Daniel Ultrasonic Flow Meters-T-2 to T-11 Transducer Upgrade Operating instructions

Brand: Daniel

Model: Ultrasonic Flow Meters-T-2 to T-11 Transducer Upgrade

Type: Operating instructions

DANIEL ULTRASONIC

METER T-2 TO T-11

TRANSDUCER UPGRADE

INSTRUCTIONS

__________________________________________

DANIEL MEASUREMENT AND CONTROL, INC.

AN EMERSON PROCESS MANAGEMENT COMPANY

HOUSTON, TEXAS

Part Number 3-9000-751

Revision A

DECEMBER 2005

IMPORTANT INSTRUCTIONS

Because these measurement instruments are sophisticated technical products, you must install, use

and maintain them in accordance with Daniel’s guidelines to ensure that they operate within the

range specified on the equipment nameplate. The following instructions must be adhered to and

integrated into your safety program when installing, using and maintaining Daniel Products.

• Read all instructions prior to installing, operating and servicing the product. If this

instruction manual is not the correct manual, call 1-713-467-6000 (24-hour response number

for both Service and Sales Support) and the requested manual will be provided. Save this

instruction manual for future reference.

• If you do not understand any of the instructions, contact your Daniel representative for

clarification.

• Follow all warnings, cautions and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation and maintenance of

the product.

• Install your equipment as specified in the installation instructions of the appropriate

instruction manual and per applicable local and national codes. Connect all products to the

proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program

and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts

specified by the manufacturer. Unauthorized parts and procedures can affect the product's

performance and place the safe operation of your process at risk. Look-alike substitutions

may result in fire, electrical hazards or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when

maintenance is being performed by qualified persons, to prevent personal injury.

• ALWAYS READ AND FOLLOW THE DANIEL ULTRASONIC METER T-2 TO T-

11 TRANSDUCER UPGRADE INSTRUCTIONS AND ALL PRODUCT WARNINGS

AND INSTRUCTIONS.

• Use of this equipment for any purpose other than its intended purpose may result in property

damage and/or serious personal injury or death.

• Before opening the flameproof enclosure in a flammable atmosphere, the electrical circuits

must be interrupted.

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DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS DEC 2005

PREFACE i

DANIEL MEASUREMENT AND CONTROL, INC.

DANIEL ULTRASONIC METER T-2 TO T-11

TRANSDUCER UPGRADE INSTRUCTIONS

NOTICE

DANIEL MEASUREMENT AND CONTROL, INC. ("DANIEL") SHALL NOT BE LIABLE FOR TECHNICAL OR

EDITORIAL ERRORS IN THIS MANUAL OR OMISSIONS FROM THIS MANUAL. DANIEL MAKES NO

WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS

MANUAL AND, IN NO EVENT, SHALL DANIEL BE LIABLE FOR ANY SPECIAL OR CONSEQUENTIAL

DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, ETC.

PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION ONLY

AND MAY BE TRADEMARKS/REGISTERED TRADEMARKS OF THESE COMPANIES.

THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES ONLY, AND

WHILE EVERY EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY, THEY ARE NOT TO BE

CONSTRUED AS WARRANTIES OR GUARANTEES, EXPRESSED OR IMPLIED, REGARDING THE

PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY. WE RESERVE THE

RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR SPECIFICATIONS OF SUCH PRODUCTS AT ANY TIME.

DANIEL DOES NOT ASSUME RESPONSIBILITY FOR THE SELECTION, USE OR MAINTENANCE OF ANY

PRODUCT. RESPONSIBILITY FOR PROPER SELECTION, USE AND MAINTENANCE OF ANY DANIEL

PRODUCT REMAINS SOLELY WITH THE PURCHASER AND END-USER.

DANIEL AND THE DANIEL LOGO ARE REGISTERED TRADEMARKS OF DANIEL INDUSTRIES, INC. THE

EMERSON LOGO IS A TRADEMARK AND SERVICE MARK OF EMERSON ELECTRIC CO.

THE DANIEL ULTRASONIC GAS FLOWMETER INCLUDING THE MARK III ELECTRONICS IS COVERED

BY UNITED STATES PATENTS 5,983,730 AND 4,646,575 AND PATENTS PENDING.

BY DANIEL MEASUREMENT AND CONTROL, INC.

