Emerson Process Management 3-9008-701 User Manual

Compact Prover

Operating and maintenance instructions

Part Number: 3-9008-701, Rev. J

January 2015

Daniel customer service

Location Tel ephone number Fax number

North America/Latin America +1.713.467.6000 +1.713.827.4805

Daniel Customer Service +1.713.827.6314 +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) [phone] [phone]

Email

• Customer Service: [e-mail]

• Customer Support: [e-mail]

• Asia-Pacific: [e-mail]

• Europe: [e-mail]

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.

www2.emersonprocess.com/EN-US/BRANDS/DANIEL/SUPPORT-SERVICES/Pages/Support-Services.aspx?

Signal words and symbols

This is a safety alert symbol. It is used to alert you to potential physical injury hazards. Obey
all safety messages that follow this syLmbol to avoid possible injury or death.

Safety alert symbol

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.

Caution indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.

Pay special attention to the following signal words, safety alert symbols and statements:

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 a “general by-the-way” content not essential to the main flow of information.

Important safety instructions

Installing, operating or maintaining a Daniel product improperly could lead to serious injury or
death from explosion or exposure to dangerous substances. To reduce this risk:

• 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 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 MANUALS 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 appropriate pressure and electrical 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
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.

: DANIEL SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN

Operating and maintenance instructions Table of Contents

3-9008-701 Rev J January 2015

Contents

Daniel customer service ................................................................................... 3

• Signal words and symbols .............................................................................. 4

• Important safety instructions ......................................................................... 5

• Notice .......................................................................................................... 7

• Warranty and Limitations............................................................................... 8

Section 1: Introduction

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

1.2 Description ................................................................................................. 1

1.3 Mechanical description ................................................................................ 2

1.4 Technical data............................................................................................. 6

Section 2: Installation and set-up

2.1 Installation ............................................................................................... 13

2.2 Set-up ...................................................................................................... 15

2.2.1 Supplying electrical power to the compact prover ....................................... 15

2.2.2 Connection of the operating computer ....................................................... 16

2.2.3 12 or 24V DC Interface Board....................................................................... 18

2.2.4 Charging the Pneumatic Spring Plenum....................................................... 21

2.3 Base volume certification ........................................................................... 23

2.4 Calibration integrity seal installation procedure .......................................... 24

Section 3: Operation

3.1 General operational theory ........................................................................ 27

3.2 Operating instructions .............................................................................. 30

Section 4: Maintenance

4.1 Seal Leak Check......................................................................................... 35

4.2 Base volume determination........................................................................ 37

4.2.1 Certification techniques............................................................................... 37

4.2.2 Water draw procedure: (Reference Figure 4-4 and notes on page 47).......... 42

4.3 Certification Data Sheet and Calculations.................................................... 49

4.3.1 Data Sheet Entries ....................................................................................... 49

4.3.2 Calculations................................................................................................. 50

4.4 Seal Replacement ...................................................................................... 52

4.4.1 Measurement Piston and Flow Tube ............................................................ 52

4.4.2 Optical Seal Support .................................................................................... 60

4.4.3 Hydraulic Cylinder and Hydraulic Seal Support............................................. 63

Table of Contents 9

Table of Contents Operating and maintenance instructions

January 2015 3-9008-701 Rev J

4.5 Optical conversion kit ................................................................................67

4.6 Detector Switch Replacement .....................................................................68

Section 5: Troubleshooting

5.1 General.....................................................................................................73

5.2 Interface Signals........................................................................................ 73

5.3 Measurement Piston Movement.................................................................. 75

5.4 The auto plenum adjust panel.....................................................................80

Section 6: Special tools and equipment

6.1 Tool list ....................................................................................................85

Section 7: Parts list

7.1 General.....................................................................................................89

7.2 Replacement Parts List ...............................................................................89

10 Table of Contents

Operating and maintenance instructions List of Tables

3-9008-701 Rev J January 2015

List of Tables

Table 1-1 Hydraulic ........................................................................................................................... 7

Table 1-2 Standard compact prover set-up data ................................................................................ 8

Table 1-3 Power requirements........................................................................................................... 9

Table 3-1 Spring plenun ‘R’ values ................................................................................................... 31

Table 4-1 Torque table ....................................................................................................................55

