150 150mm normal flow range30 300m h wide flow range15 300m h 200 200mm normal flow range80 800m7 h wide flow range40 800m h N Basic type 12Vsupply power pulse output high level I8V low level lt 0 8V A 4 20mA two wires current output remote transmitting type Type Battery supply power scene display type scene display 4 20m A two wires current output CI Scene display RS485 communication protocol C2 Scene display HART communication protocol Accuracyc 05 Accuracy class 0 5 lass 10 Accuracy class 1 0 Measurement range Ww Wide flow r2. and the vertically installed one should be same as it The site needed to run continuouslly should install the by pass pipe and reliable cut off valve It must be assured that the by pass pipe has no leakage when measuring Location of sensor in a new pipeline is replaced into a short pipe first After the pipeline inside has been cleared the short pipe can be changed back into sensor formally For this step always has been reglected the sensor may often be damaged during clearing pipeline If the measured fluid includes impurity the filter should be installed before sensor of upstream side To continuous flow liquid should install two sets of filters which clear impurity in turn or choose auto clearing type filer If the air mixes in the liquid the eliminator should be installed in the upstream side The mouth of filter or eliminator must be led to safe site If the location of sensor is at the lower point of the pipeline the drain valve should be fixed after the sensor to discharge the impurity regularly in order to prevent from dwelling deposit If the measured liquid is easy to be aerified the exit pressure of sensor should be more than Pmin in order to prevent from air pockets that may damage the accuracy and live time Prin 2 7P 1 25P Pa Prin The lowest pressure Z P the pressure loss while the sensor flow rate is the biggest P the saturation vapour pressure when the use temperature arrives at the highest
3. Cautions in Installation 1 The installation site Sensor should be installed in the sites where is convenient to maintain have no vibration of pipe no strong electromagnetic interference and hot radiation influence The typical pipe installation system of turbine flowmeter is following as the picture The each part of configuration can be chosen in view of the objects measured which needn t all It is sensitive for turbine flowmeter to velocity aberrance and rotating flow so entering sensor should be the pipe flow developed enough and match the necessary straight pipe or rectifier If upstream side components of flow resistence are variables the pipeline length upstream generally is not less than 20D and the pipeline length downstream is not less than 5D If the installation space does not satisfy these demands the flow rectifier may be installed between the component of flow resistence and sensor The sensor should be installed outside where avoids the direct sunshine and rain picture Upstream Single Double Double Concentric Open Open Downstream component 90 angle 90 angle 90 angle reducing whole half side length types bend bends at the bends at the pipe valve valve same level different level L DN 20 25 40 15 20 50 5 17 2 The installation demands on connection with pipes The horizontally installed sensor demands the pipeline inclination shouldn t be visible generally within 5
4. The sensor conbines with displayer in the first place checking the output feature the pulse frequent range level wide etc which should match the entry feature of displayer The displayer parameters must set in terms of sensor factors The sensor power wire and 22 resistance must match each other as well In addition the sensor s prepositional amplifier must be considered to prevent from electromagnetic interference for instance to take action of rain proof LWGY A turbine flow transmitter This transmitter should be set the flow rate output zero point and the full range value well according to the customer demand when purchasing When the flowmeter works on and the flow rate output zero point should be adjust on site the operation method is doing as the follows Close the valves of flowmeter pipe confirm there is not flow rate in pipe put on the power the series connected current meter can monitor the flowmeter s output current slightly adjust the W502 potentiometer on the circuit board to come the output current back to 4m A Note the flowmeter s full range value couldn t be adjusted on site after it works If need please return it to factory to complete that in the standard installation according to your need LWGY B intelligent turbine flowmeter display on site The internal parameter set only engineer operation 01 the panel keys illustration 23 e entry exit parameter set menu in the working s
