SITRANS F US SONOFLO - ucc.colorado.eduucc.colorado.edu/siemens/SFIDKPS029Y102.pdf · SFIDK.PS.029.Y1.02 3 SITRANS F US SONOFLO To ensure optimum performance of the measuring equipment

Manual, amendment

Order no.: FDK:521H1050

SFIDK.PS.029.Y1.02 - A5E00253229

SITRANS F US SONOFLO

Ultrasonic flowmeterType SONOKIT hot-tap mounted

1- and 2-track DN 200 - DN 4000Amendment to product manuals for SONOKIT 1- and 2-tracks

[ ]

*085R9429*

s

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https://industrialautomation.co/product-category/siemens/page/12660/

SFIDK.PS.029.Y1.022


Contents Preface ................................................................................................................................................ 3Location ............................................................................................................................................... 3Construction of the sensor ............................................................................................................... 4Measuring the SONOKIT .................................................................................................................... 8Drilling ................................................................................................................................................. 11Installation of the transducers ............................................................................................................. 12Mounting of transducer ........................................................................................................................ 13SONOKIT installation with tapping band ........................................................................................... 18Introduction .......................................................................................................................................... 18Installation ........................................................................................................................................... 18Tools for hot-tap installation .............................................................................................................. 23Description of hot-tap drilling adaptor ................................................................................................. 23Description of hot-tap alignment tool for pipe sizes DN 300 - DN 1200 ............................................. 24Description of angle measuring instrument ........................................................................................ 25Description of lock tool for inserting or replacement of ultrasonic transducers .................................. 26Ordering .............................................................................................................................................. 27

SFIDK.PS.029.Y1.02 3


To ensure optimum performance of the measuring equipment it is essential that the followinginstructions are followed.

Location The SONOKIT sensor can be installed both indoors andoutdoors, even in exposed surroundings.

The space requirements around the pipe for retrofittinga SITRANS F US SONOFLO ultrasonic flowmeter typeSONOKIT are given in picture:

In case of large temperature differences between themedium and the environment the sensor must be iso-lated to avoid 2-phase flow which will result in inaccuratemeasuring results.

Preface This manual describes how to install SONOKIT on filled and pressurized steel pipes (hot-tap installation).The manual is meant as an amendment to the current SONOKIT manuals delivered with the kit and containsonly special instructions on the hot-tap installation.

Siemens Flow Instruments recommends that you are familiar with the ordinary installation on empty pipesbefore getting on with a hot-tap installation and that you know how to use the special tools used with thehot-tap installation.

It is also important that you know the limitations e.g. maximum pressure, temperature and required space.

If you have any questions, please contact Siemens Flow Instruments A/S.

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SFIDK.PS.029.Y1.024


Construction of thesensor

The construction ofthe sensor is donein 4 steps:

1. Marking up thepipe

2. Installating of thealignment tool

3. Measuring thepipe geometry

4. Drilling andinserting trans-ducers

Step 1Mark up a paper drawing as described inproduct manual describing the empty pipeinstallation.

Mark the centre of the top line X1 – X2 witha centre punch. This point must form thecentre of the centre point of the alignmenttool.

Also punch points to show the transducerholder position.

Remove the (drawing/measurement)paper.

Step 2Place the cradle from the alignment toolon top of the pipe. Place the supplied awlthrough the centre point of the cradle sothat the cradle is centered in the middle ofthe top line X1 – X2.

Use a spirit lever to check that the cradleis positioned horizontally on/to the pipe-line. Move e.g. the cradle sideways nomatter whether the centre is moved a littleaway from the top line. It is important forthe further installation that the alignmenttool is balanced in horizontal and verticalpositions as the adjustment takes placeby means of a spirit lever.

Spot weld the cradle 3 – 4 places, but seeto it that it can always easily be reposi-tioned.



Mount the alignment tool as shown. It isrecommendable to finish one sound trackat a time and when installing a two-trackmeter, it is recommendable to start withthe lowest track.

