SDF Flow Sensor
Contents
1. SDF Flow Sensor Operating and Installation Manual ISO 9001 BA SDF en L 1503 SDF Flow Sensor Table of contents 1 General 1 1 Symbols 1 1 General Note 1 2 Qualified Personnel 2 Incoming Goods Inspection 3 Type Code Excerpt 4 Installation instructions 4 1 General Note 4 1 Stipulation Of The Installation Location 4 2 Stipulation Of The Installation Position 4 3 Orientation Of The SDF Flow Sensor 4 4 Mounting The Installation Components Main Bearing 4 4 1 SDF M Olive Installation Component 4 4 2 SDF F Flange Installation Component 4 4 3 SDF S Weld In Installation Component 4 4 4 End Support Installation 4 5 Installation Of Standard Sensors For Liquids And Gases 4 5 1 Steam Sensor Installation 4 5 2 FASTLOK Sensor Installation 4 6 FASTLOK Sensor Installation And Positioning 4 6 1 FASTLOK Sensor Disassembly 5 Connect Pressure Differential Transducer To Sensor 5 1 Sensor With Mounting Plate For Direct Transmitter Connection To The Sensor 5 2 Sensor With Connection Nipples To Connect The Transmitter Via Differential Pressure Pipes 6 Specific Characteristics Steam Sensors 6 1 Description Of The Measurement Set Up and Specific Notes 6 2 Steam Measurement Start Up 7 Specific Characteristics FASTLOK Sensor 8 Troubleshooting BA SDF en L 1503 2 SDF Flow Sensor 1 General 1 1 Symbols AN Hazard warning Caution observe documentation ISO 3864 no B 3 1 1 2 General Note2. 4 3 Determine installation position Gases Liquids Steam for horizontal pipe run a 3 X o FA D SY a all Sensor installation upward Sensor installation downward between 80 and 80 position between 80 and 80 position for vertical pipe run s Slightly inclined installation Slightly declined installation between 0 and 4 of sensor to between 0 and 4 of sensor to enable the condensate to flow enable air or gas bubbles to Sensor installation always level away from the sensor head back return into the process incline into the process opposite to gases Height offset calculation of end support for vertical pipe run Deviation between N On same height as installation 20 component O 4 Table 3 Determine installation position illustrations apply for SDF M sensors mechanical joint as well as SDF F sensors flange SDF S sensors weld in sensors SDF DF sensors steam sensors and FASTLOK sensors 4 4 Orientation SDF Flow Sensor SDF flow sensors are completely symmetric For this reason it is irrelevant which of the perforated sensor sides faces the flow Consequently the arrow indicating the flow direction only shows whether the SDF flow sensor is designed for horizontal or vertical flow In addition the connections are marked with the letters LK left sensor chamber and RK right sensor chamber fo
3. Wrong wiring transmitter see user manual pressure differential transmitter Transmitter incorrectly parameterised see pressure differential calculation flow sensor No zero balance of transmitter see page 20 Measurement cells admitted with hot condensate steam only for steam measurement We are aware that this list cannot be complete Please contact us directly if problems occur which are not included in this list BA SDF en L 1503 22 SDF Flow Sensor S K I Schlegel amp Kremer Industrieautomation GmbH Postfach 41 01 31 D 41241 M nchengladbach Hanns Martin Schleyer Str 22 D 41199 M nchengladbach Phone 49 0 2166 62317 0 Fax 49 0 2166 611681 Web www ski gmbh com e mail info ski gmbh com Trademarks and logos are the property of their owners Subject to technical changes Illustrations may contain options BA SDF en L 1503 23
4. pe Lock pipe with gland packing Lock pipe with gland packing Connector Safety chain head with F tube nipple Spindle as a s Ball valve to safeguard nie Selew shut off the f Bee Ball valve to shut Shut off ball off the pipe N valve Weld on nipple FASTLOK L FASTLOK S FASTLOK N Table 9 Design Overview FASTLOK Sensors Start up of FASTLOK sensors is similar to start up described above for Standard sensors BA SDF en L 1503 21 SDF Flow Sensor 8 Troubleshooting Pos Trouble Possible Cause Sensor 1 No or too low pressure differential Sensor not installed in flow direction Pressure differential connections between sensor and transducer confused see page 7 upstream side of sensor not connected to transducer chamber and downstream side of sensor not connected to transducer chamber won Primary shut off and or side not open Counterbalance valve not closed Leaks in pressure differential pipework Sensor s drill holes blocked Upstream and downstream distances too short see page 6 Air locks in sensor head differential pressure pipe or transducer see also pos 3 for steam and liquid measurements Condensate in sensor head differential pressure pipe or transducer see also pos 4 for gas measurement Sensor not completely with all drill holes inside the free pipe
