Fluid Components International ST51 User Manual
ST51 MASS FLOW METER
Installation and Operation Guide
Pre-Installation
The ST51 can be specified with integral or remote electronics. The flow element has a serial number etched into the side of the
extension pipe as shown on figure A. The transmitter circuit card has a serial number noted on the board as shown in figure B. The
flow sensor and transmitter circuit have been calibrated as a matched set and should be paired together in service unless otherwise
approved by a factory technician.
Flow Direction Alignment
All sensor elements have a flow arrow indicator marked on the element assembly at the reference flat. These flow elements have
been calibrated in a particular direction and are designed to be used in service with the flow arrow facing in the same direction as
flow in the pipe stream. See Appendix C for orientation and factory calibration details.
Flow Direction
FLOW
Figure A
Serial Number
Recommended Straight Run
To optimize flow meter system performance, FCI recommends installation with a minimum of 20 pipe diameters upstream straight run
and 10 pipe diameters of downstream straight run. Where straight run limitations significantly reduce the available pipe diameters, FCI
utilizes Vortab flow conditioners to produce a transferable flow profile from the calibration installation to actual field installations.
FCI’s proprietary AVAL software is available to make flow meter installation evaluations where straight run limitations are considered.
See Fig C for recommended installation.
Figure B
Figure C
FCI Flow Meters may be installed with less than the recommended straight run, but may have performance limitations. FCI offers
Vortab flow conditioners for use in applications that have significant straight run limitations. FCI uses the AVAL application modeling software to predict meter performance in each installation. AVAL outputs are available to review prior to order placement and
will indicate performance expectations both with and without Vortab Flow Conditioning.
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FLUID COMPONENTS INTERNATIONAL LLC ST51 MASS FLOW
Specifications
Instrument
Media Compatibility:
Gas, Air, Compressed Air, Nitrogen
Pipe/Line Size Compatibility:
Flow Range:
Accuracy: (at >0.75 sfps [>0,21 nmps] )
Standard: ± 2% reading ± 0.5% full scale
Optional: ± 1% reading ± 0.5% full scale
Repeatability:
Temperature Compensation:
Standard: 40 °F to 100 °F [4 °C to 38 °C]
Optional: 0 °F to 250 °F [-18 °C to 121 °C]
Turndown Ratio:
Agency Approvals:
ATEX/IEC Ex: II 2 G Ex d IIC T6...T3
FM, CSA:
CRN No.: 0F0303
Warranty:
0.3 sfps to 400 sfps [0,08 mps to 122 mps]
± 0.5% reading
1 year
Biogas, Digester Gas, Methane, Natural
2" to 24" [51 mm to 610 mm]
3:1 to 100:1
II 2 D Ex tD A21 IP67 T90°C...T121°C
Class I, Div. 1, Groups B, C, D (Enclosure only)
Class I, Div. 2 Pending
Flow Transmitter
Enclosure:
ports with either 1/2" Female NPT or M20x1.5 entries.
Epoxy coated.
Operating Temperature:
Input Power:
DC: 18 Vdc to 36 Vdc (6 watts max.)
AC:
Analog Output Signals:
flow rate and/or temperature (500 ohm max impedance)
and a pulse output for total flow.
Output Pulse Source:
15VDC. Pulse width at 50% duty cycle for rates 1 to
500Hz, 0.5 second pulse width for pulse rates below 1Hz.
25mA maximum load pulsed, 10mA maximum load if state
set to normally on.
Output Pulse Sink:
width at 50% duty cycle for rates 1 to 500Hz, 0.5 second
pulse width for rates below 1Hz. Customer power source
and load not to exceed 40VDC and 150mA.
Communication Port: RS-232C. Wireless IR to PDA with
optional digital display models.
NEMA 4X [IP67], aluminum, dual conduit
0 °F to 140 °F [-18 °C to 60 °C]
85 Vac to 265 Vac (12 watts max.; CE Mark Approval
for 100 Vac to 240 Vac)
Dual 4-20 mA, configurable to
Totalized flow or alarm set point.
Totalized flow or alarm set point. Pulse
Flow Element
Installation: Insertion, variable length with 1/2" or 3/4" NPT(M)
compression fitting.
Type:
Thermal Dispersion
Material of Construction:
Hastelloy-C22 thermowell sensors, 316 stainless steel
compression fitting with Teflon or stainless steel ferrule.