Table 4-2 Tie rod nut torque ............................................................................................................ 57

Table 4-3 Hydraulic cylinder tie rod nut torque................................................................................ 67

Table 4-4 Volumetric percent change for compact provers ............................................................. 71

Table 6-1 Tool size requirement ...................................................................................................... 86

Table 6-2 Torque values for pipe flange stud/nut sets...................................................................... 87

Table 7-1 Parts list ........................................................................................................................... 90

List of Tables 11

List of Tables Operating and maintenance instructions

January 2015 3-9008-701 Rev J

12 List of Tables

Operating and maintenance instructions List of Figures

3-9008-701 Rev J January 2015

List of Figures

Figure 1-1 Outline drawings - Compact prover .............................................................................. 4

Figure 1-1 Outline drawings - Compact prover (Continued)........................................................... 5

Figure 2-1 Typical prover installation........................................................................................... 15

Figure 2-2 Double chronometry .................................................................................................. 17

Figure 2-3 12V Prover interface board ......................................................................................... 19

Figure 2-4 12/24V Prover interface board.................................................................................... 20

Figure 2-5 Typical nitrogen adjust panel...................................................................................... 22

Figure 2-6 Connection diagram................................................................................................... 23

Figure 3-1 Standby position......................................................................................................... 28

Figure 3-2 Initial motion.............................................................................................................. 28

Figure 3-3 Proving ....................................................................................................................... 29

Figure 3-4 End of proving run ...................................................................................................... 29

Figure 3-5 Piston returning to upstream position ........................................................................ 30

Figure 3-6 Spring plenum ............................................................................................................ 31

Figure 3-7 Hydraulic system ........................................................................................................ 33

Figure 4-1 Leak detector kit......................................................................................................... 35

Figure 4-2 Leak detector kit installed........................................................................................... 36

Figure 4-3 Compact prover water draw assembly typical NEC style (non-explosion proof)........... 40

Figure 4-3 Compact prover water draw assembly (continued) Typical Ex-proof style ................... 41

Figure 4-4 Water draw system..................................................................................................... 42

Figure 4-5 Test measure temperature stabilization...................................................................... 45

Figure 4-6 Typical volumetric determination data sheet.............................................................. 48

Figure 4-7 Typical prover control panel assembly (12” shown) .................................................... 49

Figure 4-8 Poppet O-ring installation........................................................................................... 54

Figure 4-9 Optical seal support assembly - 8” and 18” and all units built prior to

January 1, 2006 ............................................................................................................ 61

Figure 4-10 Optical seal support assembly - 24” (built after January 1, 2006) and 34”.................... 62

Figure 4-11 Hydraulic seal support assembly................................................................................. 63

Figure 4-12 Typical hydraulic cylinder assembly ............................................................................ 65

Figure 4-13 Detector switch removal #1........................................................................................ 68

Figure 4-14 Detector switch removal #2........................................................................................ 69

Figure 4-15 Detector switch adjustment ....................................................................................... 70

Figure 5-1 Prover signal timing.................................................................................................... 74

List of Figures 13

List of Figures Operating and maintenance instructions

January 2015 3-9008-701 Rev J

Figure 5-2 Prover wiring diagram (single phase power)................................................................76

Figure 5-3 Prover wiring diagram (three phase power).................................................................77

Figure 5-4 Prover wiring diagram (ATEX internal).........................................................................78

Figure 5-5 Prover wiring diagram (ATEX external)........................................................................79

Figure 5-6 DC powered solenoids ................................................................................................82

Figure 5-7 AC powered solenoids.................................................................................................83

Figure 7-1 Spare parts diagram (flow tube)..................................................................................95

Figure 7-2 Spare parts diagram (Flow tube) (continued) ..............................................................96

Figure 7-3 Spare parts diagram (Mechanical components) ..........................................................97

Figure 7-4 Spare parts diagram (Electrical components)..............................................................98

14 List of Figures

Operating and maintenance instructions Section 1: Introduction

3-9008-701 Rev J January 2015

11
12
13
14
15
16

Section 1: Introduction

1.1 General

This manual is designed to provide information and guidance to personnel responsible for the
operation and maintenance of the Compact Prover. The content of this manual is intended to
describe the normal operational characteristics of the Compact Prover. By necessity, this
manual is written for standard provers. It does not include specific information pertinent to
specially designed items or non-standard equipment. Operating and Maintenance Instructions
for special equipment will be supplied as necessary.

