Emerson 3-9000-744 User Manual
Operation Manual
Part Number: 3-9000-744, Rev. F
September 2013
Daniel
for SeniorSonicTM 4-Path Gas Ultrasonic Flow Meters
TM
Split Clamp Extractor Tool
Daniel customer service
Location Tele p h o n e number Fax number
North America/Latin America +1.713.467.6000 +1.713.827.4805
Daniel Customer Service +1.713.827.6413 +1.713.827.6312
USA (toll free) +1.888.356.9001 +1.713.827.3380
Asia Pacific (Republic of Singapore) +65.6777.8211 +65.6777.0947.0743
Europe (Stirling Scotland, UK) +44 (0)1786.433400 +44 (0)1786.433401
Middle East Africa (Dubai, UAE) +971 4 8118100 +971 4 8865465
North America/Latin America +1.713.467.6000 +1.713.827.4805
Daniel Measurement and Control, Inc. (Headquarters)
11100 Brittmoore Park Drive Houston, TX 77041 USA
http://www.daniel.com
E-mail
• Customer Service: tech.service@emersonprocess.com
• Customer Support: daniel.cst.support@emerson.com
• Asia-Pacific: danielap.support@emerson.com
• Europe: DanielEMA.CST@EmersonProcess.com
Return Material Authorization (RMA)
A Return Material Authorization (RMA) number must be obtained prior to returning any equipment for any
reason. Download the RMA form from the Support Services web page by selecting the link below.
http://www2.emersonprocess.com/EN-US/BRANDS/DANIEL/SUPPORT-SERVICES/Pages/Support-Services.aspx
Signal words and symbols used in this manual
Pay special attention to the following signal words, safety alert symbols and statements:
Safety alert symbol
This is a safety alert symbol. It is used to alert you to potential physical injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
Danger indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Warning indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Caution indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Notice is used to address safety messages or practices not related to personal injury.
Important
Important is a statement the user needs to know and consider.
Tip
Tip provides information or suggestions for improved efficiency or best results.
Note
Note is “general by-the-way” content not essential to the main flow of information.
Important safety instructions
Failure to follow the installation, operation or maintenance instructions for a Daniel product could lead to
serious injury or death.
• Comply with all information on the product, in this manual, and in any local and national codes that
apply to the product.
• Do not allow untrained personnel to work with this product.
• Use Daniel parts and work procedures specified in this manual.
Daniel Measurement and Control, Inc. (Daniel) designs, manufactures and tests products to function
within specific conditions. Because these products are sophisticated technical instruments, it is important
that the owner and operation personnel strictly adhere both to the information printed on the product
nameplate and to all instructions provided in this manual prior to installation, operation, and maintenance.
Daniel also urges you to integrate this manual into your training and safety program.
BE SURE ALL PERSONNEL READ AND FOLLOW THE INSTRUCTIONS IN THIS MANUAL AND ALL NOTICES
AND PRODUCT WARNINGS.
Product owners (Purchasers):
• Use the correct product for the environment and pressures present. See technical data or
product specifications for limitations. If you are unsure, discuss your needs with your
Daniel representative.
• Inform and train all personnel in the proper installation, operation, and maintenance of
this product.
• To ensure safe and proper performance, only informed and trained personnel should
install, operate, repair and maintain this product.
• Verify that this is the correct instruction manual for your Daniel product. If this is not the
correct documentation, contact Daniel at 1-713-827-6314. You may also download the
correct manual from:
http://www.daniel.com
• Save this instruction manual for future reference.
• If you resell or transfer this product, it is your responsibility to forward this instruction
manual along with the product to the new owner or transferee.
• ALWAYS READ AND FOLLOW THE INSTALLATION, OPERATIONS, MAINTENANCE AND
TROUBLESHOOTING MANUAL(S) AND ALL PRODUCT WARNINGS AND INSTRUCTIONS.
• Do not use this equipment for any purpose other than its intended service. This may result
in property damage and/or serious personal injury or death.
Product Operation Personnel:
• To prevent personal injury, personnel must follow all instructions of this manual prior to
and during operation of the product.
• Follow all warnings, cautions, and notices marked on, and supplied with, this product.
