RMG USZ 08 series Operating Instructions Manual

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Serving the Gas

Industry Worldwide

Ultrasonic Flowmeter USZ 08

OPERATING INSTRUCTIONS

STATUS JUNE 2015

CONTENTS

...............................................................................................................................................................................................................

Manual USZ 08 · EN05 · 2015-06

INTRODUCTION ................................................................................... 1

Geometric arrangement of the paths of the USZ 08-6P ...................................... 3

Geometric arrangement of the paths of the USZ 08-3P ...................................... 4

Survey of equations used ................................................................................... 10

Equations for the ERZ 2000 USC / USE 09-C ............................................................. 10

Path velocity ............................................................................................................................................ 10

Corrected path velocity ............................................................................................................................ 10

Weighted flow velocity ............................................................................................................................. 10

Corrected weighted flow velocity ............................................................................................................. 10

Flow rate at measurement conditions ..................................................................................................... 10

Corrected flow rate at measurement conditions ..................................................................................... 10

Base correction of the gas meter ....................................................................... 11

Polynomial ............................................................................................................................................... 11

Error curve linearization of the gas meter ......................................................... 11

Polynomial ............................................................................................................................................... 11

INSTALLATION AND COMMISSIONING ............................................ 12

Installation of the meter ..................................................................................... 12

Unidirectional operation .............................................................................................. 12

Bidirectional operation ................................................................................................ 12

Pipe diameter .............................................................................................................. 13

Combination with the WBZ 08 vortex meter ................................................................ 13

Outdoor installation ..................................................................................................... 13

Seals ........................................................................................................................... 14

Screws ........................................................................................................................ 15

Electrical connections ........................................................................................ 16

Terminal assignments of the measuring element ........................................................ 16

ERZ 2000(-NG) terminals ............................................................................................. 17

Earthing and screening ................................................................................................ 19

Start-up................................................................................................................ 20

OPERATING THE ULTRASONIC COMPUTER ..................................... 21

General information about the ERZ 2000 USC .................................................. 21

Overview of functions .................................................................................................. 21

Gas meter / volume data logging ................................................................................ 22

Special information: "Parameters for the volume at measurement conditions in

conjunction with ultrasonic flowmeters" ..................................................................... 24

DZU: ERZ 2000 with USE 09-C ultrasonic flowmeter control unit ........................................................... 24

Error curve linearization of volume metering when using the USE 09-C .................................................. 25

IGM: ERZ 2000 with integrated ultrasonic controller ............................................................................... 25

Acknowledging alarm and warning messages and events ....................................................................... 35

CONTENTS

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Manual USZ 08 · EN05 · 2015-06

RMGVIEW DIAGNOSTIC SOFTWARE ................................................ 37

Functions ............................................................................................................. 37

Installation .......................................................................................................... 37

System requirements .................................................................................................. 37

Installing the program ................................................................................................. 37

Connecting a PC .................................................................................................. 38

Calibration switch of the USE 09 ....................................................................... 38

Operating the program ....................................................................................... 38

USE 09 MEASURED VALUES AND PARAMETERS ............................ 39

Access ................................................................................................................. 39

List of measured values and parameters ........................................................... 39

Pressure (option) ......................................................................................................... 40

Temperature (option) ................................................................................................... 40

USE09-C measured values .......................................................................................... 40

USE09-C flow rate Qm ................................................................................................ 41

USE09 parameters ...................................................................................................... 41

USE09-C polynomials .................................................................................................. 42

Frequency, pulse outputs ............................................................................................ 42

Current output ............................................................................................................. 42

Serial ports .................................................................................................................. 43

DSP, FPGA values ........................................................................................................ 44

Path# measured values ............................................................................................... 44

Path# signal analysis ................................................................................................... 44

USE09 measured values .............................................................................................. 45

USE09 diagnosis ......................................................................................................... 45

Time and date .............................................................................................................. 46

USE09-C totalizers ...................................................................................................... 46

ID ................................................................................................................................ 46

Mode ........................................................................................................................... 48

Faults .......................................................................................................................... 49

DSP parameters .......................................................................................................... 49