HOUSTON, TEXAS, U.S.A.

copied in any form or by any means - graphic, electronic or

mechanical - without first receiving the written permission of

Daniel Measurement and Control, Inc., Houston, Texas, U.S.A.

DEC 2005 DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS

PREFACEii

WARRANTY

1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein and except as otherwise expressly

provided herein, Daniel Measurement and Control, Inc. ("Daniel") warrants that the firmware will execute the

programming instructions provided by Daniel, and that the Goods manufactured or Services provided by Daniel will be

free from defects in materials or workmanship under normal use and care until the expiration of the applicable warranty

period. Goods are warranted for twelve (12) months from the date of initial installation or eighteen (18) months from

the date of shipment by Daniel, whichever period expires first. Consumables and Services are warranted for a period

of 90 days from the date of shipment or completion of the Services. Products purchased by Daniel from a third party for

resale to Buyer ("Resale Products") shall carry only the warranty extended by the original manufacturer. Buyer agrees

that Daniel has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement

and shipping of the Resale Products. If Buyer discovers any warranty defects and notifies Daniel thereof in writing during

the applicable warranty period, Daniel shall, at its option, promptly correct any errors that are found by Daniel in the

firmware or Services, or repair or replace F.O.B. point of manufacture that portion of the Goods or firmware found by

Daniel to be defective, or refund the purchase price of the defective portion of the Goods/Services. All replacements or

repairs necessitated by inadequate maintenance, normal wear and usage, unsuitable power sources, unsuitable

environmental conditions, accident, misuse, improper installation, modification, repair, storage or handling, or any other

cause not the fault of Daniel are not covered by this limited warranty, and shall be at Buyer's expense. Daniel shall not

be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing

in advance by an authorized Daniel representative. All costs of dismantling, reinstallation and freight and the time and

expenses of Daniel's personnel for site travel and diagnosis under this warranty clause shall be borne by Buyer unless

accepted in writing by Daniel. Goods repaired and parts replaced during the warranty period shall be in warranty for the

remainder of the original warranty period or ninety (90) days, whichever is longer. This limited warranty is the only

warranty made by Daniel and can be amended only in a writing signed by an authorized representative of Daniel. Except

as otherwise expressly provided in the Agreement, THERE ARE NO REPRESENTATIONS OR WARRANTIES OF

ANY KIND, EXPRESSED OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE,

OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. It is understood that

corrosion or erosion of materials is not covered by our guarantee.

2. LIMITATION OF REMEDY AND LIABILITY: DANIEL SHALL NOT BE LIABLE FOR DAMAGES

CAUSED BY DELAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF

WARRANTY HEREUNDER SHALL BE LIMITED TO REPAIR, CORRECTION, REPLACEMENT OR REFUND

OF PURCHASE PRICE UNDER THE LIMITED WARRANTY CLAUSE IN SECTION 1 HEREIN. IN NO EVENT,

REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN CONTRACT,

INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT OR OTHERWISE), SHALL DANIEL'S

LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXCEED THE PRICE TO BUYER OF THE SPECIFIC

GOODS MANUFACTURED OR SERVICES PROVIDED BY DANIEL GIVING RISE TO THE CLAIM OR CAUSE

OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL DANIEL'S LIABILITY TO BUYER AND/OR ITS

CUSTOMERS EXTEND TO INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE

TERM "CONSEQUENTIAL DAMAGES" SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF

ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE AND COST OF CAPITAL.

DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS DEC 2005

TABLE OF CONTENTS iii

TABLE OF CONTENTS

1.0 INTRODUCTION .................................................... 1-1

1.1 General........................................................ 1-1

2.0 BEFORE YOU BEGIN! ............................................... 2-1

2.1 Tools and Materials Required ...................................... 2-1

3.0 KEY POINTS........................................................ 3-1

4.0 TRANSDUCER UPGRADE PROCEDURE............................... 4-1

APPENDICES

APPENDIX A REMOVAL AND RE-INSTALLATION OF WRITE-

PROTECTION JUMPER ON MARK II ELECTRONICS . . . . . A-1

DEC 2005 DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS

TABLE OF CONTENTSiv

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DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS DEC 2005

INTRODUCTION 1-1

1.0 INTRODUCTION

1.1 General

Welcome to the Daniel Ultrasonic Meter T-2 to T-11 Transducer Upgrade Instructions Manual.

This manual has been designed to provide you with a step-by-step set of instructions for upgrading

Daniel JuniorSonic™ and SeniorSonic™ meters from T-2 to T-11 transducers.