• Verify that this is the correct instruction manual for your Daniel product. If this is not the
correct documentation, contact Daniel at 1-713-827-6314. You may also download the
correct manual from:
http://www.daniel.com
• Read and understand all instructions and operating procedures for this product.
• If you do not understand an instruction, or do not feel comfortable following the
instructions, contact your Daniel representative for clarification or assistance.
• Install this product as specified in the INSTALLATION section of this manual per applicable
local and national codes.
• Follow all instructions during the installation, operation, and maintenance of this product.
• Connect the product to the proper pressure sources when and where applicable.
• Ensure that all connections to pressure and electrical sources are secure prior to and
during equipment operation.
• Use only replacement parts specified by Daniel. Unauthorized parts and procedures can
affect this product's performance, safety, and invalidate the warranty. “Look-a-like”
substitutions may result in deadly fire, explosion, release of toxic substances or improper
operation.
• Save this instruction manual for future reference.
Notice
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. ALL SALES ARE GOVERNED BY DANIEL'S TERMS AND CONDITIONS, WHICH ARE AVAILABLE
UPON REQUEST. 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.
TO THE BEST OF DANIEL'S KNOWLEDGE THE INFORMATION HEREIN IS COMPLETE AND ACCURATE. 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 INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS
OF PRODUCTION, LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT
LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF THIRD PARTIES.
PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION ONLY AND MAY BE
TRADEMARKS/ REGISTERED TRADEMARKS OF THESE COMPANIES.
Warranty and Limitations
1. LIMITED WARRANTY: Subject to the limitations contained in Section 2 herein, Daniel Measurement & Control,
Inc. (“Daniel”) warrants that the licensed firmware embodied in the Goods will execute the programming
instructions provided by Daniel, and that the Goods manufactured by Daniel will be free from defects in materials
or workmanship under normal use and care and Services will be performed by trained personnel using proper
equipment and instrumentation for the particular Service provided. The foregoing warranties will apply 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, 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 or environmental conditions,
accident, misuse, improper installation, modification, repair, use of unauthorized replacement parts, 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 Daniel. All costs of dismantling, reinstallation and freight and the time
and expenses of Daniel's personnel and representatives 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 by Daniel 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 Daniel. THE WARRANTIES AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE. THERE ARE NO
REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR
PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES. Buyer
acknowledges and agrees that corrosion or erosion of materials is not covered by this warranty.
2. LIMITATION OF REMEDY AND LIABILITY: Daniel shall not be liable for damages caused by delay in performance.
the remedies of buyer set forth in this agreement are exclusive. 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, revenue or use and costs
incurred including without limitation for capital, fuel and power, and claims of buyer's customers.
Operation Manual Table of Contents
3-9000-744 Rev F September 2013
Contents
Preface
\Daniel customer service
Signal words and symbols used in this manual
Important safety instructions
Notice
Warranty and Limitations
Section 1: Introduction
1.1 Overview ............................................................................................ 1
1.2 Extractor tool specifications ................................................................. 4
1.3 Extractor tool pre-use and post-use inspection ...................................... 6
Section 2: Operation preparation and part replacement notes
2.1 Operation preparation ......................................................................... 9
2.2 Part replacement notes ...................................................................... 12
Section 3: Tool requirements
3.1 Tool list for the extractor tool with T-slot extractable transducers ........ 13
Section 4: Removing a transducer assembly
4.1 Steps to remove a transducer assembly from a meter while
the meter is under line pressure ................................................................. 15
Section 5: Installing a transducer assembly
5.1 Installing a transducer assembly while
the meter is under line pressure ................................................................. 25
Section 6: Maintenance
6.1 Extractor tool maintenance ................................................................ 33
Section 7: Parts list
7.1 Extractor tool parts list ...................................................................... 35