Use a spirit level to control that the upperguiding beam is positioned horizontallyand make sure that it is thoroughly fasten-ed.

Use a spirit level to control that the verticalguiding beams are plumb.

Shorten the transducer holder accordingto the actual pipe wall thickness (t). Theshortening can be done with a grinder ora saw. Cut parallel to the angle of thetransducer holder.

• At an angle of 45° the transducerholder is shortened by t x 1.4.

• At an angle of 60° the transducerholder is shortened by t x 1.15.

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SFIDK.PS.029.Y1.026


Mount the adaptor on the shortened trans-ducer holders. Then mount guidingbeams as shown.Adjust the guiding beams until the trans-ducer holders follow/aim at the marking-out.

Make sure that the distance between thetwo horizontal guiding beams are thesame on both sides of the pipe.If not, the lower guiding beams with thetransducer holders must be adjusted.

Check that transducer holders and guid-ing beams run parallel to the upper guid-ing beam. A visual control or a control bymeans of plumb lines will do. Both meth-ods require that you stand on the pipe.

Tack weld the transducer holders in 3places and check that also after the tackwelding they are positioned correctly. Ifso, the complete welding can be made.Please note that with hot-tap installationsno mounting plates are needed like is thecase with empty pipe installations.If during the welding the transducer holderhas bended, it can be adjusted by meansof a hammer and the supplied 1½” endcap. Check with spirit level.



Step 3Before proceeding it is a good idea tomeasure Lmax. of the sound track justfinished. By means of a plumb line theends of the transducer holders aretranspositioned to the upper guidingbeam.

Lmax. can now be measured with a meas-uring tape on the upper guiding beam.Enter the values in the measuring report.

* Valid for standard 160 mm transducers.With other transducer lengths, set in dimensions correspond-ing to these lengths.

*

*

Step 1The distance between the transducerwindows (L) is calculated based on Lmaxas shown.

The standard transducer length is160mm. If other lengths have been or-dered, use the new values in the calcu-lation.

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SFIDK.PS.029.Y1.028


Measuring theSONOKIT

To allow theoretical calibration by the SONO3000 signal converter the sensor geometry mustbe measured.

The following sensor data must be known:⇒ θ = Angle between sound track and longi-

tudinal axis of the pipe

⇒ L = Distance between transducer windows

⇒ Di = Inner diameter of the pipe

⇒ h = Distance between sound track andcentre axis of the pipe

∆θ DN 400-3000 0.1°∆ L DN 400-1000 0.8 mm

DN 1000-2000 2.0 mmDN 2000-3000 4.0 mm

∆Di DN 400-1000 0.8 mmDN 1000-2000 2.0 mmDN 2000-3000 4.0 mm

∆ H DN 400-1000 0.8 mmDN 1000-2000 2.0 mmDN 2000-3000 4.0 mm

The table shows the required measuring accu-racy:

Measuring the inner diameter (Di)The inner diameter Di can be calculatedon the basis of the circumference C ac-cording to the following formula:(t = wall thickness)

Di = (C / π)π)π)π)π) - (2 x t)

Measure the angle (θ) of each trans-ducer holder. To get the most accuratevalue, it is recommended to take severalmeasurements and calculate the aver-age of these. Then calculate the averageangle for each sound track. Enter thevalues in the measuring report.

To make sure that angle meter and pipe-line are level you may place a spirit levelon the angle meter.

Measuring the distance h between soundtrack and centre axis

To determine h measure Ha and Hb witha measuring tape or a sliding gauge andcalculate h using the formula:

Ha + Hbh =4

Enter h into the measuring report.



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SFIDK.PS.029.Y1.0210


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SFIDK.PS.029.Y1.02 11


Drilling Step 4Prepare to drill through the pipe wall withthe hot-tap drill adaptor. At first mount theball valve from the lock tool. Make surethat the valve is open.

Mount the hot-tap drill adaptor on the ballvalve by means of the hook spannersfrom the lock tool. Make sure that flatgaskets and o-rings have been mountedin the drill adaptor.Lubricate the drill with oil. Do not usegrease as it can be difficult to flush outand will pick up drill chips which maydamage the transducer o-ring.