5. microprocessor technology to make up of new intelligent flowmeter with turbine flow sensor and accumulative calculation displayer integration It has many obvious advantages which are double row LCD display at the scene compact structure direct and clear reading high reliability anti interference from outside power anti thunder attack and low cost etc It has the instrument factors three points rectified non linear intelligently compensated and revision at the scene High clear LCD display simultaneously shows both instant flow rate four valid figures and accumulative flow rate eight valid figures and accumulative flow rate eight valid figures with reset All valid data can be kept for ten years This kind of turbine flowmeters all are explosion proof products and the explosion proof class is ExdIIB6 This type of turbine flowmeters can be divided into type LWGY B and LWGY C in terms of supply power and the remote signal transmitting methods LWGY B type supply power 3 2VIOAH Lithium battery can continuously run more than four years but no signal output LWGY C type supply power 24V DC outside output normal two wires current signal 4 20 m A and can add RS485 or HART communication according to different scene demand VI Type Choice
6. 5 Explode proof Class ExdIIBT6 Protection Class IP65 2 Measurement range and Working pressure for liquid Nominal Regular Expanding Regular tolerance Special tolerance Diameter Flow rate flow rate pressure Mpa pressure Mpa mm m h m h flange connection DN4 0 04 0 25 0 04 0 4 6 3 12 16 25 DN6 0 1 0 6 0 06 0 6 6 3 12 16 25 DN10 0 2 1 2 0 15 1 5 6 3 12 16 25 DNI15 0 6 6 0 4 8 6 3 2 5 flange 4 0 6 3 12 16 25 DN20 0 8 8 0 45 9 6 3 2 5 flange 4 0 6 3 12 16 25 DN25 1 10 0 5 10 6 3 2 5 flange 4 0 6 3 12 16 25 DN32 1 5 15 0 8 15 6 3 2 5 flange 4 0 6 3 12 16 25 DN40 2 20 1 20 6 3 2 5 flange 4 0 6 3 12 16 25 DN50 4 40 2 40 2 5 4 0 6 3 12 16 25 DN65 7 10 4 70 2 5 4 0 6 3 12 16 25 DN80 10 100 5 100 2 5 4 0 6 3 12 16 25 DN100 20 200 10 200 2 5 4 0 6 3 12 16 25 DN125 25 250 13 250 1 6 2 5 4 0 6 3 12 16 DNI150 30 300 15 300 1 6 2 5 4 0 6 3 12 16 DN200 80 800 40 800 1 6 2 5 4 0 6 3 12 16 10 3 Measurement range and Working pressure for gas Model Diameter Flow Rate Initial Flow Rate Tolerance mm m h m h pressure Mpa flange connection LWQ 25A 0 7 7 0 6 4 0 Flange or Thread LWQ 25B 25 17 1 5 15 1 0 4 0 Flange or Thread LWQ 25C 3 30 2 0 4 0 Flange or Thread LWQ 40A 4 40
7. 2 5 4 0 Flange or Thread 40 1 5 LWQ 40B 8 80 3 4 0 Flange or Thread LWQ 50A 10 100 3 5 4 0 Flange 50 2 LWQ 50B 15 150 4 4 0 Flange LWQ 80 80 3 15 300 4 1 6 Flange LWQ 100 100 4 20 400 5 1 6 Flange LWQ 150 150 6 50 1000 8 1 6 Flange LWQ 200 200 8 100 2000 20 1 6 Flange LWQ 250 250 10 150 3000 30 1 6 Flange LWQ 300 300 127 200 4000 40 1 6 Flange V Product Category 1 LWGY series can be divided into two categories by function Turbine flow sensor transmitter Intelligent integration Turbine Flowmeter 2 Function illustration gt Turbine flow sensor transmitter This kind of products have no scene display function only produce 11 signals to transmit output to far distance The flow signals can be divided into pulse or current 4 20ma signal This instrument has low price high assemble small size so can be applicable to match second displayer PLC DCS so on computer control system to use According to different signal outputs its can be divided into LWGY N and LWGY A types LWGY N sensor 12 24V DC power supply three wires pulse outputs high level 28 low level lt 0 8V signal transmission distance lt 1000M LWGY A transmitter 24V DC power supply two wires current 4 20mA signal output signal transmission distance lt 1000M gt Intelligent integration turbine flowmeter It adopts an advanced super low power consumption single chip
8. MAINTENANCE MANUAL FOR TURBINE FLOW METER Liquid Turbine Flow Meter SHANGHAI COWELL MACHINERY CO LTD Content Generality Principle of Operation Product Feature Basic Parameter Technical Specification Product Category Types Choice Installation Size Caution in Installation Connection Adjustment and Application Caution in Using Problem amp Solution XIII Transportation amp Storage XIV Cautions in Unpacking X V Necessary Knowledge on Order I Generality Turbine Flow Meter Abbr TUF is a main type of Impeller Flowmeters also including the Anemoscope and Water meter TUF is made up of Sensor and Conversion Show The Sensor reacts to the average velocity of fluid with multi blades rotor so as to speculating the flow value and the accumulative flow value The velocity or circles of rotor can be picked up by the way of mechanism electromagnetic induction photoelectricity before displaying and transmitting the records by reading device It is said that America announced the first TUF patent early in 1886 The patent in 1914 recorded that the TUF flow value is relevant to frequency The first developed TUF in 1938 is applied to measuring the fuel flow in the aircraft It is eventurelly achieved to use in the industry until the end of the world war two since it is urgent for the jet engine and liquid jet fuel to demand high accuracy quick responses flow measurement instrument Nowadays it can be extensi