Path# parameters ....................................................................................................... 50

Service ........................................................................................................................ 51

Data logger .................................................................................................................. 52

Site information ........................................................................................................... 52

CONTENTS

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Manual USZ 08 · EN05 · 2015-06

ALARM- UND WARNING MESSAGES USE 09 ................................... 53

Alarm messages .................................................................................................. 53

Warning messages .............................................................................................. 54

Hints .................................................................................................................... 55

BRIEF DESCRIPTION OF THE USE09 MODBUS ................................ 56

Parameterizing Modbus ...................................................................................... 56

TECHNICAL SPECIFICATIONS ........................................................... 59

SEAL DIAGRAMS ............................................................................... 60

Seals of the USE 09 ultrasonic electronic system ............................................. 60

Seals of the USE 09-C-LT ultrasonic electronic system .................................... 61

Seals of the measuring element of type USZ 08-6P (with USE 09) ....................... 62

Seals of the measuring element of type USZ 08-6P (with USE 09-C) ..................... 63

Seals of the type plate of the USZ 08 measuring element ................................ 64

ANNEX ............................................................................................... 65

Type examination certificates ............................................................................ 65

CONTENTS

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Manual USZ 08 · EN05 · 2015-06

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

1

Introduction

By means of the transit times of ultrasonic pulses, the USZ 08 ultrasonic flowmeter measures the

flow velocity of the gas from which it calculates the flow rate at measurement conditions. Here use

is made of the fact that ultrasonic pulses move faster in the direction of flow than in the opposite

direction.



v

D

L

S1

S2

The transit times from S1 to S2 and from S2 to S1 are calculated as follows:



cosvc

L

t

0

12S 

cosvc

L

t

0

21S

where: v: mean flow velocity

c

0: velocity of sound

: path angle to the pipe

L: path length

If measurements are taken alternatively in both directions, the velocity of sound depending on the

type of gas is no longer included in the calculation of the flow velocity:

















21S12S t

1

t

1

cos2

L

v

In order to take the flow profile into account, the USZ 08-6P takes measurements with a total of six

acoustic paths in three planes. In the case of the 3-path design of type USZ 08-3P, the two paths of

each plane crossing each other are replaced by one V-path with single reflection.

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

2

For non-fiscal metering also the 2-path design of typ USZ 08-2P can be used. This version is

equivalent to a reduced 6-path design, which only has the two acoustic paths in the middle plain.

Signals are evaluated by the USE 09(-C) ultrasonic electronic system which is installed on the meter

case. As a result, the flow velocity is determined for each acoustic path from the transit times

measured.

There are the following two variants of the ultrasonic electronic system available:

1. USE 09

- Meter without display in the meter head

- PTB-approved

- Basic version for digital connection to the ERZ 2000 USC

Every ultrasonic flowmeter relies on an ERZ 2000 USC to calculate the flow velocity averaged

through the pipe diameter from the data of the individual paths. The readings of the volumes at

measurement conditions for forward and reverse flows can also be taken at the computer.

2. USE 09-C

- Meter with electronic totalizers

- MID-approved

- Full version of the USE 09 with integrated controller function

With this configuration, it is possible to evaluate even flow rate and totalizer readings without

an ERZ 2000 USC; other types of correctors can be connected via pulse outputs.

Using a PC, you can access the USE 09(-C) data via a service interface. To do this, you can use the

RMGView diagnostic software.

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

3

Geometric arrangement of the paths of the USZ 08-6P

A

90°

A

Paths 1&2

Paths 5&6

Paths 3&4

Level 2

Level 1

Level 2

Level 3

TD2.1 (TD1.1)

TD6.1 (TD5.1)

TD4.1 (TD3.1)

TD1.2 (TD2.2)

TD5.2 (TD6.2)

TD3.2 (TD4.2)

TD1.1

TD3.1

TD5.1

TD2.2

TD4.2

TD6.2

TD2.1

TD4.1

TD6.1

TD1.2

TD3.2

TD5.2

In each of the three planes, there are two paths crossing each other. The ultrasonic flowmeter has

been designed symmetrically with regard to the middle plane and axially with regard to the centre

of the meter.