Please read the ‘Before You Begin’ section to make sure you have all the components

necessary to perform the upgrade before taking the JuniorSonic™ and SeniorSonic™ meters

out of service.

DEC 2005 DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS

INTRODUCTION1-2

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DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS DEC 2005

BEFORE YOU BEGIN 2-1

2.0 BEFORE YOU BEGIN

This section lists all of the parts and tools required to perform the upgrade. Ensure that all of these

items are available before taking the JuniorSonic™ and SeniorSonic™ meters out of service.

SERIOUS PERSONAL INJURY OR DEATH POSSIBLE

If the meter cannot be depressurized, use the ultrasonic extraction tool to remove and re-

install the transducer assemblies.

Failure to follow the Ultrasonic Extractor Tool Operation Manual (3-9000-729) procedures

may result in serious personal injury or death and may cause equipment damage.

If the meter cannot be depressurized, then the Daniel Ultrasonic Extractor Tool will be

required to remove the transducer assembly while the meter and associated piping remains

under pressure. If you do NOT have this tool, it can be purchased or rented from Daniel

Measurement Services.

2.1 Required Tools and Materials

1. 1¼" wrench or ratchet wrench c/w 1¼" socket

2. 1/4" flat-blade screw driver

3. 1/16" Allen wrench (2 or more recommended)

4. Heat gun (type used for heat shrink tubing)

5. Dow Corning® III silicone grease or equivalent

6. Nickel anti-seize compound (P/N 3-9960-134)

7. Sharpie® (or equivalent) permanent ink marker pen

8. Laptop computer complete with Daniel CUI 3.10 or later installed

9. Zero Flow Calibration Data Sheet (transducer assembly dimensions)

DEC 2005 DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS

BEFORE YOU BEGIN2-2

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DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS DEC 2005

KEY POINTS 3-1

3.0 KEY POINTS

EQUIPMENT DAMAGE

DO NOT proceed with the transducer upgrade if the original component lengths are not

available. Obtain the Zero Flow Calibration Data Sheet from Daniel. The original

component lengths of all equipment being replaced must be known in order to calculate

the new path length for each chord.

Exchanging any component in the transducer assembly may alter the length of the chord.

Document each component exchanged to ensure that the changes are correctly entered into the

meter configuration. Failure to do so, or entry of erroneous data, may impact meter accuracy.

• It is recommended that Daniel CUI 3.10 or later be used for this procedure. Although older

versions will work, the latest version is always recommended.

All the screen images in this document are from Daniel CUI 3.10. Daniel CUI updates are

available at the following website: http://www.emersonprocess.com/daniel/.

• Transducers are always replaced in pairs, and it is recommended they be installed one pair

at a time to avoid accidental interchange of components, leading to erroneous dimensions.

When replacing the transducers, it is important to note their position (upstream or

downstream) and replace them in the correct location to ensure proper low-velocity

performance. Each transducer pair is marked with either a number 1 or 2 that relates to the

meter location (i.e. A1, A2, B1, B2, etc). The number “1” transducers must be installed in

a location such as A1, B1, C1 or D1 and the “2” transducer must be installed in the

corresponding A2, B2, C2 or D2.

• The transducer kit, P/N 2-9-3400-847, includes four pairs of transducers and is designed for

the SeniorSonic™ meter. If a JuniorSonic™ meter is being upgraded, this kit can be used,

and the remaining transducers can be kept as spares. If the spares are not needed, contact

Daniel Measurement Services for a list of components and part numbers.

DEC 2005 DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS

KEY POINTS3-2

• Older transducer assemblies (transducer, stalk, and holder) did not have the lengths etched

on the individual component. New ones do. These lengths are required for the Daniel CUI

3.10 software to calculate the new chord length.

To ensure that the required information is available, it is highly recommended that the original

Zero Flow Calibration Data Sheet be obtained from Daniel prior to replacing the transducer

pair.

The data sheet, shown in Figure 4-13, provides all of the serial numbers (S/N) and length data

pertaining to the meter’s original transducer assembly components. This data sheet can be obtained

by contacting Daniel Measurement Services at 713-827-6314.