5. For the sake of clarity this manual does not contain detailed information about all types of products and cannot take every conceivable case of installation operation or maintenance into consideration Please contact us directly for further information or in case of problems which are not sufficiently explained in this manual May we draw your attention to the fact that the contents of the manual are not part of a previous or existing agreement approval or legal relationship or an amendment thereof All obligations of S K I GmbH result from the purchase contract which also contains the entire and solely valid warranty agreement These contractual warranty conditions are neither extended nor restricted by the contents WARNING This equipment should only be installed and operated after qualified personnel has made sure that during normal operation or in case of malfunction no potential dangers emanate pro the equipment or parts thereof Danger of serious injuries and or considerable damages in case of improper handling The manufacturer is not responsible for these injuries damages Safe and faultless operation of this equipment requires proper transport correct storage assembly and installation a well as attentive operation and maintenance Unless stated otherwise SDF Sensors are designed for static loads according to AD2000 and EN13480 respectively They are not designed for external static loads of the manual 1 3 Qualified Pe
6. process connection via 12mm pipe and tensioning ring screw joint Ball valves with tensioning ring screw joint optional 1 Installation flange 2 SDF sensor Figure 14 Arrangement for transmitter connection via differential pressure pipes Caution follow above instructions for installation position The sensor must be installed according to page 7 Table 3 Pipework and pressure differential transmitter connection must be strictly monotonous inclined for gases and strictly monotonous declined for liquids and steam Zero balance must be executed before start up Both chambers must be under the same pressure Close an upstream valve and open the middle valve for the pressure to be present at both chambers See further procedure in the manual of the pressure differential transmitter manufacturer BA SDF en L 1503 18 SDF Flow Sensor 6 Specific Characteristics Steam Sensors 6 1 Description of the Measurement Set Up and Specific Notes SDF flow sensors for steam are generally supplied with condensate pots 2 and mostly with pre assembled shut off valves 5a 5b In standard sensors for steam the condensate pots are integrated in the compact head what simplifies the alignment of the SDF sensor The sensors must always be installed horizontally Figure 15 Steam Sensor Illustration SDF DF 22 Separate transducer installation The connection between sensor and transmitter is made via compression fitting Ensur
7. cutting ring to avoid tension due to heat Now insert the mounting piece tack weld it and align perpendicular to pipe axis After finishing the weld around the mounting piece insert the cutting ring and securethe union nut with several turns Gc Necessary torque T accardina to P Ybenmurimutier ISO 9974 1 ISO Union nut 32 T1 Form X DIN 3852 T3 Form W metric thread ot Installation component for SDF M _ Schneidring SDF M 10 Ta Cutting ring SDF M 22 T 330 Nm SDF M 32 Ta Mounting Piece Q Einschwei stuzen N AN Above values ony ior reierence and must be observed for every application Figure 4 Olive Installation Component 4 5 2 SDF F Flange Installation Component The pipe wall must be drilled or welded to Dp see Table 5 at the installation location Then place the flange on the pipe and tack weld Align the flange perpendicular to pipe axis Attach the flange to enable functional sensor installation The alignment of the flange drill holes must correspond with Figure 6 Now finish the weld of the installation flange Flange with Flange with 4 drill holes 8 drill holes Welding neck flange Pipe Pipe axis Figure 5 Flange Installation Figure 6 Alignment Of Flange Installation Component Component EinschweiBmuffe BA SDF en L 1503 SDF Flow Sensor 4 5 3 SDF S Weld In Installation Component The pipe wall must be drilled or welded to Ds see Table 5 at the
8. diameter see page 12 Condensate containers or condensate receivers not aligned on equal height different condensate column heights see page 20 only for steam measurement 2 Measurement range exceeded Upstream and downstream distances too short see page 6 Primary shut off in differential pressure pipe of side not open Sensor s drill holes blocked Sensor not completely with all drill holes inside the free pipe diameter see page 12 Condensate containers or condensate receivers not aligned on equal height different condensate column heights see page 20 only for steam measurement 3 Trapped air in sensor differential pressure pipe and or transmitter for liquid measurement Faulty installation of SDF sensor or differential pressure transmitter see page 7 Incorrect bleeding see user manual pressure differential transmitter Differential pressure pipes installed without decline see page 20 for steam and liquid measurements Transducer not installed below sensor see page 20 for steam and liquid measurements 4 Condensate formation in sensor differential pressure pipe and or transmitter for gas measurements Faulty installation of SDF sensor see page 7 Pressure differential Transmitter 5 No or wrong output signal Faulty installation of differential pressure transmitter see user manual pressure differential transmitter