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

4

Geometric arrangement of the paths of the USZ 08-3P

A

90°

A

Path 1

Reflector

Reflection on the inner wall of the pipe

Reflector

Path 3

Path 2

Level 2

Level 1

Level 2

Level 3

TD1.1

TD3.1

TD2.1

TD1.2

TD3.2

TD2.2

TD2.1 TD2.2

TD1.1

TD3.1

TD1.2

TD3.2

In each of the three planes, there is a reflection path (what is called a V-path). The ultrasonic

flowmeter has been designed symmetrically with regard to the middle plane and axially with regard

to the centre of the meter.

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

5

1. Measuring element type USZ 08-6P/3P

2. Signal processing unit type USE 09

3. EEx e connection box (optional)

4. Ultrasonic flowmeter computer

type ERZ 2000 USC

4

Pressure

(RS 485)

4 Current outputs (0/4 - 20 mA)

110VAC/230VAC/24VDC

8 Contact outputs

ERZ 2000 USC

externe

Umwertung

Temperature

COM1 Interface

max. distance 500m

24 VDC

Pr

T

1

23

Basic version with an ERZ 2000 USC

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

6

TD 5.1

TD 5.2

TD 6.2

TD 6.1

Path 5

Path 6

TD 3.1

TD 3.2

TD 4.2

TD 4.1

Path 3

Path 4

TD 1.1

Pos. direction of flow

TD 1.2

TD 2.2

TD 2.1

Path 1

Path 2

Power supply

24 VDC

Rs485 to the ERZ 2000 USC

USE09

spare

Pos. direction of flow

Drw.-No.057286.4

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

7

Inner wall of pipe

Pos. direction of flow

Path 3

TD 1.2

Reflector

TD 2.1 TD 2.2

TD 3.1 TD 3.2

Reflector

TD 1.1

Path 1

Path 2

Pos. direction of flow

Power supply

24 VDC

Rs485 to the ERZ 2000 USC

USE09

spare

Drw.-No.057288.4

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

8

Side view:Front view:

Top view:

S0 / S1S0 / S1

* Meter body from

cast steel

Clearance for changing transducers

S0: meter without pressure

S1: meter pressurized,

with special tool

L

H

Di

B

DN L Di H B S0 S1 Weight (kg)

100 (4”) 300 102 330 400 250 ------ 90*

150 (6”) 450 150 350 410 300 ------ 140*

200 (8”) 600 202 360 530 375 1520 260*

250 (10”) 750 255 390 590 400 1550 400*

300 (12”) 900 303 420 640 425 1575 530*

400 (16”) 1200 378 450 710 475 1620 885*

500 (20”) 1500 476 530 820 525 1670 1465*

600 (24”) 1200 560 510 940 600 1725 1500*

700 (28”) 1200 736 650 980 615 1750 1730*

800 (32”) 1500 787 800 1100 675 1800 2100*

900 (36”) 1500 889 950 1250 750 1875 2530*

1000 (40”) 1500 990 1100 1350 800 1930 2950*

Drw. No. 061413.4 Status: 02.10.2009

The values shown in the table are guide values (dimensions in mm).

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

9

Drw. No.057287.4

The values shown in the table are guide values in mm.

A1/ A2

A3

Top view:

aa

Di

H

L

Front view:

a

90°

Di

r

A2

A1

A3

Side view:

Connection diagram

of the three paths acc. to

Drw. No. 057288.4

DN L Di H A1 A2 A3 a

100 ( 4”) 500 102 360 50° 50° 50° 36

150 ( 6”) 900 150 380 50° 50° 50° 53

200 ( 8”) 1000 199 400 40° 40° 40° 71

250 (10”) 1000 250 430 40° 40° 40° 88

300 (12”) 1200 300 450 40° 40° 40° 106

400 (16”) 1200 377 500 40° 40° 40° 133

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

10

Survey of equations used

Equations for the ERZ 2000 USC / USE 09-C

Path velocity

vi = Flow velocity, (m/s)

measured in path i

ti1 = Transit time in direction 1 (path i) (s)

ti2 = Transit time in direction 2 (path i) (s)