The Compact Prover is not a stand-alone system. The prover requires the use of an operating
computer that is capable of Dual Chronometry Pulse Interpolation. The operating computer will
process and summarize all proving data. Refer to the Operation section of this manual for more
information.

1.2 Description

The Compact Prover provides improved accuracy, rapid operation and continuous flow for
performance testing, or ‘proving’, of liquid flow meters in an operational line. Modern
electronics permit exact time determination and pulse counting, which provides high accuracy
proving with a smaller volume and fewer flowmeter pulses than any previous proving
technology.

Because of its reduced size and a unique patented piston design, which includes an internal
poppet valve, the Compact Prover can be easily installed in most operational lines and operated
with minimal disturbance to flow. The prover’s internal design incorporates an inherent fail-safe
feature constructed to assure uninterrupted liquid flow.

The Interface Enclosure contains a printed circuit board which conditions the signals generated
by the prover. The operating computer, which is typically located in a control room, receives
these signals and generates data from the proving passes. This data can be printed for manual
implementation to the process line flow meter. Some proving applications can be programmed
for automatic implementation.

A typical proving run should generate the following raw data:

1. The exact time interval, in seconds, for the certified volume of the prover to be
displaced.

2. The exact time interval, in seconds, to tabulate flow meter pulses.

3. The exact number of whole meter pulses generated by the liquid displaced during the
proving run.

Typical data given by the operating computer include:

• Frequency: Flowmeter pulses/second, Hz

• Flow rate: Units of volume/minute or hour (Can be gpm, bph, lpm or m /hr.)

• K-Factor: Flowmeter pulses/unit of volume

General 1

Section 1: Introduction Operating and maintenance instructions

January 2015 3-9008-701 Rev J

• Meter Factor: Correction factor (multiplier) for meter readout

1.3 Mechanical description

The basic outline of the compact prover and its component parts are shown in Figure 1-1. The
compact prover consists of a free flowing measurement piston and a coaxial mounted poppet
valve, all within a precision flow tube. The poppet valve is incorporated within the measurement
piston and is connected to the hydraulic cylinder by way of an actuator shaft. A calculated
pressure in the pneumatic spring plenum, in combination with the hydraulic system, operates
the actuator piston within the hydraulic cylinder. The pressure in the pneumatic spring plenum
closes the poppet valve, allowing the piston to proceed through a proving pass. Once the pass is
complete, the hydraulic system returns the piston to the upstream (standby) position while
holding the poppet valve open. Normal flow of the liquid will pass through the open poppet
valve. Optical sensors are used to detect the position of the piston inside the flow tube. These
sensors generate position signals, which are used for proper operation and data calculation.
Refer to Section 3: Operation for complete operation instructions.

Flow tube:

The flow tube is a stainless steel tube with a precision machined, hard chrome-plated bore. It
contains the prover piston, poppet valve, and fail-safe mechanism.

End connections:

The inlet and outlet end connections for installing the compact prover in line are ANSI 16.5
raised face flanges. Reference Section 1.4 for Technical data.

Hydraulic cylinder:

The hydraulic cylinder contains the actuator piston to act as a barrier between the gas in the
pneumatic spring plenum and the hydraulic oil. It provides the forces necessary to open and
close the poppet valve and to operate the prover through it’s cycle. Connected to the actuator
piston is the actuator shaft, which is connected to the poppet on the opposite end.

Optical assembly:

This intrinsically safe component is precision designed for accurate volume measurement within
5 ten thousandths (0.0005) of one inch or 0.0127 mm. There are three optical sensors
(switches) used: one for the upstream (standby) position, and two for defining the displaced
volume of fluid flowing through the prover. These slotted switches have an infrared LED and a
phototransistor on opposite sides of the slot. The prover generates a signal when a “flag” passes
through the slot and blocks the infrared light from the phototransistor. The flag is attached to

2 Mechanical description

Operating and maintenance instructions Section 1: Introduction

3-9008-701 Rev J January 2015

the measurement piston by means of the detector shaft. The passage of the flag through the
slotted optical switches defines the displaced volume (base volume) of the prover. For detailed
information on the Optical Assembly, see Section 4: Maintenance.