9. end with the packing gland a female thread connection for the drive spindle This spindle connection must be exactly perpendicular to the pipe axis after sealing the screw joint This ensures that the inserted sensor is properly aligned with its drill holes and will face the flow direction correctly Table 8 Final Installation Procedure for FASTLOK Sensor Figure 11 Packing Gland Design BA SDF en L 1503 Union nut _ Clamping ring Graphite seal Graphite seal Packing gland At delivery the packing is already inserted in the gland spare packing is also included 14 SDF Flow Sensor 4 7 FASTLOK Sensor Installation And Positioning FASTLOK sensors can be installed under process conditions FASTLOK L Installation FASTLOK L sensors are only suitable for media whose discharge is not harmful since during installation and disassembly media is discharged for a short time Installation and disassembly should be performed by two persons to minimize media discharge 1 Insert the SDF sensor with the tip in the mechanical joint and align with the flow arrow in correct orientation 2 Open the shut off ball valve and slide the SDF sensor into the pipe until it touches the opposite pipe wall 3 Fix the sensor in this position and tighten the mechanical joint Ensure that the alignment is not changed FASTLOK S and FASTLOK N Installation Ball valve must stay closed up to point 4 if the pipe is already pr
10. 7 I D 3 l D The flow profile mainly deforms in the plane of the elbow Therefore the sensor should be installed in the same plane in order to detect the variations in velocity at the individual measuring points Example 2 Correct installation is not possible at the measuring point due to structural 1 0 ID 3 ID conditions This can be remedied by correction of the SDF sensor s k factor This is done by means of a testing instrument e g a pitostatic tube to determine the flow velocity at the sensor s 7 d 3 l D installation location and comparison with the displayed value at the stationary measuring equipment In case of deviations the application specific k factor must be calculated from the calculation 20 ID 5 ID formulae and the measuring equipment must be re parameterised Find details in a special application report if required For more information contact our consulting and commissioning service Table 2 Required Upstream And Downstream Sections Pay attention to interferences existing upstream and downstream of the selected installation location Passive elements e g elbows cause less interference than active elements e g fans Harmonic changes in the pipe run elbows with large radii reductions according to DIN are more favourable than sudden or less harmonic changes corners stops Contact the manufacturer or responsible sales engineer if necessary BA SDF en L 1503 6 SDF Flow Sensor
11. For End Support for pressure eT from PN63 the bore diameters Dp of the flange installation components correspond with the inner diameter of the used welding neck flange The end support is tack welded to the pipe and aligned in such way that the end support aligns with the previously welded installation component This guarantees trouble free insertion of the sensor without wedging Overview Different End Support Versions Closed End Support GG Pipe S Gap Flanged End Support GF rn End Support Flange End _ Closed end End Support cap Support support Blind flange with end support sleeve Table 7 Overview End support Note Ensure that the drill hole in the pipe SDF10 14mm SDF22 26mm SDF32 34mm and SDF50 54mm is completely kept as passage und weld the end support to the pipe Recommended procedure for end support alignment After drilling insert the sensor or a straight pipe with respective outer diameter through the installation component already installed and loosely slide the end support over the projecting sensor end or pipe Tack weld it to the pipe after properly aligning the end support do not wedge Remove the sensor or pipe and complete the weld After installing the sensor cover the end support with the supplied cap or blind flange depending on the version 4 For special designs the bore diameters may deviate and must be enquired separately 5 This design can on
12. al Calculation BA SDF en L 1503 Tel 49 0 2166 62317 0 Fax 49 0 2166 611681 Figure 1 Type Label SDF set point for pressure differential SDF Flow Sensor 3 Type Code Excerpt Table 1 SDF Type Code Excerpt Pipework installation Weld in union with mechanical joint Mounting flange Steam sensor with mounting flange Special version Inner diameter Numerical value with unit Wall thickness Numerical value with unit Sensor material W no 1 4571 316 Ti W no 1 5415 W no 2 4819 Hastelloy C276 W no 2 4816 Inconel 602 Special material Installation component materials End support with pipe thread and cap Closed end support End support with flange Special version Process connections Nipple with 1 2 14 NPT male thread Nipple with 1 4 18 NPT male thread Nipple with R1 2 male thread Nipple with R1 4 male thread Pipe element 12mm Hose stem 8x1mm Flange plate for mounting 3 way valve block Steam version with condensate container up to 400 C in compact design made of 1 4571 Special version Ball valves made of 1 4401 Shut off valves made of carbon steel Shut off valves made of 1 4571 different versions 3 way valve block made of 1 4401 with flange plate only different versions 5 way valve block made of 1 4401 different versions Special accessories none 1 pair of screw joints for pipe connection 12mm carbon steel 1 pair of screw joints for pipe connectio