9. ange turbine mark S Standard measurement range turbine ded S 304 Stainless steel L 316 L Stainless steel No mark non explosion proof E Explosion proof ExdIIBT6 Bub alae N Normal reference to picture before H x High pressure reference to picture before Note DN15 DNA0 need thread connection regularly but can be made into flange connection through adding the FL to the nominal diameter at its end 14 Vil Installation Size LWGY 4 10 Sensor Structure amp Installation Diagram 1 Strainer 2 Before Straight Pipe 3 Impeller 4 Preamplifier 5 Body 6 Back Straight Pipe LL SL gl gl al a a a LLIA LWGY 15 40 Sensor Structure amp Installation Diagram 1 Body 2 Former Guide Part 3 Impeller 4 Back Guide Part 5 Preamplifier 15 TA p i PIR Less LWGY 50 200 Sensor Structure amp Installation Diagram 1 Ball Bearing 2 Former Guide Part 3 O ring 4 Body 5 Preamplifier 6 Impeller 7 Bearing 8 Shaft Nominal hole diameter mm mu S number 4 295 1 2 6 330 1 2 10 450 1 2 15 75 Gl 65 14 4 20 80 Gl 75 14 4 25 100 G5 4 85 14 4 32 140 G2 100 14 4 40 140 G2 110 Q 18 4 50 150 125 Q 18 4 65 170 Q 145 Q 18 4 80 200 160 Q 18 8 100 220 p 180 Q 18 8 125 250 210 25 8 150 300 250 25 8 200 360 295 25 12 16 Vil
10. e that the conversion factor or instrument factor should comply with some conditions which calibration condition is the reference condition If it deviate from this condition the factor will happen to change The changes would be determined in terms of the sensors type the pipe installation condition and fluid physical parameters 2 Theoretical flow rate equation According moment of momentum theorem can list the equation of motion impeller J dw dt M M gt M 3 M In the formula J impeller inertia moment dw dt rotational acceleration M Liquid driven torque M 5 Viscous resistance moment Ms Bearing friction moment 4 Magnetic moment When impeller is rotating according to constant velocity J dw dt 0 and _ Through the analysis in theory and verification in experiment the formula can be deduced that is n Aq B C qy In the formula n refers to impeller rotational speed qv refers to volume flow rate A the factors related to fluid physical properties include density viscosity etc impeller structure parameters blade angle impeller diameter flow channel cross sectional area etc B the factors related to top vane gap and fluid flow velocity distribution C the factor related to friction moment The scholars domestic and abroad have put forward to many flow equations in theory applied to various sensors structures and fluid working conditions Until now the hydrodynam
11. g into running X The sensor that have not the branch pipe should slightly open up the half upstream valve then the downstream valve When running for a while through a small rate about ten minutes open the whole upstream valve and the downstream valve to the normal flowrate 25 C2 33 XThe sensor with branch should first open the branch pipe valve the half upstream valve the downstream valve close the branch valve to small flowrate and running for a while Then open the whole upstream valve close the whole branch valve be assure of no leak finally adjust the downstream valve to the needed flowrate The low and high temperature fluid starts up When low temperature fluid flows through the pipe first the water should be expelled then running for fifteen minutes with a minimum flow and gradually rise to the normal flow When stop flowing also should gradually reduce to approaching pipe temperature and ambient temperature The high temperature fluid s running is similar to this low one Other notes 1 Opening and closing the valve should be slow If adopted the auto control switch it is best to use two open two close way to prevent the fluid against vane wheel to damage it 2 Check the sensor s downstream pressure to adopt measures to prevent cavitation 3 For the sensor factors could appear to change should regularly calibrate away from pipe line If the flow is not within the allowed range sensor sh
12. good groud wire strengthen the pipe line or install blacket to prevent from vibracation maintain or replace valve gradually check and clear up the interference source 2 3 4 27 The displaying value has 1 The sensor s internal 1 4 need first find cause obvious difference with tunnel wrong so that use the correct experience estimation one 2 Sensor s interior methods appears cavitation 5 replace the magnet 3 The flow inside pipe material causes problems 6 choose the proper sensor 4 The displayer interior wrong 5 The effect of permanent magnet material is weaker and weaker 6 The real flow is not within its normal range XIII Transportation and Storage The sensor should be put in the solid wooden box small diameters can be put in carton and cannot be free to wobble in the box When carrying it must be care to put down and refuse to load or unload crustily The location of reservation should be confirmed to the conditions as the following 1 avoid rain and humidity 2 avoid mechanical vibration and strike 3 temperature 20 55 4 relative humidity not more than 80 5 ambient environment does not include corrosive gas XIV Cautions in unpacking When opening box files and accessory should be complete The files in the box include a user manual a piece of test certificate and 28 a piece of packing list The sensor should be obser