Hydraulic control valve:

This normally closed two-way valve controls the hydraulic operation of the prover. The valve is
energized to open during a proving pass, and de-energized to close for the piston return to the
upstream (standby) position. There are two styles of control valve used. Style is dependent
upon prover size and electrical system (NEC or ATEX Type). See Figure 1-1.

Hydraulic pump:

The hydraulic pump is a variable displacement vane-type unit driven by an electric motor. It
supplies the power necessary to overcome the plenum pressure and return the piston
upstream. Once the piston has reached the upstream position, the pump assumes a neutral
condition maintaining hydraulic pressure at no flow for minimum power consumption.

Pneumatic spring plenum:

The charge of pressurized gas in the pneumatic spring plenum supplies the energy necessary to
overcome the shaft seal friction and close the poppet valve. A portion of the charge is required
to overcome the force generated by the product pressure within the prover acting on the
actuator shaft and the detector shaft. When properly adjusted, this charge allows for minimum
pressure differential (usually only a few inches of water column) across the piston.

Mechanical description 3

Section 1: Introduction Operating and maintenance instructions

January 2015 3-9008-701 Rev J

Figure 1-1 Outline drawings - Compact prover

Typical 8”, 12”, 18”, 24”, 34” and 40” NEC Type

Typical 8”, 12”, 18”, 24”, 34” and 40” ATEX Type

4 Mechanical description

Operating and maintenance instructions Section 1: Introduction

3-9008-701 Rev J January 2015

Figure 1-1 Outline drawings - Compact prover (Continued)

Typic a l 12” Mini NEC Type

Typic a l 12” Mini ATE X Type

Mechanical description 5

Section 1: Introduction Operating and maintenance instructions

Follow all the safety and equipment limits recommended in 1.4 Technical data of this manual. It is the owner’s and/or purchaser’s responsibility to comply with these parameters.

PERSONAL PROTECTION HAZARD

Follow all parameters for the compact prover indicated below.

Failure to do so may result in injury or equipment damage.

January 2015 3-9008-701 Rev J

1.4 Technical data

Materials of construction:

Standard: 17-4 stainless steel flow tube with hard chrome plating, carbon steel pipe and flanges

Standard maximum working pressure:

8" to 24" Size: 150 lb. ANSI  285 psig (1965 kPa) @ 100.F (38.C)

260 psig (1793 kPa) @ 200.F (93.C)

8" to 24" Size: 300 lb. ANSI  740 psig (5102 kPa) @ 100.F (38.C)

675 psig (4654 kPa) @ 200.F (93.C)

8" to 24" Size: 600 lb. ANSI  480 psig (10204 kPa) @ 100.F (38.C)

1350 psig (9308 kPa) @ 200.F (93.C)

34" and 40" Size: 300 lb. ANSI  740 psig (5102 kPa) @ 100.F (38.C)

675 psig (4654 kPa) @ 120.F (49.C)

For intermediate pressures refer to ANSI B16.5

Prover size based on flow tube diameter.

Maximum working temperature:

8” to 24" Size: -20 to 200.F (-29 to 93.C)

6 Technical data

Operating and maintenance instructions Section 1: Introduction

3-9008-701 Rev J January 2015

34” and 40" Size: 20 to 120.F (-7 to 49.C)

Standard ambient temperature range: -4.F to 104.F (-20.C to 40.C)

Consult factory for other changes.

Important

Temperature span differential between tie rods and flow tube not to exceed 200.F (93.C) on
standard 8" to 24" models and 100.F (38.C) on 34” and 40" models.

Performance:

Repeatability 0.02% or better (water draw)

Standard capacities and specifications:

• Flow Range (1000:1): See Table 1-2

• Prover Nominal Base Volume (dependent on size): See Tabl e 1- 2

• Volume Ratio (Upstream/Downstream Volume): See Ta ble 1-2

• Hydraulic System: Fill with type MIL-H-5606 (Aviation Grade E Hydraulic Fluid) or

equivalent in quantities. See Table 1-1

Table 1-1 Hydraulic

Prover size System capacity

8”

12” Mini

12”

18”

24”

34”

40”

3 gal (11.4 L)

3 gal (11.4 L)

3 gal (11.4 L)

10 gal (38 L)

25 gal (95 L)

60 gal (227 L)

93 gal (352 L)

Note: Possible equivalents:

• Mobile Aero HF series

• Aeroshell 41

Technical data 7

Section 1: Introduction Operating and maintenance instructions

January 2015 3-9008-701 Rev J

Table 1-2 Standard compact prover set-up data

Nominal
prover
shipping
dimension
s (L X W X
H)

Approxima
te shipping
weight

Nominal
flow tube
dia.