13. arefully Close the ball valve immediately if the gland leaks and re tighten the packing gland A further packing must be inserted under the pressure ring if the gland cannot be tightened further 5 Move the sensor for N with the drive spindle through the fully open ball valve until the sensor point touches the opposite pipe wall if the gland is leak proof 6 For installation with end support the sensor is inserted until the distance between pipe outer wall and upper edge sensor head and or flange plate corresponds with the value marked on the rear of the type label The sensor point reaches now approx 30mm into the end support 7 Check the gland again for leaks and tighten if necessary Important for installation First tighten the gland then carefully open the ball valve 4 7 1 FASTLOK Sensor Disassembly The FASTLOK sensors can be removed under process conditions 1 FASTLOK L Fix the SDF sensor and loosen the mechanical joint to remove the sensor This must be done with the necessary care Remove the SDF sensor from the mechanical joint FASTLOK S Ensure that the safety chain is connected to the sensor head Loosen the gland to remove the sensor Only remove as far as necessary and very careful medium may be discharged Carefully pull the sensor manually outward until the ball valve can be closed The safety chain should now be nearly taut FASTLOK N Remove the sensor with the crank as far from the pipe until the sensor
14. ction Finally both flanges are bolted together SDF S After all installation components and the end support if required are attached the sensor can be inserted in the welding sleeve The flow direction arrow on the sensor head must be aligned with the flow direction Two cases are to be differentiated For installation without end support ensure that the sensor touches the opposite pipe wall The distance between the external pipe wall and the lower edge of the sensor head amounts to approx 80mm for SDF 10 100mm for SDF 22 and SDF 32 or 120mm for SDF 50 plus possibly present neck extension H When installing with end support the sensor is inserted until the distance between the external pipe wall and the lower edge of the sensor head amounts to 80mm for SDF 10 100mm for SDF 22 and SDF 32 or 120mm for SDF 50 plus possibly present neck extension H The sensor point reaches approx 30mm into the end support Finally the sensor is welded to the welding sleeve 80 H for SDF M 10 100 H for SDF M 22 100 H for SDF M 32 H Neck extension 80 H for SDF F 10 100 H for SDF F 22 100 H for SDF F 32 120 H for SDF F 50 H Neck extension Figure 9 Neck Extension For SDF F Sensors Figure 8 Neck Extension For SDF M Sensors 4 6 1 Steam Sensor Installation Generally installation is similar as above Observe the following particular characteristics Ensure during installation that the condensate pots are installed on e
15. e that the compression fittings have sufficient decline over the entire distance towards the pressure differential transmitter The steam condensates in the pipes and the condensate serves as a guard to avoid direct contact of steam an electronic equipment Please note that these condensate water columns generate additional pressure at the measuring cell They can distort the pressure differential measurement if the individual height of condensate columns are not exactly the same To ensure equal condensate height the SDF flow sensors are fitted with condensate containers which are filled with condensate to a clearly defined height during normal operation Transmitter direct installation Steam sensors for direct installation of the pressure differential transmitter are always supplied with compact head and welded 5 way valve block Horizontal alignment of the compact head can easily be checked with a spirit level during installation Due to low condensate receivers the condensate containers integrated in the compact head must be filled with water before measuring start up via the blow off valves integrated in the 5 way valve block BA SDF en L 1503 19 SDF Flow Sensor Sensor Compact head Steam pipe Measuring pipe connection Initial shut off Pressure differential valves Counterbalance valves Blow off valves Transmitter 0 Pressure differential pipe SP OONDOBRWDND Figure 16 Measurement Set Up team Sensors See the typical pipe
16. essurised 1 Carefully insert the sensor with the point without wedging in the gland with the union nut loosened if necessary 2 For type N While inserting the sensor further in the transporting pipe the lower end of the drive spindle remove lock nut at the lower spindle end must reach into the spindle connector Turn the hand crank to move the sensor all the way to the ball valve without putting pressure on it Place the lock nut in this position on the lower end of the spindle and fix with the grub screw For type S Insert the sensor in the shut off pipe until it touches the ball of the ball valve Now move it approx 5mm back Attach the safety chain with the snap hook at the shut off pipe Sensor uncoupled from process in the transporting pipe Ball valve closed Packing gland can be loosened via screw down nut With the removing mechanism the pre assembled Figure 12 FASTLOK N Sensor Design BA SDF en L 1503 Sensor installed Ball valves opened Shut off pipe under process pressure DanLinn Alana eingebaut Sensor inside the transportir isolated from process Ball valve closed Packing gland can be loc via screw down nut Sensor can be installed lt installed from this positio the removing mechanism SDF Flow Sensor 3 Tighten the gland so that it seals the sensor neck pipe but movement of the SDF sensor is possible without too much force 4 Now open the ball valve c