13. ic characteristic of turbine instrument ones is still unclear for it has complicated relationship with fluid physical property and flow characteristics For instance when there appears to swirling and unsymmetry velocity distribution in flow field the hydrodynamic characteristics are very complicated So instrument factors can not be deduced by theoretical formula can be confirmed by real flow calibration But theoretical formula has been significant in practice It can be used in instruction in the design of sensor structure parameter and the forecast and assessment of instrument factor changing rule 1 2 3 4 5 6 7 8 9 Product Feature High accuracy regular accuracy 1 R O 5 R highest accuracy 0 2 Good repeatability short term one reaches 0 05 0 2 priority to be used in trade settlement for its extremely high accuracy in the regular calibration or on line calibration Pulse frequency signal output is applicable to totality calculation and computer connection with no zero drift and strong anti interference capacity High frequency 3 4kHz can be achieved and has high resolution Wide rangeability medium or large diameter may reach 1 20 and small diameters are 1 10 Compact and light weight structure convenient installation and maintenance extensive application ability Application to high pressure measurement with its unnecessary opening hole to be made into high pre
14. l one 1 Practical equation Q f k Qm Qy vp Q refers to volume flow rate unit m s Qnm refers to mass flow rate unit kg s f referto output signal frequency unit Hz referto the Flowmeter factor unit The related curve of flowmeter factor and flow rate is in the graph Diagram Turbine flowmeter characteristic curve As your seeing the factor curve can be divided into two parts of linearity and non linearity The linear part accounts for two thirds of the entire curve which feature is related to the structure size of sensors and fluid viscosity The feature in non linearity part is influenced by friction force from bearing the viscosity resistance of liquid When flow rate is below the lower limit of sensor the instrument factor are quickly increasing with it The value of pressure loss and the flow rate are similar to be square relations If flow rate surpassed the upper limit pay attention to preventing from cavitation When the turbine flowmeters have similar structure their curves have similar feature but have different system errors Diagram Turbine flowmeter characteristic curve The sensor factor can be worked out by calibration instrument which may have no consideration of the sensor s inside fluid mechanism and can be confirmed by inputed flow rate and outputed pulse signals of 5 frequency So we can see the sensor as a black box that is convenient for application But please not
15. ould be change 26 4 Cleaning the pipe needs confirm to the standards of used flow direction value pressure and temperature etc otherwise can make the accuracy fall even damage 5 Strengthen the check for sensor in order to assurance of long time normal working As finding the unnormal the measure should be taken For instance hearing the unnormal voice as monitoring the vane wheel rotation Problem and Solution problem Possible reason solution No showing or no total adding when liquid normally flows The flow showing is gradually falling Check 1 circuit loose contact wire power wire fuse coil PCB 2 the vane wheel has no rotation 1 filter blocks up 2 valve in pipe is loose to the core vane wheel has impurity 3 1 find the problem point with electrical meter or replace this circuit board with spare one 2 clean or replace vane wheel and assure no rubbing with its neighboring parts 1 clean up the filter 2 repair or replace the valve clean the sensor then need to calibrate again 3 Its screen has still flow showing when liquid has no flow 1 the cable has no good groud wire with the outer interference the pipe with vibracation to produce error signal the cutoff valve has leakage with leaking flow internal circuit component of displayer is damaged to produce interference 2 3 4 or 1 repair or replace to have a
16. point Flow control valve should be fixed in the sensor s downstream and the cut off valve at the upstream side all should be opened whose valves may not produce vibracation and leakage toward outside To the flow range that might make the reversed flow should prevent the fluid s reversed flow with fixing the check valve Both sensor and pipeline should be concentric The sealed washer is not allowed to have it protruded into the pipeline The liquid sensor should not be fixed at the top of the horizontal pipeline lest the air converging into the pipe stops in the sensor not to be expelled so as to effect the measurement The sensor s front and back pipe sections should be supported firmly so as not to produce vibration If the fluid is easy to condense the measurement of keeping temperature should be taken in the sensor and its front and back sections of pipeline IX Connection Way Turbine flow sensor transmitter model LWGY N model LWGY A Basic type ra Js f lik vb fi rv EWIE LWGY L A type turbine transmitter connection way 20 24VDC 2 Anti explosion type LWGY LIN type turbine flow meter sensor connection way LWGY L A type turbine flow transmitter connection way Intelligent integration turbine flowmeter model LWGY C X Adjustment and Application LWGY N basic type turbine flow meter This sensor has been calibrated and adjusted before sales so needn t examination