• Prior to replacing the transducers, it is imperative that each of the transducer pairs be

installed in the correct location (i.e. A1, A2, etc) since changing the transducers, or any

components of the assembly, will impact the chord length. Mark the location on the

Transducer Pair Data Sheet (see Figure 4-13, the data sheet included in the upgrade kit for

new transducers), and also mark the location on the side of the transducer with the marker

pen (see Figure 4-5 for these components). This will prevent any confusion when the

transducers are installed and the meter’s configuration parameters are updated. The values

on the Transducer Pair Data Sheet relate to a unique pair of transducers. Do not mix

transducers from different pairs.

• It is recommended that only one pair (i.e. A1 & A2 or B1 & B2 etc.) of transducer assemblies

be removed at a time to avoid installing the transducer assemblies in the wrong position.

When this isn’t practical, before removing the transducer assemblies from the mount, ensure

that the transducer location (i.e. A1, A2, etc) is marked on one of the flats of the 1¼" holder

head (see Figure 4-4). Ensure the marking will not be accidentally erased during removal

of the old transducer.

• When the transducers are replaced, the applicable chord parameters must be updated. Use

the Transducer Swap-out Wizard in Daniel CUI (see Figures 4-6 through 4-9 for screen shots

of this wizard). This procedure requires writing changes to the meter. If the write-protection

jumper (JP2 on the DFI Board) is installed, it will need to be removed.

DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS DEC 2005

TRANSDUCER UPGRADE PROCEDURE 4-1

4.0 TRANSDUCER UPGRADE PROCEDURE

1. Prior to starting the transducer replacements, a minimum of a two-minute maintenance log

file should be collected.

2. Use the Edit/Compare Configuration Wizard to read the configuration from the meter.

3. Name the configuration file clearly to indicate it is before the transducer upgrade (by editing

the Daniel CUI automated file name shown in the Edit/Compare Configuration Wizard

screen (e.g. "Meter Name, Meter config, T-2 Transducers, 3-3-2005 4-48-58 PM.cfg").

4. When the upgrade procedure is complete and all of transducers are replaced and the data

updated, save the configuration file named "Meter Name, Meter config, T-11 Transducers,

3-3-2005 5-10-07 PM.cfg".

The chart in Figure 4-1 shows a typical SOS (Speed of Sound) comparison chart for a meter at zero

flow. It can be seen on the Charts sheet in the maintenance log file.

Figure 4-1. Typical SOS Comparison Chart

DEC 2005 DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS

TRANSDUCER UPGRADE PROCEDURE4-2

SERIOUS PERSONAL INJURY OR DEATH POSSIBLE

If the meter cannot be depressurized, use the Ultrasonic Extraction tool to remove and

re-install the transducer assemblies.

Failure to follow the extractor tool manual procedures may result in serious personal injury or

death and may cause equipment damage.

If the meter cannot be depressurized, refer to the Daniel Ultrasonic Extractor Tool Operation

Manual (P/N 3-9000-729). The most recent copy of this manual may be downloaded from the Daniel

website (http://www.emersonprocess.com/daniel/). Follow the steps in Section 4 of the Ultrasonic

Extractor Tool Operation Manual for removing the transducers under pressure, instead of steps 5

through 8 below.

5. Depressurize the meter and isolate the meter run piping, and vent the gas to atmosphere.

Verify that the pressure is 0 psig before proceeding.

6. Prior to removing the holder cover, put an alignment mark on the edges of both the holder

cover and the mount cover using the marker pen. This will help facilitate rotational

alignment during the re-assembly. Remove the holder cover (see Figure 4-2) by completely

loosening the two captive screws. Gently pull back the cover and cable, unplug the cable and

expose the mount cover assembly.

Figure 4-2. Side and End View of M-Mount Transducer Assembly

DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS DEC 2005

TRANSDUCER UPGRADE PROCEDURE 4-3

7. After labeling the mount cover location (A1, A2, etc.), loosen the two screws in the mount

cover as shown in Figure 4-3, below. Note that these two screws may or may not be captive.

If they are not captive, remove them carefully. With the two screws fully unscrewed, pull the

mount cover off of the hex head of the holder exposing the mount and holder assembly.

Figure 4-3. Mount Cover

8. Loosen the T-Slot transducer assembly holder with the 1¼" wrench or socket (see Figure 4-

4). Once it has been loosened, it should be possible to unscrew it by hand.

Unless the meter/piping has a vent open to the atmosphere, pressure may build up in the

meter/piping due to minor valve leakage.

Ensure there is no pressure buildup before completely unscrewing the holder. Carefully pull

out the transducer assembly (Figure 4-5).