17. fic pull out mechanism from the process pipe The primary shut off is made with the ball valve directly at the pipe as shown in the illustration Especially convenient is the combination of FASTLOK L sensors with a pressure differential transducer or flexible tubes as differential pressure pipe which are directly mounted on a flange plate here the complete array can be moved without any further disassembly FASTLOK L type is available for profiles 10 and 22 FASTLOK S type is used if sealing of the pipe and securing of the sensor during installation and disassembly is necessary e g in water or steam pipes but can be held without risk with normal force in the pipe Contrary to the L type the pipe is shut off before removing the sensor completely from the installation equipment In this way only the media inside the equipment escapes lock SDF sensor types FASTLOK N are suitable for the safe installation and disassembly at higher pressure max PN16 150 Ibs by only one person The installation and disassembly mechanism allows controlled installation and disassembly with self protection up to sealing the pipe and complete disassembly at any time Via the valves on the transducer or primary shut offs the residual pressure inside the installation equipment can be completely discharged before the complete disassembly of the sensor FASTLOK N types have a standard hand crank to actuate the installation mechanism
18. ide of the sensor i e with the side in front of the direction of the arrow Both sealing faces between sensor and valve block and between valve block and transmitter must be equipped with sealing rings in the provided grooves These sealing rings are supplied The necessary seals are loosely included with the delivery The complete parts list for the start up of the sensor must include e Sensor including the installation components for pipe installation e 1 3 way valve block for direct installation at transmitter and sensor including all seals and screws e 1 pressure differential transmitter will be mounted directly to the sensor additional support is not necessary Flow sensor with direct installed electric pressure difference transmitter and 3 way valve block flanged in between 1 Installation flange 2 SDF sensor 3 Pressure difference transmitter 4 3 way valve block Figure 13 Arrangement of directly installed differential pressure transmitter on 3 or 5 way valve block Caution Follow above instructions for installation position The sensor must be installed according to page 7 Table 3 Zero point balance must be executed before start up Both chambers must be under the same pressure Close an upstream valve and open the middle valve for the pressure to be present at both chambers See further procedure in the manual of the pressure differential transmitter manufacturer BA SDF en L 1503 17 SDF Flo
19. installation nt an Sow tnaa thn welding sleeve tack weld and align perpendicular to pipe axis After finishin Welding Sleeve sleeve insert the sensor align and tack weld Now finish the weld Figure 7 Weld In Installation Component Welding Sleeve Weld In Connection M SDF S 22 22 E 32 32 50 Table 5 Bore Diameters For pressure stages from PN63 the bore diameter Dp of the flange installation component corresponds with the inner diameter of the used welding neck flange For welding sleeves the bore diameter Ds is 2mm greater special designs may include deviating bore diameters 4 5 4 End Support Installation Follow the installation steps below if the sensor is fitted with an end support First stipulate the installation location of the end supports it is positioned exactly opposite the mounting component Recommended procedure for stipulating the opposite point First mark the centre of the installation component to be installed on the pipe Then pass a tape of at least 30mm width and appropriate length tightly around the pipe and align it in such way that after one turn it exactly covers the first layer Start by holding one end of the tape to the point marked on the pipe Mark the tape at the point which after one turn is directly adjacent to the marked centre of the installation component The distance from the start of the tape to this point is equal to the outer diameter of the pipe Remove the tape and determi
20. ly be utilized up to a certain pressure stage max PN40 and depending on the temperature resistance of the sealant Bore diameters apply for sensors with flange installation up to and including PN40 Above pressure stage PN 40 the bore diameters correspond with the inner diameters of the used flange according to DIN EN 1092 BA SDF en L 1503 11 SDF Flow Sensor Sc 4 6 Installation Of Standard Sensors For Liquids And Gases SDF M After all installation components and the end support if required are attached the sensor can be inserted in the union nut which is only screwed on the welding flange with a few turns The flow direction arrow on the sensor head must be aligned with the flow direction Two cases are to be differentiated For installation without end support ensure that the sensor touches the opposite pipe wall When installing with end support the sensor is inserted until the distance between the external pipe wall and the lower edge of the sensor head amounts to approx 80mm for SDF 10 and 100mm for SDF 22 and ASDF 32 plus possibly present neck extension H The sensor point reaches approx 30mm into the end support Finally the union nut is firmly tightened SDF F After all installation components and the end support if required are attached the sensor can be inserted after inserting a seal between installation flange and sensor flange The flow direction arrow on the sensor head must be aligned with the flow dire