17. ssure instruments Complete tailored version sensors can be designed to different kinds of types according to users special needs For instance low temperature type high pressure type sanitary type etc Insertion type can be made that is applicable to large normal diameters measurement for its little pressure loss low price unnecessary stopping flow to take out it and convenient installation and maintenance IV Basic Parameters Technical Specification 1 Technical Specification 4 6 10 15 20 25 32 40 tread connection 15 20 25 32 40 tread and flange connection 50 65 80 100 125 150 200 flange connection Nominal Diameter mm and Connection method Regular accuracy 1 R 0 5 Highest accuracy 0 2 Accuracy Class Measurement Range Rate 1 10 1 15 1 20 Instrument material 304 stainless steel 316L stainless steel etc Medium Temperature 20 120 C Temperature 10 55 C Ambient Conditions Relative Humidity 5 90 Atmosphere Pressure 86 106Kpa Sensor pulse frequency signal low level lt 0 8V high level28V Transmitter current signal 4 20mA DC two wires Sensor 12V DC 24V DC option Supply Power Transducer 24V DC Signal Output Scene display type meter 3 2V Lithium cell Signal Transmission Line STVPV 3 X0 3 three wires 2X0 3 two wires Transmission Distance lt 1000m Signal Line Interface Internal thread M20 X 1
18. tate simultaneously press the key Xand key e cursor moves towards right in the parameter set state press the key e cursor adds one figure in the parameter set state press the key parameter menu switch in the parameter set state press key F e cumulative flow value to clear in the working state simultaneously press the key and key a 02 internal parameter illustration The flow meter program includes three menus which shows with three screens that is the three points modification the top one is the value of frequency the bottom one is the meter factor of this flow point The three menus can circularly be switched with the key F wae ht 1 0000 i 000000 00 ss ART S DU HBL LWGY C intelligent turbine flow meter display on site with 4 20mA current output 24 XI 01 The panel key illustration The turbine flow meter with battery and supply power on site display 02 Internal parameter illustration The meter has four menu programs which displays in four screens the first three menus are three points parameters modification the same as the type o f battery supply on site display turbine flow meter the fourth one is the full range value of current 4 20m A the 20m A point flow value These menus can be circularly switched with the key F aS it T 4 000000 D utu AUR Jy 20 ifi Cautions Using 1 The switch order puttin
19. ved whether it happens damage during transportation so that dealing with it well Users must protect the certificate from loss otherwise the instrument factors cannot be set X V Necessary knowledge on order User should notice that when ordering turbine flowmeter the proper model specification should be chosen according to fluid s nominal diameter operating pressure operating temperature flow range the fluid category and the surrounding condition The anti explosion type sensor should be chosen when having explosion proof demand and noticing strictly the explosion proof classes When the display instrument is matched by our company please refer to the related instruction to choose your proper model or use our design of technological engineer for your choosing in terms of your information offering The cable using in sending signal you want should provide the length and specification 29
20. vely used in the fields of oil chemical defence science measuring etc LWGY series Turbine Flowmeters draw the leading technology integrating with advanced design to produce the new generation of turbine flowmeter with the features of simple structure light weight high accuracy good repeatability flexible reaction convenient installation maintenance application etc It is widely applied to measuring the liquid of which kinematic viscosity is under 5 10 m s and have no impurify of fibre grain etc and no corrosive interaction with the stainless steel 1Cr18Ni9Ti 2Cr13 and 1203 and hard alloy in seal pipes The liquid of kinematic above 5 10 m s can be measured after real liquid calibration of flowmeter It can be used in value control siren when excess if co ordination with special display instrument So it is the ideal instrument of measuring flow value and saving energy II Principle of Operation As the measured liquid flows through the sensor the drived vane begins to turn which velocity is in direct proportion to average flow one in the pipe The turn of vane periodically changes the magnetic resistance value of magnetoelastic transducer Magnetic flux in the magnetic test coil happens to change cyclically with it to produce periodic induced voltage it is the pulse signal that will be sent to the display to show after amplified by magnifier Flow rate equation of Turbine Flowmeter includes both practical and theoretica
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