Appendix A: Piston and line pressure
A.1 Extractor tool piston pressure.............................................................................. 37
Appendix B: Extractor tool pre-use and post-use inspection checklist
B.1 Inspection checklist............................................................................................. 39
Appendix C: Engineering drawings
3.1 Extractor tool drawings ....................................................................................... 41
Table of Contents i
Table of Contents Operation Manual
September 2013 3-9000-744 Rev F
ii Table of Contents
Operation Manual List of Tables
3-9000-744 Rev F September 2013
List of Tables
Table 1-1 Daniel extractor tool specifications .................................................................................... 5
Table 3-1 Extractor tool list for T-slot extractable transducers ......................................................... 13
Table 7-1 Extractor tool parts list ..................................................................................................... 35
Table A-1 Extractor tool piston and line pressure stabilization.......................................................... 37
Table B-1 Inspection checklist.......................................................................................................... 39
List of Tables iii
List of Tables Operation Manual
September 2013 3-9000-744 Rev F
iv List of Tables
Operation Manual List of Figures
3-9000-744 Rev F September 2013
List of Figures
Figure 1-1 J-mount transducer identification ................................................................................. 1
Figure 1-2 J-mount transducer identification ................................................................................ 2
Figure 1-3 M-mount transducer identification .............................................................................. 3
Figure 1-4 ANSI Class pressure rating stamp on lubricator chamber assembly flange ................... 4
Figure 1-5 Split clamp extractor tool assembly dimensions (inches) .............................................. 5
Figure 4-2 Extractor tool with O-ring on flange ............................................................................ 17
Figure 4-3 Lubricator chamber assembly flange screws .............................................................. 23
Figure 4-4 Transducer holder, stalk and transducer assembly...................................................... 24
List of Figures v
List of Figures Operation Manual
September 2013 3-9000-744 Rev F
vi List of Figures
Operation Manual Section 1: Introduction
A.
B.
A. Mount length identifier
B. Mount style identifier
3-9000-744 Rev F September 2013
11
12
13
14
15
16
Section 1: Introduction
1.1 Overview
The Daniel Ultrasonic Split Clamp Extractor Tool is designed for use on Daniel SeniorSonicTM
4 Path Gas Ultrasonic Meters only. The Daniel Ultrasonic Split Clamp Extractor Tool Operation
Manual (P/N 3-9000-744) provides operating instructions for 4 Path meters fitted with T- Slot
design transducer mounts (see Figure 1-2). The following mounts are included:
• 150 ANSI to 600 ANSI Ultrasonic meters with style J mounts (example J00, J25, J50 and
J75)
• 900 ANSI and 1500 ANSI Ultrasonic meters with style K mounts (example K00, K25,
K50, and K75)
All transducer mounts and holders are stamped, identifying the mount length, mount style,
serial number, and purchase order information (see Figure 1-1 and) Figure 1-2).
Figure 1-1 J-mount transducer identification
Overview 1
Section 1: Introduction Operation Manual
A.
A. Mount identification (serial number, length, purchase order number and style)
B. T-slot transducer holder
B.
September 2013 3-9000-744 Rev F
Figure 1-2 J-mount transducer identification
2 Overview
Operation Manual Section 1: Introduction
A.
A. Mount identification (serial number, length, purchase order number and style)
B. Threaded mount
B.
38⁄
38⁄
3-9000-744 Rev F September 2013
Daniel Ultrasonic meters with M-mount (150 ANSI to 600 ANSI) or P-mount
(900 ANSI to 1500 ANSI) T- slot transducer holders are not designed for the Split Clamp
Extractor Tool and this manual does not apply to these mount styles. M-mount and P-mount
bodies are threaded to accept extractor tool coupling and will not accept split clamp extractor
tool (see Figure 1-3). Refer to the Daniel Ultrasonic Extractor Tool Operation Manual,
Daniel P/N 3-9000-729 for threaded body types.
Figure 1-3 M-mount transducer identification
Important:
The ultrasonic extractor tool requires a valve with an NPT female threaded port as a pressure
point for the line pressure. This valve must be installed within six inches of the ultrasonic meter
pressure tap hole provided on the ultrasonic meter housing.
For ANSI #300 and #600 meters, use a valve with a ¼”or ½” NPT female threaded port.
The ¼” reducer provided in the tool kit must be used with the ½” NPT female threaded port.
For ANSI #900 and #1500 meters, use a valve with a “or ½” NPT female threaded port. The
“reducer provided in the tool kit must be used with the ½”NPT female threaded port.