21. n 12mm made of 1 4571 3 way valve block with 1 2 NPT female thread for direct installation on electric pressure differential transducer made of 1 4571 Weld on 5 way valve block for direct installation on electric pressure differential transducer Integrated temperature sampling with PT100m class B 3 pole Multi way cock PN100 with flush connections made of 1 4401 Pipe run Horizontal Vertical also inclined run Find a complete type code in our technical information for SDF sensors BA SDF en L 1503 SDF Flow Sensor 4 Installation Instructions 4 1 General Note During installation observe applicable national regulations especially Pressure Equipment Directive 97 23 EG if applicable related standards such as AD2000 or DIN EN 13480 if applicable Machine Directive 2006 42 EG if applicable depressurise pipework and or channel before installation disassembly clean pipework if toxic narmful media are present before installation disassembly 4 2 Determine installation location Find the longest straight part of pipework or channel and divide this into upstream and downstream distance respectively according to the table below Required calming sections Pipe run Upstream Downstream The indicated upstream and downstream distances are reference values They can be shortened by intelligent installation What does intelligent installation mean Example 1 Sensor installation downstream of elbow
22. ne the centre between the start of the tape and the point marked on the tape and mark the centre of the tape Place the tape again around the pipe as described above The point marked last on the tape centre is the position exactly opposite the installation component Finally you only have to transfer this point to the pipe If there is no tape available you can also use a cord to determine the diameter In this case it is important to check the axial alignment of the cord by measuring the distance to the next flange Now install the installation component as described above Then drill or weld a respective hole at the opposite point see above Find the required diameter in the following Table 1 Bore diameters apply for the installation of sensors with cutting ring installation Please contact us for drill hole sizes for directly welded sensors above SDF S regularly used for high pressure 2 Bore diameters apply for sensors with flange installation up to and including PN40 Above pressure stage PN 40 the bore diameters correspond with the inner diameters of the used flange according to DIN EN 1092 3 Bore diameters apply for sensors up to and including PN40 Above pressure stage PN 40 or for special designs the bore diameters may deviate and must be enquired separately BA SDF en L 1503 10 SDF Flow Sensor Closed End Support GG End Support With Cap SC End support With Flange GF Type SDF FO fmm Ff Table 6 Bore Diameter
23. nsate collects in the condensate container Open the primary shut offs after a while for the condensate to run into the impulse pipes After some more waiting open the pressure differential valves of the valve block and the cooled condensate reaches the measurement cell After the condensate containers have filled again zero balancing can be carried out first close the pressure differential valves and then open the counterbalance valve and the measurement can be started BA SDF en L 1503 20 SDF Flow Sensor 7 Specific Characteristics FASTLOK Sensor Advantages and Areas Of Application For FASTLOK Sensors FASTLOK sensors are used if installation and disassembly are to be ensured during operation For adjusting the process data different FASTLOK sensor versions are available FASTLOK L sensor without safeguard against moving of the sensor FASTLOK S sensor with a safety chain FASTLOK N sensor with a spindle Generally a version up to pressure stage PN63 is possible FASTLOK L sensors without pull out mechanism PN2 FASTLOK S sensors with pull out safeguard max PN6 FASTLOK N sensors with simple pull out mechanism max PN16 The most simple of all FASTLOK sensors is suitable for a further application as standard sensor everywhere where in the range of the atmospheric pressure or slight over or under pressure in non toxic gaseous media is to be measured Here the pressure differential sensor can be removed without speci