Pressure (Maximum Operating without Damage):
Stainless steel ferrule: 500 psig [34 bar(g)]
Teflon ferrule: 150 psig [10 bar(g)]
Operating Temperature:
Stainless steel ferrule: 0 °F to 250 °F [-18 °C to 121 °C]
Teflon ferrule: 0 °F to 200 °F [-18 °C to 93 °C]
Process Connection:
steel or Teflon ferrule.
Insertion Length (Field Adjustable):
1" to 6" [25 mm to 152 mm]
1" to 12" [25 mm to 305 mm]
1" to 18" [25 mm to 457 mm]
316L stainless steel body with
1/2" MNPT or 3/4" MNPT with stainless
Digital Display:
measured value and engineering units. Top line assigned to
flow rate, second line user assignable to temperature
reading, flow totalizer or alternating. Display can be
rotated in 90° increments for optimum viewing orientation.
Installation and Mounting:
or remote mountable
up to 50' [15 m].
Two-line x 16 character LCD; displays
Integral with sensor element
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Installing Flow Element
Insertion Depth
Warning: The element is shipped with a protective sleeve surrounding the flow element. After removing the sleeve,
take care to prevent the element from sliding through the compression fitting and contacting the opposing wall with any
force as it may cause damage to the element and potentially upset the calibration.
The ST51 is available with both Teflon compression fitting ferrules and metal ferrules. While the Teflon ferrule configuration can be
readjusted, it is possible that over tightening may result in permanent positioning or damage to the extension pipe and will make
future adjustment difficult. While Teflon provides for some adjustability, it has a lower process pressure rating and is not designed
for continuous adjustments. The metal ferrule version can only be tightened down once and it becomes permanently positioned. The
Ferrule type is indicated in the instrument part number displayed on the instrument tag. This can be cross referenced to the ordering
information sheet.
All flow meters have been calibrated with the flow element located at the centerline of the pipe and flow stream as indicated in Figure
D. Couplings and threadolets come in various dimensions. Proper installation requires that the element be measured with consideration to process connection dimensions and pipe centerline. FCI recommends that the element be first installed in the line with the
compression fitting lightly tightened around the extension, then slowly move the pipe extension forward until the element is at
centerline as shown.
Warning: On top mount installations, particularly, take care to prevent the element from sliding through the compression fitting and contacting the opposing wall with any force as it may cause damage to the element and potentially upset
the calibration.
FLOW ELEMENT INSTALLATION & “U” LENGTH ADJUSTMENT
FLUID COMPONENTS
INTERNATIONAL LLC
0.000 SFPS
32.2 DEGREES F
~
~
~
~
Figure D
Note: For proper performance, element shall be installed so that tip of probe is .25 inches [ 6mm] past pipe centerline. Instrument is
specifically calibrated for centerline referenced installation. Critical for line sizes 4" [ 25mm] and smaller.
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To assist in final installation, FCI suggests making a readable mark on the extension pipe to indicate the final desired compression
fitting position that will place the element at the centerline reference once the system is tightened down into place. With the compression fitting lightly tightened , hold the element assembly along the outside of the installation, or directly above, to visually verify the
compression fitting location will ensure centerline installation. To calculate the actual “U” length dimension, take the inside diameter
of the pipe or duct divide by 2 , then add 0.25", then add for the pipe wall thickness and the process fitting offset that allows the
compression fitting to securely seat in the process port. See Figure D above.
Align the flat parellel to flow and adjust the instrument depth. Upon determination of the final compression fitting location on the
extension pipe, apply the proper thread sealant to the NPT threads, firmly tighten the compression fitting into the mating process
connection. Torque varies per application. Tighten the compression nut to the torque indicated with the corresponding ferrule
material. Manufacturer recommends 1-1/4 turns from hand tight baseline.
Ferrule Torque
Teflon 65 in – lbs
316 SST 65 ft – lbs
Instrument Wiring
Before the instrument is opened to connect power and signal, FCI recommends that the following ESD precautions be observed:
Use a wrist band or heel strap with a 1 megaohm resistor connected to ground. If the instrument is in the shop setting, there should be
a static conductive mat on the work table or floor with a 1 megaohm resistor connected to ground. Connect the instrument to ground.
Apply antistatic agents such as Static free made by Chemtronics (or equivalent) to hand tools to be used on the instrument. Keep
high static producing items away from the instrument.