Mount a standard hand-held drillingmachine on the hot-tap drill adaptor. Adrilling machine of 700 – 1000 W issufficient. Remember to open the valvebefore drilling. Once the drilling is fin-ished pull the drill back passed the ballvalve. Close the ball valve and demountthe drill adaptor.It is recommended to open the ball valvefor a moment to flush out possible drillchips and/or the drill core.

To determine the exact inside diameterof the pipe, measure the width of the core(t) with a sliding gauge.

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Installation of thetransducers

Prepare a transducer for mounting in thedrilled transducer holder.Demount the spring clips with the springclips gripper.Remove the silicone plug and carefullyput the wires into the transducer.

To avoid liquids penetrate into the trans-ducer during installation, mount the brassadaptor from the lock tool on the trans-ducers. Be careful when putting the wiresinto the transducer so that they will not bedamaged when screwing on the adap-tor.

Be careful with the mounting of the trans-ducer. Make sure that the gasket ismounted and not damaged.

SFIDK.PS.029.Y1.02 13


Mounting of trans-ducer

Mount the transducer on the mandrel ofthe lock tool.

Push the snap coupling forward until the2 teeth of the coupling snaps in place onthe transducer.

Make sure that the lock tool is turnedback to rear position, i.e. maximum length.Place the mandrel with transducer in thelock tool.

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Mount the hex screw nut in the end of themandrel.

Mount the spring clip through the nut andmandrel.

Make sure that the gasket is mountedand not damaged.

Mount the lock tool on the ball valve. It isessential that both lock tool and ballvalve have been thoroughly tightenedby means of the hook spanners.

SFIDK.PS.029.Y1.02 15


Slowly open the valve to avoid pressuresurge.

Turn the tripod of the lock tool clockwise.

Turn the tripod of the lock tool to stop. Thetripod must be turned clockwise right tothe end. If this is not possible, the trans-ducer may have knocked against anedge on its way through the valve.

Use a spanner key to turn the screw nutat the end of the mandrel approx. 10rounds clockwise. When you feel a stop,the transducer has been correctlymounted.

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Demount ball valve and lock tool fromthe transducer holder.

Remove ball valve and lock tool from thetransducer holder.

When the transducer has been correctlymounted, open the air nozzle to removethe pressure in the lock tool. Close the airrelease valve again. If the pressure re-establishes, the transducer has not beencorrectly mounted or the gaskets aredamaged.

Remove spring clips and screw nut.

SFIDK.PS.029.Y1.02 17


Pull back the snap coupling and removethe mandrel.

Tighten the transducer by means of thepipe wrench.

Remove the brass adaptor from the trans-ducer by means of a fork spanner.

Mount spring clips and silicone plug.

The hot-tap installation of this transduceris now finished. Continue with the re-maining transducers following the sameprocedure.

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SONOKIT installa-tion with tappingband

The Siemens Flow InstrumentsSONOKIT Tapping band is an ultrasonicflow meter designed to be fitted to pipe ofcircumference, pipe wall thickness andpressure rating nominated at the time ofordering.

The Siemens Flow InstrumentsSONOKIT Tapping band is recom-mended for installation of SONOKIT ul-trasonic flow meters on non weldablepipes, such as: Cast iron, Plastic pipes,Glass reinforced plastic pipes (GRP) orConcrete pipes.

The Siemens Flow InstrumentsSONOKIT Tapping band is designed forinstallation on pipes under pressure (hot-tap) and on empty pipes.

Introduction

Installation Unpack the Tapping band and check that all components are included. Some small items can bemisplaced during shipping and Customs inspection. If the list below does not check out, please contactSiemens Flow Instruments.

• Each band has an associated Data Sheet with information unique to that band. If more than one bandof the same size are delivered, ensure that each Data Sheet can be identified individually with its band.

• The number of segments in the band depends upon the band circumference and pressure rating.Check that the gap numbers stamped on the solid strips at the edge of each segment form a fullsequence.