24. of FASTLOK sensors installation and disassembly need more space than a standard SDF sensor Take this fact into consideration when stipulating the installation location Space requirements in sensor removing direction FASTLOK L OD insulation thickness 350mm FASTLOK S 3 x OD 4 x insulation thickness 850mm FASTLOK N 3 x OD 4 x insulation thickness 1000mm OD pipe outer diameter If this space is not available at FASTLOK S and FASTLOK N sensors the shut off pipe can be unscrewed above the ball valve with the ball valve closed This reduces the necessary space requirements to FASTLOK S 2 x OD 3 x insulation thickness 800mm FASTLOK N 2 x OD 3 x insulation thickness 900mm OD pipe outer diameter Further FASTLOK Sensor Installations FASTLOK L FASTLOK S FASTLOK N BA SDF en L 1503 13 SDF Flow Sensor The supplied ball valve is The supplied ball valve is screwed on the weld in screwed on the weld in support and in here the support and in here the mechanical joint is screwed transporting pipe with and sealed packing gland is screwed and sealed After sealing the ball valve can be closed and the pipe pressurised with process pressure The supplied ball valve is screwed on the weld in support and in here the transporting pipe with packing gland is screwed and sealed Observe the following component alignment with each other under all circumstances The transporting pipe has at the
25. onent materials as far as possible consistency of the scope of delivery with the order confirmation documentation operating manual flow calculation see below drawings etc Pressure Differential Calculation For SDF Sensors Date Customer Project Tag no measuring point Process Pipe and sensor data Pipe cross section SDF sensor type no Inner diameter cold Wall thickness Insulation Pipe material k factor cold Design and calculation criteria Type of medium Calculation State and process variables Temperature Absolute pressure Cinematic viscosity Operating volume flow Operating density k factor warm Inner diameter warm Expansion number Flow velocity Reynolds number Results Calculated pressure differential Remaining pressure loss 8 November 2010 S K I GmbH 41320001 internal round SDF22 250mm 4mm Omm carbon steel St37 or similar 0 6522 air according to current volume flow Unit 15 45 15 C 100 3 100 3 100 3 kPa abs 1 5e 05 1 8e 05 1 5e 05 m2 s 2700 1800 1800 m3 h 1 225 1 1 1 225 kg m3 0 6522 0 6522 0 6522 250 0 250 1 250 0 mm 0 9996 0 9999 0 9998 15 28 10 18 10 19 m s 256393 144213 170929 SKL Schiegel amp Kremer industieautomation GmbH Phone 49 0 2166 62317 0 FAX 40 0 2166 611687 Hanns Matin Schieyer Stra e 22 D 41199 Moenchengiadbach mai infog ski gmbn com WAW nttpi www ski gmbn com Figure 2 Pressure Differenti
26. pipe is within the transporting pipe Loosen the gland somewhat if necessary Only loosen carefully and as far as necessary medium may be discharged 2 Close the ball valve completely and secure against accidental opening if necessary 3 FASTLOK S Loosen the gland completely Caution medium may be discharged and unhook the safety chain Remove the sensor manually from the transporting pipe without wedging the sensor FASTLOK N Remove the lock nut at the lower end of the spindle fixed with grub nut Loosen the gland completely and crank out the sensor until the spindle is no longer engaged Remove the sensor manually from the transporting pipe without wedging the sensor Important for disassembly First close the ball valve completely then loosen the gland for FASTLOK S N and remove the sensor BA SDF en L 1503 16 SDF Flow Sensor 5 Connect Pressure Differential Transmitter to Sensor 5 1 Sensor with Mounting Plate for Direct Transmitter Connection to the Sensor The easiest and most cost effective form of connecting sensor und transmitter is offered by sensors with mounting plate for the direct installation of the transmitter For this a sandwich is made of sensor 3 or 5 way valve block and transmitter which are held by 8 screws 4 per side Condition is that the permissible temperatures at the transducer membrane are not exceeded The side of the transmitter must be connected with the upstream s
27. r horizontal pipes and with OK upper chamber and UK lower chamber for vertical pipes The design of the sensors ensures that the connections are always on the same level meaning that the flow indicating arrow on sensors for vertical pipelines is offset by 90 with regard to the connections The sensors must be installed with the engraved letters normally readable in upright position The following table shows the allocation of sensor chamber and transmitter connection depending on pipe run and flow direction The pipework is to be carried out accordingly BA SDF en L 1503 7 SDF Flow Sensor Flow direction side of side of transducer transducer from top to bottom from bottom to top M Table 4 Chamber Allocation Inflow Side For Flow Direction from left to right gt f Alignment tolerances for SDF sensors considering points 4 2 and 4 3 Figure 3 Alignment Tolerances For SDF Sensors A axial orientation B radial orientation C orientation to flow direction in horizontal pipe run D orientation to flow direction in vertical pipe run Observe for steam sensors points C and D in chapter 4 6 1 BA SDF en L 1503 SDF Flow Sensor 4 5 Mounting Installation Components Main Bearing 4 5 1 SDF M Cutting Ring Installation Component The pipe wall must be drilled to Dy see Table 5 at the installation location Before inserting the weld in connection screw on the screw down nut but remove the