The above precautions are minimum requirements. The complete use of ESD precautions can be found in the U.S. Dept of defense
handbook 263.
Warning: Only Qualified personnel are to wire or test this instrument. The operator assumes all responsibility for safe
practices while wiring and trouble shooting.
FCI recommends installing and input power disconnect switch and fuse near the instrument to interrupt power during
installation and maintenance. Operator must have power disconnected before wiring.
See Safety instructions in Appendix A for the use of the ST51 series (AC and DC versions) in Hazardous Areas
Category II (Zone 1). Approval, KEMA 08ATEX0045/IECEx KEMA08.0012 for Category 2 GD protection Ex d IIC
T6..T1, Ex tD A21 IP67 T 90°C...Τ 121°C.
Input Power
The ST51 is available with both VDC and VAC input power configurations. Customers selecting VDC input power will have a VDC
input board only. Similarly, the VAC power board is supplied only with VAC powered units. In addition, both boards are marked for
either AC or DC power. Only connect the power specified on the wiring module as shown on Figures E and F respectively. Both
VAC and VDC inputs require a Gnd wire to be connected. Input power terminal blocks are rated for 14-26 AWG.
To wire the instrument, ensure that the power is off. Pull the power and signal output wires through the port, using care not to
damage wires. FCI recommends using crimp lugs on the output wires to ensure proper connection with the terminal strip. Connect
the output wires as shown on figures E and F. Note that when the 4-20mA outputs are used simultaneously, a single return lead is
used.
Analog Output
4-20mA: The instrument is provided with a standard set up, of two 4-20mA outputs. Output 1 configured for flow and Output 2
configured for temperature. Terminal blocks rated for 14-28 AWG., 500 ohm max load per output.
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Pulse Output Activation
The ST51 provides a pulse output feature. Instruments ordered with volumetric or mass flow units will be factory set with totalizer
and pulse output activated. The mode can be changed in the field. Wiring either sink or source mode is shown in Figures E and F
below. Though only one configuration is shown with the VAC and VDC power supplies, the source or sink can be utilized with either
power input.
Sink Mode: 40 VDC Max, 150 mA max. Customer supplied power source
Source Mode: 15 VDC output, 50 mA max
VDC Power Connection
RS 232 Connection
VAC Power Connection
RS 232 Connection
Figure E
VDC Power
As Shown:
18-36VDC power connected with gnd
4-20mA connected for flow and temperature
Pulse Out in source mode
Note: In source mode, 15VDC Output max, 50mA max.
Power Disspation
AC Version
Power dissipation values under nominal conditions:
Instrument (Electronics + Sensor): 11.6 Watts
Sensor only: 0.25 Watts
Figure F
VAC Power
As Shown:
85-265 VAC power connected with gnd
4-20mA connected for flow and temperature
Pulse Out in sink mode
Note: In sink mode, 40VDC max, 150mA max customer
supplied power source.
DC Version
Power dissipation values under nominal conditions:
Instrument (Electronics + Sensor): 4.5 Watts
Sensor only: 0.25 Watts
Power dissipation values under maximum load conditions:
Instrument (Electronics + Sensor): 12 Watts
Sensor only: 0.30 Watts
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Power dissipation values under maximum load conditions:
Instrument (Electronics + Sensor): 6 Watts
Sensor only: 0.30 Watts
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Setup Interface
All parameters on this meter are set through the RS232 interface connection (P3 plug) or PDA IR interface. A jumper selection
determines which communication mode is active. The factory default communication mode is set for the RS232 interface. This
setting allows the instrument to be setup with either a FC88 hand held communicator or a computer. The FC88 is powered through the
meter and comes with the serial interface cable. If a computer interface is used, an adapter (RJ to 9 pin Computer Serial Port) is
required and may be obtained from FCI: Part No. 014108-02.
Using Windows Terminal (usually located in Accessories) execute the program by double-clicking on the Terminal Icon.
1. Go to Settings.
2. Click on Communication.
3. Set for COM1 or COM2, 9600 Baud, 8 Bit, and No Parity. Press OK
4. Press the ENTER key to see the Input Mode? prompt.
5. Enter any of the meters single letter commands to execute a function (reference complete function menu in Appendix B).
If the PDA IR interface is used for communication, then jumper JP5 needs to be moved to the alternate position, see Figure G and H.