• A set of small packets is included containing lubricant. The material embedded in the tissues is PipeJoint Lubricant.

Handle the segments carefully at all times, paying attention to the feathered edges of the rubber mats.Curling or tearing of these edges can compromise the seal.

Step 1

Prepare the segments for installation byunwinding the nuts almost off the end ofeach stud.The Fish plate which spans several studsmust be inserted between the washersand opposing tension plate at installa-tion.Ensure that these fish plates are free tomove along the studs and can be cor-rectly placed with ease.

SFIDK.PS.029.Y1.02 19


Step 2

Completely expose the pipe and cleanthe surface for a distance equal to thelength of the band plus approx. 200 mmeach side.Ensure all loose flakes of paint and rustare removed. Old paint and pipe-wrapcan be retained if not forming a hardedge which the rubber mat could notclosely follow and seal completely along.

Step 3

Spread the lubricant across the wholesurface of the rubber mat on each Tap-ping band segment. A liberal amountensures adequate slip between the matand the pipe surface, and will not at alldegrade the sealing properties of theband. Spread lubricant on the upperside of the feathered edge of each mat topromote good overlap slip.

Step 4

Place the segments in sequence start-ing at the top of the pipe and evenlydistributing the weight on either side.Ensure that the alignment spikes arecorrectly interleaved with the studs andthe studs are in their correct slots.

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The feathered edges of each mat is flatagainst the pipe and not curled or caught.

The fish plates shall be correctly placedagainst the tension plates and the foldededge can be hooked beneath them.

Step 5

Run the nuts to about half-way downeach stud when a segment is placed toensure that the later alignment stage canproceed easily. The work can be doneeasily with a hand held drilling machine.

SFIDK.PS.029.Y1.02 21


Step 6

At the last gap, carefully interleave thestuds and spikes, locking home the fishplates and running the nuts to about ¾down each stud.Do not at any point close any gap as thiswill severely compromise the ability ofthe Tapping band to seal in the future.

Step 7

Before tightening the nuts, ensure thatthe transducer holders are correctly ori-ented and that they are either correctlyplaced over their pre-cut holes, or that ahot-tap drill can fit into the availablespace.The clearance against a nearby wall canbe improved by rotating the band up to45° from the horizontal.

Step 8

Take note of the recommended torquestamped on the band and set the torquewrench to half that value.Torque up all nuts in an even manner,making sure that no gap is closed andthat no one point is unevenly tightened.Best results are obtained for both thesealing of the band and the accuracy offlowmeter calibration when all the gapsare kept the same.

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Step 9

Reset the torque wrench to the recom-mended setting and tighten all nuts. Keepthe sequence even across the length ofthe band and move regularly to othergaps to ensure even tightening.

Step 10

Place the stud covers on the exposedends to prevent grit collecting in thethread. This aids the removal of the bandif that should later be required.

Step 11

The installation of the tapping band isfinished. Proceed to the hot-tap instruc-tion for further steps regarding drilling,transducer installation and pipe geom-etry measurement.

SFIDK.PS.029.Y1.02 23


Tools for hot-tapinstallation

Description ofhot-tap drillingadaptor

For use up to maximum 15 bar line pressure

(1) Drill cylinder for mounting on to the valve from lock tool

(2) & (3) Stainless steel drill rod for 50 mm and 160 mm transducersThe drill is screwed on to the end with the thread M13 and the other end is connected to ahand-held drilling machine

(4) SANDVIK holesaw (drill). Four pcs are supplied with the adaptor. SANDVIK holesaws aresupplied from SANDVIK AB in SwedenType of drill Sandflex 3830-25-VIP ø25

(5) Flat gasket between drill cylinder and valve. Four pcs code No. FDK:085B0903 are suppliedwith the machine

(6) O-ring for sealing between drill cylinder and drill rodTwenty pcs code No. 991X5086 are supplied with the machine

Siemens Flow Instruments code no. FDK:085B5392

(1)

(6)

(3)

(2)

(5)(4)