L = Path length (cm)

d = Axial distance (cm)

2i1i

i

2

itt

t

d2

L

v







2i1ii ttt







Corrected path velocity

vci = Corrected path velocity (m/s)

ki = Correction factor for path i

iici vkv





Weighted flow velocity

vw = Weighted flow velocity (m/s)

wi = Weighting factor regarding the flow profile





 6

1i

ciiw vwv

Corrected weighted flow velocity

vwc = Corrected weighted flow (m/s)

velocity

KV = Meter factor

KR = Correction factor, Reynolds number

F = Error from error curve linearization

Re = Reynolds number

A, B, C = Parameters for Reynolds number correction function





100

F

VRwwc 1KKvv 





C

RRelogBAK 

Flow rate at measurement conditions

Qm = Flow rate at measurement conditions

vw = Weighted flow velocity

Di = Inside pipe diameter

h

s

3600

4

D

vQ

2

i

wm 

Corrected flow rate at measurement conditions

Qmc = Corrected flow rate at measurement conditions

vwc = Corrected weighted flow velocity

Di = Inside pipe diameter

kc = Correction factor, error curve linearization

h

s

3600

4

D

vkQ

2

i

wccmc 

INTRODUCTION

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Manual USZ 08 · EN05 · 2015-06

11

Base correction of the gas meter

Polynomial

The base correction of the meter is performed via a quartic polynomial which reproduces the error

curve.

Error equation: F1 = A-2  vwr-2 + A-1  vwr-1 + A0 + A1  vwr + A2  vwr2

F1 = Deviation of the error curve (%)

vwr = Weighted flow velocity

corrected by Reynolds number (m/s)

An = Constants

The constants An (n = -2 to n = 2) are calculated from the measured value pairs Error F1i and flow

velocity vwr. Instead of the constant meter factor KV, the corrected meter factor KVc is used for

further calculation.

KVc = KV  (1+F1/100)

Error curve linearization of the gas meter

Polynomial

The error curve linearization is also performed via a quartic polynomial which represents the error

curve of the gas meter.

Error equation: F2 = B-2  Qm-2 + B-1  Qm-1 + B0 + B1  Qm + B2  Qm2

F2 = Deviation of the error curve (%)

Qm = Flow rate at measurement conditions (m3/h)

Bn = Constants

The constants Bn (n = -2 to n = 2) are calculated from the measured value pairs Error F2i and flow

rate Qmi. In order to further calculate the corrected flow rate at measurement conditions, the

correction factor of error curve linearization Kc is used.

Kc = (1+F2/100)

INSTALLATION AND COMMISSIONING

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Manual USZ 08 · EN05 · 2015-06

12

Installation and commissioning

Installation of the meter

The USZ 08 ultrasonic flowmeter is to be operated with an inlet pipe and an outlet pipe. The

following details are identical to the requirements of the PTB approval certificate and are therefore

binding for custody transfer metering. These specifications are also recommended for secondary

metering; if they are not observed, it is likely that the accuracy of measurement will be lower.

Unidirectional operation

Standard installation without a flow straightener:

P

r

10 D 3D

1.5-5 D

3D

Compact installation with a flow straightener:

5D 3D

1.5-5 D

3D

P

r

Bidirectional operation

10 D 10 D

3-5 D

3D

P

r

INSTALLATION AND COMMISSIONING

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Manual USZ 08 · EN05 · 2015-06

13

Pipe diameter

Øi = D

Øi = D-2%

... D+5%

Øi = D-2% ... D+5%

P

r

The inside diameters of the inlet and outlet pipes may be up to 2% smaller or up to 5% larger than

the inside diameter of the meter.

Combination with the WBZ 08 vortex meter

In the case of nominal diameters from DN 200 to DN 600, a 6-path ultrasonic flowmeter can be

installed upstream of a WBZ 08 vortex meter so that it forms a part of the inlet pipe of the vortex

meter.