28. rsonnel AN are persons familiar with the installation assembly commissioning and operation of the product and who have the appropriate qualifications for their activities such as gt Training instruction or authorization to operate and maintain devices systems according to the standards of safety technology for pressure components gt Training or instruction in maintaining and operating appropriate protective equipment according to safety standards gt First Aid training Caution Before installation and operation the pipework and process data must be checked against the specifications on type label and delivery note Only the specifications on the type label of the equipment apply Deployment In Explosive Environs Applicable national standards and regulations are to be complied with if the equipment is deployed in potentially explosive atmospheres BA SDF en L 1503 3 SDF Flow Sensor 2 Incoming Goods Inspection Any shipment leaving S K I GmbH is inspected to the best of our knowledge and with great care Nevertheless it is necessary for the customer to crosscheck as soon as possible after receipt of the delivery Only then legitimate claims can be settled quickly and without further dispute Check upon receipt of goods consistency of type label see below type code see page 5 and delivery note consistency of delivered and ordered version especially correct sensor length sensor material and comp
29. w Sensor 5 2 Sensor with Connection Nipples to Connect the Transmitter via Differential Pressure Pipes The connection between sensor and remote installed transmitter is made via differential pressure pipes For this usually pipes are used which are screwed to the sensor or valve block and transmitter Generally screw joints with cutting ring or tensioning ring matching the selected pipe connections are used e g 612mm or 14mm The screw joints can be ordered from S K I GmbH For higher pressure generally welding is recommended For this we offer primary shut offs with welding joints The complete parts list for the start up of the sensor must include Sensor including the installation components for pipe installation 2 ball valves shut off valves for initial shut off of the differential pressure pipes of the flow sensor can be omitted for depressurised pipes 2 fittings each to align the primary shut off connections of the 3 or 5 way valve blocks with the differential pressure pipe 1 3 or 5 way valve block for direct installation on the transducer with matching process connection including all seals and screws and necessary oval adapters 1 of differential pressure transmitter with pipe or wall bracket Sufficient piping in Please contact our responsible sale engineer or representative in case you wish start up of the sensors by S K I GmbH Standard flow sensor for horizontal and vertical pipe run e g
30. work and shut off valve array between sensor and pressure differential transmitter in the measurement set up In real life valve combinations 6 7 8 are combined in multi valve blocks For cost efficiency often the blow off valves are omitted In this case valve combination 6a 6b 7 is achieved with a 3 way valve block If in addition blow off valves 8a 8b are desired then a 5 way valve block is deployed To protect the transmitter from thermal overload ensure that hot steam does not get straight into the measuring cell This is achieved with so called condensate guards water columns from condensated steam The transmitter is generally installed in sufficient distance below the sensor 6 2 Steam Measurement Start Up Ensure before measurement start up that all connections are leak proof and the impulse pipes and condensate containers are filled Fill via the blow off valves if a 5 way valve block is used The valves upstream of the transmitter must initially be closed Filling is only permitted if the water pressure is higher than the steam pressure otherwise steam can escape For this reason generally only fill if the steam piping is depressurized Filling is only possible if primary shut offs if present are open For steam sensors with separately installed pressure differential transducer alternatively the accruing condensate can be used for filling However this method is time consuming After installation close all valves initially Conde
31. xactly the same level Place a spirit level on condensate pots or compact head for alignment See further information and details in chapter 6 4 6 2 FASTLOK Sensor Installation BA SDF en L 1503 12 SDF Flow Sensor The complete FASTLOK sensor assembly including transporting pipe and safety guard and or drive spindle is pre assembled For initial installation in the pipework first the installation support including shut off ball valve must be disassembled from the shut off pipe see further information about FASTLOK sensors in chapter 4 8 During the initial installation of a FASTLOK sensor the pipe must be depressurised and emptied before installing the welding support The sensor can be removed later under process conditions The pipe wall must be drilled or welded at the installation location SDF L S N HD 10 18mm SDF L S N HD 22 31mm SDF L S N HD 32 38mm SDF L S N HD 50 57mm The weld in support for the ball valve must be tack welded in such way that the drill hole in the pipe is entirely kept as passage Now align the installation component with the inner bore perpendicular to the pipe axis and weld it to the pipe Connector head with hose nipple Cutting ring connection 4 Shut off ball valve Weld on nozzle Figure 10 FASTLOK L Sensor Design IMPORTANT NOTICE For FASTLOK sensors with gate valve support the sensor due to the high weight in a suitable manner Due to the specific installation process
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