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Description ofhot-tap alignmenttool for pipe sizesDN 300 - DN 1200

For use on pipe sizes in the range DN 300 to DN 1200

(1) Cradle for mounting on the pipe after the transducer locations have been marked

(2) Awe used to position the cradle

(3) Centre holder for mounting on the cradle to keep the alignment barrels in the right position

(4) Adaptor to keep the transducer holder in the right position before the welding. Two pcs aresupplied

(5) Holders to keep the vertical rods and the rods holding the transducer in the right positionduring installation

(6) The cradle can be tack welded onto the pipe. On non weldable pipes, use the enclosedwebbing spanners

(7) Alignment rods - 8 pcs in setØ = 25 mm, L = 500 mm


(1)

(6)

(7)

(2)(3)(4)

(5)

SFIDK.PS.029.Y1.02 25


Description ofangle measuringinstrument

(1) TESA angle measuring instrument providing an accuracy ± 0.1°

(2) Fixing device between angle instrument and angle holder

(3) Angle holder

(4) Alignment rod (supplied with the SONOKIT mounting set)

(5) Transducer holders

(6) Slide the blade into the required position and lock with lever (1a)

(7) To measure the angle, open lever 2a and place the angle tool in the angle between pipeand transducer holder. Lock lever 2a and read the angle on gauge


(1)

(2)

(3)(3)

(4)

(2a)

(1a)

(5)

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Description of locktool for inserting orreplacement ofultrasonic trans-ducers

The lock tool can insert transducers when installing SONOKIT under pressure (hot-tap), or it can be usedto replace transducers on ultrasonic flowmeters Type SONO 3100 with Type SONO 3200 O-ring transducersinstalled.

(1) Spanner key for transducer type SONO 3200 o-ring type

(2) Hex nut with hole for spring clip

(3) Spring clip

(4) Hook spanners

(5) 19 mm spanner key for the lock tool hex nut and brass adaptor

(6) Gaskets for ball valve, lock tool and brass adaptor

(7) Brass adaptor to mount on the transducers

(8) Mandrel with snap coupling to hold the transducer

(9) Lock tool including ball valve and pressure gauge

Siemens Flow Instruments code Nos:Transducer length 50 mm FDK:085B5331Transducer length 160 mm FDK:085B5333Transducer length 230 mm FDK:085B5335

(1)(2) (3)

(8)

(9)

(4)

(5)

(6) (7)

SFIDK.PS.029.Y1.02 27


Ordering SONOKIT TAPPING BAND - -

1. No of tracksOne sound track .............................................................................. 1Two sound tracks ............................................................................ 2

2. Circumference of pipe (measured)460 mm to 6283 mm .................................................................................... 0 9 6 1

(961 mm)

3. Pipe wall thickness 4 mm to 200 mm ........................................................................................................................... 0 8 7

(87mm)

4. Pressure ratingPN 6 ................................................................................................................................................................... APN 10 (max. pipe diameter DN 1800) ............................................................................................................. BPN 16 (max. pipe diameter DN 1200) ............................................................................................................. C

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We have checked the contents of this manual for agreement with the hardware andsoftware described. Since deviations cannot be precluded entirely, we cannot guaranteefull agreement. However, the data in this manual are reviewed regularly and anynecessary corrections included in subsequent editions. Suggestions for improvementare always welcomed.

Technical data subject to change without prior notice.

The reproduction, transmission or use of this document or its contents is not permitted withoutexpress written authority.Offenders will be liable for damages. All rights, including rights created by patent grant orregistration of a utility model or design, are reserved.

Copyright © Siemens AG 08.2000 All Rights Reserved

Siemens Flow Instruments A/SNordborgvej 81DK-6430 Nordborg

Order no.: FDK:521H1050-01Printed in: Denmark

Documents

SITRANS F US SONOFLO - ucc.colorado.eduucc.colorado.edu/siemens/SFIDKPS029Y102.pdf · SFIDK.PS.029.Y1.02 3 SITRANS F US SONOFLO To ensure optimum performance of the measuring equipment