Provers rate ranges
minimum maximum

Nominal
prover
base
volume

Multiplier
for stream
volume

Flowtube
I.D

Wall
thickness

Inlet/
Outlet
flange size

8”

12” Mini

12”

18”

24”

34”

40”

0.25 gpm

0.946 lpm

0.357 bph

3

0.057 m

1.0 gpm

3.78 lpm

1.43 bph

3

0.227 m

1.75 gpm

6.623 lpm

2.5 bph

3

0.397 m

3.5 gpm

13.247 lpm

5.0 bph

3

0.794 m

7.0 gpm

24.495 lpm

10.0 bph

3

1.595 m

12.6 gpm

47.691 lpm

18.0 bph

3

2.860 m

17.5 gpm

66.237 lpm

25.0 bph

3

3.972 m

ph

ph

ph

ph

ph

ph

ph

250 gpm
946 lpm
357 bph

3

57 m

ph

1000 gpm

3.780 lpm
1430 bph

3

227 m

mp

1750 gpm
6623 lpm
2500 bph

3

397 m

ph

3500 gpm
13247 lpm
5000 bph

3

794 m

ph

7000 gpm
26495 lpm
10000 bph

3

1595 m

ph

12600 gpm
47691 lpm
18000 bph

3

2860 m

ph

17500 gpm
66237 lpm
25000 bph

3

3972 m

ph

5 gal
(20 liters)

10 gal
(40 liters)

15 gal
(60 liters)

30 gal
(120 liters)

65 gal
(250 liters)

100 gal
(400 liters)

170 gal
(650 liters)

0.990590 8.250
(20.955
cm)

0.991670 12.250
(31.115
cm)

0.991670 12.250
(31.115
cm)

0.993020 17.500
(44.450
cm)

0.993464

Pre 2006

25.500
(64.770
cm)

.992369

0.988536 34.00
(86.360
cm)

0.985938 40.00
(101.60
cm)

0.6875
(1.746 cm)

0.8750
(2.222 cm)

0.8750
(2.222 cm)

1.2500
(3.175 cm)

1.0625
(2.699 cm)

1.2500
(3.175 cm)

1.500
(3.810cm)

2” 121" x 56" x

50" (307cm
x 142cm x
127cm)

4” 147" x 62" x

55" (373cm
x 157cm x
140cm)

6” 172" x 67 x

57" (437cm
x 170cm x
145cm)

8” 193" x 76" x

56" (490cm
x 193cm x
142cm)

12” 220" x 96" x

66" (559cm
x 244cm x
168cm)

16” 230" x 102"

x 74"
(584cm x
259cm x
188cm)

20” 240" x

130"x77"
(610cm x
330cm x
196cm)

2,200 lbs
(998 kgs)

4,400 lbs
(1,995 kgs)

4,900 lbs
(2,223 kgs)

7,300 lbs
(3,311 kgs)

13,400 lbs
(6,078 kgs)

19,200 lbs
(8,709 kgs)

35,000 lbs
(13,876
kgs)

Notes:

1. Temperature and pressure tap on the outlet flange (1” dia.) can be supplied upon
request.

2. Fluid viscosity ranges up to 10,000 centistokes.

3. Considerations for meter type and pulse output quality should be made for all compact
prover applications.

4. Compact prover performance depends upon the quality of the pulse signal from the
meter being proved.

8 Technical data

Operating and maintenance instructions Section 1: Introduction

3-9008-701 Rev J January 2015

5. For more information on pulse quality and compact provers, reference API Chapter 4.2.

6. For certified dimensional drawings, please contact the factory.

7. Upstream multipliers are approximate. Actual values can be obtained from the Base
Volume Certification (water draw) method.