See PDA IR Communication Interface section for more details.
An additional command line interface (CLI) is available through the RS232 port. This interface is accessed with the “Y” command
using a computer or FC88. The command line password is “357”. See Appendix B - Table 6 for command line details.
JP5
Figure G
JP5 factory set for RS232 interface
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Figure H
JP5 set for PDA IR interface
Infra Red Communications Window
Flow Rate, Total and Temperature Indicator
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Start up and Commissioning
1. Verify all Input power and output signal wiring is correct and ready for initial power start up.
2. Apply power to instrument. The instrument will initialize in the Normal Operation Mode. All outputs will be active and instruments with the display option will indicate flow with the factory set flow unit. Allow 10 minutes for the instrument to warm up
and come to the thermal equilibrium.
The following FC88 commands are typical commands that are used during start up and commissioning:
Command Name Description
T Normal Operation Mode All outputs are active
Z Flow Unit Set-Up Select Flow Units(4 English, 4
Metric)Pipe Dimensions
W Totalizer Enable/Disable
V Output Configuration Select one of 4 Configurations:
Pulse and/or AlarmPulse factor and/or
setpoint
F K-Factor (default=1) Flow factor
N Warm Re-set Re-initialize C/B
S Totalizer Menu Enables W menu (Option)
If the instrument is installed, and the process flow is zero, the instrument should indicate 0.000.
Flow Unit Modification
Example: SCFM Flow Units and 3 inch Sch 40 round pipe size set up:
Enter Display Description
Enter menu: > From Normal Operation Mode
Z E for English M for Metric > Flow Unit Set-Up menu
E
0=SFPS, 1=SCFM, 2=SCFH, 3=LB/H,
4=GPM #
1 R round duct or S rectangular> Select Standard Ft
R Select Round Duct
Dia.: 4.0260000
Change? (Y/N)>
YEnter value: #
3.068 3 inch Sch. 40 pipe I.D.
N
Y
area: 7.3926572 CMinflow: 0.0000000
Change? (Y/N)>
Maximum flow: 462.04
Enter to continue
Cmaxflow: 462.04
Change? (Y/N)>
Y#
462.04
N
N
N
CMintemp (F): -40.00000
Change? (Y/N)>
CMaxtemp (F): 250.00000
Change? (Y/N)>
Percent of Range is: OFF
Change to ON?>
LCD Mult Factor x1
Change? (Y/N)>
N 100.0 SCFM
English units
/Min (SCFM)
3
Instrument will end up in Normal
Operation Mode
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RS232 / FC88
Menu Control and Organization
Most entries require at least two key strokes; a Capital letter and the [ENTER] key, or one or more numbers and the [ENTER] key. All
user entries begin at the input mode prompt “>”,except when the instrument is in the Main Function Mode (just press the desired
function letter and [ENTER] to make an entry).
Backspaces are made using the backspace [BKSP] key. Some entries are case sensitive between numbers and letters. Be sure the
SHIFT key is pressed to indicate the correct case. A square after the prompt caret indicates the FC88 is in lower case. A slightly
raised rectangle in the same spot indicates the FC88 is in the upper case.
It is recommended that the FC88 be plugged into the instrument before power is applied. If the FC88 is plugged in while the
instrument power is on and the FC88 does not respond, press [ENTER], if there is still no response Press [N] or cycle the power.
Note: The Zero and Span may be changed from the original calibration, provided the new values are within the original calibrated
range. i.e. If the original calibration was 1 to 100 SCFM (4-20mA), the new zero (4mA) must be equal to or greater than 1
SCFM, the new span (20mA) must be equal to or less than 100 SCFM.
Some entries require a Factory pass code. If this occurs contact FCI Field Service to continue programming the instrument. The
instrument will prompt the user when this is necessary. Do not change any parameters that require this code unless there is an absolute
understanding of the instrument's operation. The user can not exit some routines unless all entries are completed or the power is
recycled.
The top level of the menu is shown in Appendix B - Table 5. Enter the large letter in the tables below to activate a command. The user
may exit a command at any time entering “Q” [ENTER] in the menus: D, K, V, W, or Z.
C Calibration Information
Display only: A/D, Delta-R, Ref-R data values
D Diagnostics
Display only: List of unit prameters.
K Factory Calibration Settings
Display only: Cal. parameters, i.e. linearization
and temperature compensation coefficients.