If the hex head of the holder does not clearly indicate the location of the transducer assembly

(A1, A2, etc. as shown in Figure 4-4), mark it now with a Sharpie® marker pen (or equivalent)

to ensure the assembly is re-installed in the correct location.

DEC 2005 DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS

TRANSDUCER UPGRADE PROCEDURE4-4

Figure 4-4. Mount and T-Slot Transducer Assembly

9. Loosen the three 6-32 set screws that hold the transducer in place. The screws do not need

to be completely removed. On some of the older assemblies, Loc-Tite™ is used on the set

screws. If the set screw is very tight and does not appear to come out without damage to the

wrench or the set screw, try heating the area around the set screw with a heat gun. Often this

will help in releasing the bond and allows the screw to be removed without damage. Use

caution when heating the stalk area around the set screw. Overheating may cause damage

to the stalk.

If the inside of the set screw is stripped due to Allen wrench slippage and the screws cannot be

extracted, it may be necessary to loosen the set screws by holding the stalk in place. If this is

the case, a new stalk must be obtained and installed. The length of the replacement stalk will

be required to update the meter configuration.

DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS DEC 2005

TRANSDUCER UPGRADE PROCEDURE 4-5

Figure 4-5. Transducer Assembly

10. After all three set screws have been loosened, as shown in Figure 4-5, remove the transducer

from the holder assembly.

11. Replace the O-rings and back-up rings on the transducer holder. It is recommended that they

be replaced while the transducer is removed from the holder/stalk to prevent damage to the

transducer.

12. Install the new transducer designated for that location. The parts are keyed so that they only

fit together one way. Tighten the three set screws equally to lock the new transducer into

place. DO NOT OVER TIGHTEN. Confirm the serial number of the transducer, and

installation location (i.e. A1, A2, etc.) previously marked on the Transducer Pair Data Sheet.

See annotated data sheet in Figure 4-13.

13. Clean the transducer ports, mounts, and T-Slot transducer before re-installing the new

transducer pair.

DEC 2005 DANIEL T-2 TO T-11 TRANSDUCER UPGRADE INSTRUCTIONS

TRANSDUCER UPGRADE PROCEDURE4-6

14. Lubricate the O-rings/back-up rings with a small amount of Dow Corning III silicon grease

(or equivalent).

15. Apply a small amount of Nickel anti-seize compound (P/N 3-9960-134 or equivalent) to the

threads on the transducer holder.

SERIOUS PERSONAL INJURY OR DEATH POSSIBLE

If the extractor tool was used to remove the transducer assemblies while under pressure,

use the tool to re-install the transducers. Follow the procedures in Section 5 of the

Ultrasonic Extractor Tool manual, instead of step 16 in this procedure. Once the

transducer has been installed, continue with step 17.

Failure to follow the extractor tool manual procedures may result in serious personal injury or

death and may cause equipment damage.

16. Carefully insert the assembly into the assigned transducer port. With the 1¼" wrench or

socket, tighten the holder in the mount, until it is snug and securely seated (specification

torque = 35 lb-ft). DO NOT OVER TIGHTEN.

17. Repeat the entire procedure for each of the remaining transducer pairs being replaced.

18. With the system sealed, apply minimal pressure to the meter. Using soapy water, or other

leak check method, check for leakage around the transducer mounts and holder. Fix any leak

before proceeding. If no leaks are detected, fully pressurize the meter to line conditions (or

at least 200 psi).

19. Replace the mount covers in their original locations. Position them so the cover slips over

the 1 ¼” hex head screw of the transducer holder and the screw slots on the side allow access

to the screw-hole in the transducer mount underneath. Observe the alignment marks applied

in step 6. The metal locking plate on the surface of the cover can be rotated approximately

¼" to engage the plate on the 1¼" hex head of the holder. While holding the body of the

cover, rotate the locking plate by pushing on the tabs with the thumb and finger while

pushing down (see Figure 4-3). Once the locking plate is engaged and the cover is fully

seated on the mount, install the two screws that attach the cover to the mount.

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Daniel Ultrasonic Flow Meters-T-2 to T-11 Transducer Upgrade Operating instructions

Daniel Ultrasonic Flow Meters-T-2 to T-11 Transducer Upgrade Operating instructions

Daniel Ultrasonic Flow Meters-T-2 to T-11 Transducer Upgrade Operating instructions

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