Outdoor installation

In case of outdoor installation of an USZ 08 with viewing

window and electronic display, a cover for the electronics

case is required. The display must definitely not be

exposed to direct solar radiation, since otherwise it will

be destroyed by UV radiation!

Ultrasonic flowmeters can be equipped with a cover in the

factory. Also retrofitting on site is possible.

INSTALLATION AND COMMISSIONING

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Manual USZ 08 · EN05 · 2015-06

14

Seals

It must be guaranteed that flange seals of RMG turbine meters do not protrude from the flange into

the gas line.

All seals approved as per DVGW can be used depending on the requirements for stability and reli-

ability.

We recommend seals with the following maximum material characteristic values according to the

AD2000 rules:

− gaskets: k0 x KD = 20 x bD | k1 = 1.3 x bD [N/mm]

− grooved seals: k0 x KD = 15 x bD | k1 = 1.1 x bD [N/mm]

− spiral seals: k0 x KD = 50 x bD | k1 = 1.4 x bD [N/mm]

− octagonal ring joint seal: KD = 480 N/mm2

For recommended dimensions, see the tables below.

Gaskets PN 10 PN 16 ANSI 150 PN 25 PN 40

DN d1 d2

50 2" 77 107 107 105 107 107

80 3" 90 142 142 137 142 142

100 4" 115 162 162 175 168 168

150 6" 169 218 218 222 225 225

200 8" 220 273 273 279 285 292

250 10" 274 328 330 340 342 353

300 12" 325 378 385 410 402 418

400 16" 420 490 497 514 515 547

500 20" 520 595 618 607 625 628

600 24" 620 695 735 718 730 745

Grooved seals ANSI 300 / ANSI 600 PN 64

DN d1 d2 d1 d2

50 2" 107 107 107 107

80 3" 142 142 142 142

100 4" 162 162 168 168

150 6" 218 218 225 225

200 8" 273 273 285 292

250 10" 328 330 342 353

300 12" 378 385 402 418

400 16" 490 497 515 547

500 20" 595 618 625 628

600 600 695 735 730 745

1.5 up to 5 mm

d1

d2

INSTALLATION AND COMMISSIONING

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Manual USZ 08 · EN05 · 2015-06

15

Spiral seals ANSI 300 PN 64 ANSI 600

DN d1 d2 D1 d2 d1 d2

50 2" 69.9 85.9 66 84 69.9 85.9

80 3" 101.6 120.7 95 119 101.6 120.7

100 4" 127.0 149.4 120 144 120.7 149.4

150 6" 182.6 209.6 174 200 174.8 209.6

200 8" 233.4 263.7 225 257 225.6 263.7

250 10" 287.3 317.5 279 315 274.6 317.5

300 12" 339.9 374.7 330 366 327.2 374.7

400 16" 422.4 463.6 426 466 412.8 463.6

500 20" 525.5 577.9 530 574 520.7 577.9

600 24" 628.7 685.8 630 674 628.7 685.8

Screws

Temperature ranges for screws and nuts

-10°C to +80°C -40°C to +80°C

Pressure Variant 1 Variant 2 Variant 3

up to and

including

40 bar

Screws complying

with

DIN EN ISO 4014

made of material 5.6,

Nuts complying with

DIN EN ISO 4032

made of material 5-2

Screws complying

with

DIN EN ISO 4014

made of material

25CrMo4,

Nuts complying with

DIN EN ISO 4032

made of material

25CrMo4

from 40 bar Screw bolts complying

with

ANSI B1.1

made of material

ASTM A193 Grade B7,

Nuts complying with

ANSI B1.1

made of material

ASTM A194 Grade 2H

Screw bolts

complying with

ANSI B1.1

made of material

ASTM A320 Grade L7,

Nuts complying with

ANSI B1.1

made of material

ASTM A320 Grade L7

Screw bolts

complying with

ANSI B1.1

made of material

42CrMo4,

Nuts complying with

ANSI B1.1

made of material

42CrMo4

Anti-fatigue bolts

complying with DIN

2510

made of material

25CrMo4,

Nuts complying with

DIN 2510

made of material

25CrMo4

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