Table 1-3 Power requirements

Size

8” and 12” Mini

12”

AC line voltage,
frequency and
phase

115/60/1

220/50/1 &230/60/1

380/50/3

415/50/3

460/60/3

115/60/1

220/50/1 & 230/60/1

380/50/3

415/50/3

460/60/3

115/60/1

220/50/1 & 230/60/1

Hydraulic system
motor full load
amps

13.4

6.7

3.0

2.7

2.2

19

8.4

3.0

2.7

2.2

19

19

Hydraulic system
motor
configuration

1Hp Single 10

1 Hp Single 5

1.5 Hp Single .2

1.5 Hp Single .2

1.5 Hp Single 5

1.5 Hp Single

1.5 Hp Dual, 2 Circuits .2

1.5 Hp Dual, 1 Circuit .2

Hydraulic control
valve in-rush
amperage

10

5

.2

.2

5

380/50/3

18”

24”

Technical data 9

415/50/3

460/60/3

690/50/3

230/60/3

380/50/3

415/50/3

460/60/3

690/50/3

9.4

8.2

6.5

4.8

13

9.4

8.2

6.5

4.8

5 Hp Single .2

5 Hp Single .2

5 Hp Single .2

5 Hp Single .2

5 Hp Single

.2

.2

.2

.2

.2

Section 1: Introduction Operating and maintenance instructions

January 2015 3-9008-701 Rev J

Table 1-3 Power requirements

Size

34”

40”

AC line voltage,
frequency and
phase

230/60/3

380/50/3

415/50/3

460/60/3

690/50/3

230/60/3

380/50/3

415/50/3

460/60/3

Hydraulic system
motor full load
amps

39

22

20

19.5

12.8

50

28

26

25

Hydraulic system
motor
configuration

15 Hp Single

20 Hp Single

Hydraulic control
valve in-rush
amperage

.2

.2

.2

.2

.2

.2

.2

.2

.2

Notes:

1. Consult the factory for optional voltages not listed.

2. The operating computer must be connected to a power source separate from that of
the prover to avoid variance in signal caused by line load charge and discharge.

3. Grounding wire within power cable must be connected to the installed location
electrical system grounding bus or electrical equivalent. A supplemental grounding
cable is available as an option.

4. For provers that are not equipped with a main circuit breaker, sizing of the main circuit
breaker should be based upon the hydraulic system motor full load amperage. Follow
applicable electrical codes for proper requirements.

Connection requirements:

Reference Tab le 1 - 2 for flange sizes

Pneumatic spring plenum:

Dry compressed nitrogen is required for charging the spring plenum.

Pressure drop: (Inlet flange to outlet flange)

Approximately 11.2 psig on gasoline at maximum flow (Metric units - .79 kg km ) Piston only:
Approximately 3 inches (7.6 cm) of water during a proving pass.

Approvals: For standard provers, sizes 8” thru 24” Canadian Standards Association (CSA) for
Class 1, Division 1, Group D File Number: LR 32408-18, Class 2258-02, Process Control

10 Technical data

Operating and maintenance instructions Section 1: Introduction

3-9008-701 Rev J January 2015

Equipment for Hazardous Locations PED - sizes 12” Mini, 12”, 18” and 34”, British Standards
Institute

ATEX - 8" through 34", DEMKO 03 ATEX 0322369 (Option 1 designs only)

Ex d e ia m IIB T4

Certifications are pending for sizes not listed here.

Technical data 11

Section 1: Introduction Operating and maintenance instructions

January 2015 3-9008-701 Rev J

12 Technical data

Operating and maintenance instructions Section 2: Installation and set-up

3-9008-701 Rev J January 2015

21TOP (14)

Section 2: Installation and set-up

2.1 Installation

The compact prover may be installed permanently in a process line or used as a portable unit.
The prover is intended for above ground use and should be operated level to prevent the
formation of air pockets within the flow tube. A permanently installed standard prover should
be set up horizontally with considerations given to the accessibility of electrical power and
control operation. Consult a Daniel representative for further information regarding portable
provers.

Important

For optional vertical installation, special modifications to the prover hydraulic system and flow
tube supports will be required. The standard prover built for horizontal installation should not
be installed in a vertical position without proper modifications.