Overview 3
Section 1: Introduction Operation Manual
A.
A. ANSI Class pressure rating identification location
EXTRACTOR TOOL HANDLING HAZARD
The extractor tool, when it is fully assembled is heavy (144-160 lbs), long (6 ft) and may be difficult to operate in
tight quarters. Take care not to lean on, sit on, or step on the unit.
Failure to follow the handling instructions may cause the tool to fall and cause serious personal injury.
September 2013 3-9000-744 Rev F
1.2 Extractor tool specifications
The Daniel Extractor Tool is available in two ANSI pressure ratings, 600 and 1500. The pressure
rating is stamped on the Lubricator chamber assembly flange (item M, drawing D-08248). See
Appendix C and Figure 1-4.
Figure 1-4 ANSI Class pressure rating stamp on lubricator chamber assembly flange
4 Extractor tool specifications
Operation Manual Section 1: Introduction
HAZARDOUS MATERIALS
Do not use the Daniel Extractor Tool in environments with hydrogen sulfide present. The tool is
not designed for use in these environments.
Failure to follow these instructions will cause death from asphyxiation, fire, or explosion.
3-9000-744 Rev F September 2013
Table 1-1 Daniel extractor tool specifications
Extractor tool weight by disassembled component Weight (lbs),
ANSI 600 ANSI 1500
Suitcase 52 52
Extractor tool valve assembly (Split clamp) 24 30
Lubricator chamber assembly 32 42
Extractor tool piston assembly 15 15
2 hoses (one black and one stainless steel) 4 4
Tool kit 17 17
Extractor tool total weight 144 160
Extractor tool length and operating temperature Length and operating temperature range
Tool length
Operating temperature - 4 °F to 212 °F (-20 °C to 100 °C)
(see Figure 1-5)
Figure 1-5 Split clamp extractor tool assembly dimensions (inches)
Extractor tool specifications 5
Section 1: Introduction Operation Manual
September 2013 3-9000-744 Rev F
1.3 Extractor tool pre-use and post-use inspection
Prior to and after using the extractor tool, the following inspection procedure must be followed:
Refer to drawing D-08248 Detail D (see Appendix C).
1. Prior to connecting the Lubricator Chamber Assembly to the Piston Assembly verify
the extractor rod (N) on the Lubricator Chamber Assembly is correctly indicating by
performing the following steps.
a. Make sure the extractor rod is clean and free of dirt and it smoothly pulls in and
out of the Lubricator Chamber Assembly.
b. Grasp the extractor rod (N) and gently pull it out until it stops.
c. The scribe mark at the end of extractor rod (N) is clearly visible.
2. Visually verify that all hoses are intact with no kinks or tears.
3. Visually inspect the four bolts that hold the Piston Assembly onto the Lubricator
Chamber Assembly. Make sure they are clean and that the threads are not galled,
stripped or damaged.
4. Make sure that there are at least eight (8) backup O-Rings
replace all transducer holders extracted. If not enough, order enough for current and
uture use. See Daniel Service Group for O-Ring part numbers.
f
5. Perform a bench test to verify the pressure gauge and regulator on the Lubricator
Chamber Assembly are working properly. Follow Section 4.1, Step 1C to Step 6A in this
manual to prepare the Extractor tool for the bench test.
a. Close the Extractor Tool Valve (H) and use 300 psi nitrogen pressure to pressurize
the extractor tool.
b. Visually verify that there are no leaks at the NPT thread connections. Use Snoop
or soapy water solution for this visual leak check.
c. Confirm that the Lubricator Chamber Assembly line pressure gauge (T) is
indicating the correct line pressure. Adjust the regulator (V) to the required
piston pressure (
Piston Assembly gauge (U) indicates according to Tab le A -1 .
d. Check all Joints including ball seal for leaks using Snoop or a soapy water solution.
Turn the line pressure valve off. Use the Lubricator Chamber vent valve (R), and
bleed the line pressure from the tool. Confirm that both gauges show a slow
decrease in pressure until zero pressure is reached.
e. Close the vent valve (R).
see pressure references Table A-1 Appendix A). Verify that the
and enough lubricant to
®
6 Extractor tool pre-use and post-use inspection
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