Refer to Figure 2-1 for a typical, permanent, compact prover installation in a process line.
Installation of a double block and bleed valve configuration is recommended in the process line
to assure that all metered fluid is passing through the prover. Be sure to follow API guidelines for
ANSI flanged connections and proper locating distance from the meter under test. Use gaskets
and retaining bolts of proper size and pressure rating for prover inlet and outlet flanges.
ReferenceTabl e 1 -2 for correct flange information. Consideration of available workspace around
the prover is necessary for normal operation and maintenance.

When installing this equipment, bolting must conform to the requirements of ASME B16.5
paragraph 5.3 and to the material requirements of ASME B16.5 Table 1B. Gaskets must conform
to the requirements of ASME B16.20.

It is the customer's responsibility to ensure that piping or other attachments connected to the
compact prover do not place adverse stresses on the compact prover. The design of the
compact prover has not been assessed for the effects of traffic, wind or earthquake loading.

It is the customer's responsibility to provide fire prevention measures and equipment per local
regulations.

The compact prover has been designed with a minimum of 1.5mm (1/16 inch) corrosion
allowance. The customer should implement a periodic inspection and maintenance program to
ensure that no part of the compact prover's pressure-retaining components has corrosion or
erosion exceeding this amount.

Installation 13

Section 2: Installation and set-up Operating and maintenance instructions

EXPLOSION HAZARD

Do not exceed the maximum working pressure of prover as stamped on the nameplates.

Failure to observe pressure rating limits may result in serious personal injury and equipment
damage.

January 2015 3-9008-701 Rev J

Important:

It is the customer's responsibility to install this equipment in a system that provides adequate
over-pressure protection.

Important:

Lines should be flushed thoroughly to rid piping of potentially damaging foreign material such
as welding bead, pipe scale, etc. before the prover is placed into service. A strainer of proper size
should be installed upstream of the prover to protect it from the introduction of foreign
material.

14 Installation

Operating and maintenance instructions Section 2: Installation and set-up

3-9008-701 Rev J January 2015

Figure 2-1 Typical prover installation

2.2 Set-up

2.2.1 Supplying electrical power to the compact prover

Reference Table 1-3 for standard voltage and amperage information. Optional voltage and
amperage information not listed in Table 1-3 is provided with the documentation package
(electrical schematic) shipped with every prover. If this information is not included with the
shipment, contact a local Daniel representative for assistance.

Standard provers are shipped with a multi-conductor power cable for connection to a power
supply. If an electrical conduit connection is desired, remove the existing power cable. Access to

Set-up 15

Section 2: Installation and set-up Operating and maintenance instructions

January 2015 3-9008-701 Rev J

the motor starting switch will be necessary for this conversion. Be sure to follow all applicable
electrical codes for the area of installation.

2.2.2 Connection of the operating computer

Standard provers are shipped with a control cable for connection to the operating computer. If
an electrical conduit connection is desired, remove the existing control cable. Access to the
interface enclosure will be necessary for this conversion. Be sure to follow all applicable
electrical codes for the area of installation.

The compact prover control signals are designed to worldwide control standards. This includes
digital and analog signals. The electrical schematic will define how each connection (conductor)
is used. Manuals and instructions supplied with the operational computer of choice will assist
with proper control connections. Reference Section 5.2 for additional troubleshooting
information. If you require further assistance for these connections, contact a local Daniel repre­sentative.

The operating computer will need to be properly configured for the application and must be
capable of Dual Chronometry Pulse Interpolation
computer to have a high frequency master oscillator, which counts time in 0.000001 parts of a
second.

. This calculation method requires the

This master oscillator must operate two counters, referred to here as “Time A” and “Time B”.
Time “A" must start counting when the flag trips the first detector switch. Time “B” must start
counting with the leading edge of the first flowmeter pulse after Time A has started.

Time “A” is stopped when the flag trips the final detector switch. Time “B” is stopped with the
leading edge of the first flowmeter pulse after Time “A” has stopped, (Reference Figure. 2-2).
Using the ratio of Counter Time “A” and Counter Time “B” will allow for accurately counting a
fraction of a flowmeter pulse to within 1 part in 10,000 as shown below:

K= K-Factor, or counts per unit volume, from the flowmeter

A = Time for displaced volume B = Time for whole meter pulses

C = Total number of whole meter pulses

D = Displaced volume

Qualified personnel who are knowledgeable of the computer’s operating system, configuration
variables, and compact proving applications should complete the configuration of the
operating computer.

16 Connection of the operating computer