R Factory Reset
Replaces user data with factory calibration data
Table 1. Diagnostics and Factory Settings
Analog out
Select 1 2 3 4
4-20mA out 1 Flow Flow Temp Temp
4-20mA out 2 Temp Flow Flow Temp
Pulse out
Select 1 2 3 4
Source out Pulse Pulse Alarm0 Alarm0
Set Factor Factor Set pt.0 Set pt.0
Set Period Period State0 State0
Set State0 State0
Units
Select E=English M=Metric
Select 0= SFPS 5 = SMPS
or 1 = SCFM 6 = NCMH
or 2 = SCFH 7 = NCMM
or 3 = LBS/H 8 = KG/H
or 4 = GPM 9 = LPM
For Volumetric or Mass Flow
Select R = Round pipe or duct
or S = Square duct
Set Diameter or Wide X High (in inches or mm)
Set CMaxflow = Maximum flow rate (span)
Set CMinflow = Minimum flow rate (zero)
Note: Changing units requires rescaling the unit (set new zero and span).
Table 2. “Z” Flow Units Set-Up and Scaling
Sink Pulse Alarm1 Pulse Alarm1
Table 3. “V” Output Configuration Set-Up
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Set Set pt.1 Factor Set pt.1
Set State1 State1 Period State1
State1
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“V” Menu Output Configuration Set Up
NOTE: The display comes up to the last setting saved and stays for 2 seconds. If N or [ENTER] is entered, the menu
proceeds to the Pulse out. If Y is entered, the display moves to the selection options and/or asks for confirmation. If you
miss the option, select [Enter] repeatedly to loop around.
Analog out
Output Mode
Selected
4-20mA #1: Flow
4-20mA #2: Temp
Change? (Y/N)>
4-20mA #1: Flow
4-20mA #2: Temp
Enter 1 to make
the selection__
4-20mA #1:
4-20mA #2: Flow
Enter 2 to make
the selection__
4-20mA #1: Temp
4-20mA #2: Flow
Enter 3 to make
the selection__
4-20mA #1: Temp
4-20mA #2: Temp
Enter 4 to make
the selection__
Pulse out
Pulse Out
Selected
Source: Pulse
Sink: Pulse
Change? (Y/N)>
Source: Pulse
Sink: Pulse
Source: Pulse
Sink: Alarm1
Source: Alarm0
Sink: Pulse
Source: Alarm0
Sink: Alarm1
Enter 1 to make
the selection #__
Enter 2 to make
the selection #__
Enter 3 to make
the selection #__
Enter 4 to make
the selection #__
PFactor: 1.000
Change? (Y/N)>
if yes
Enter new factor: ____
Sample Period: 1 second
Change? (Y/N)>
if yes
Enter new Sample Period: ____
If alarm is a selected output
Set point1: 000 Set points are in the
Change? (Y/N)>
if yes
Enter new set point: ____
Resume normal operation
Source state:
High to Low
Change to Low to High?>
Example: COMMAND V (Reference Table 3)
Case: 4-20mA #1 = flow, 4-20mA #2 = Temperature, Source Out = Pulse, Sink = Alarm
Pressing [V] [ENTER] will display “Output Mode Selected” followed by:
“4-20mA #1 = Flow” “ 4-20mA #2 = Temp” followed by
“Change? (Y/N)”
Press [ENTER] (no change).
The last saved mode will display at this point. i.e.,
“Source: Pulse” “Sink: Pulse” followed by,
“Change? (Y/N)” Select Y [Enter]. The display reads,
“Source: Pulse” “Sink: Pulse” followed by,
“Enter 1 to make the selction #.” Select [ENTER]. The next display reads,
“Source: Pulse” “Sink: Alarm” followed by,
“Enter 2 to make the selction #.” Select 2 and [ENTER]. The next prompt reads,
“PFactor: 1.000” “Change? (Y/N)>” (this factor can be anywhere from 0.001 to 1000 - A
pulse factor of 1.000 will output 1 pulse per unit of
flow.)
If no change, select N and/or [ENTER] to continue.
The next prompt is, “Sample Period”
“Change? (Y/N)>” (this value may be set from 0.5 to 5 seconds)
If no change, select N and/or [ENTER] to continue.
The next prompt is, “Source state: ” “High to Low” Change to “Low to High?>” (this selection toggles the pulse
signal normally high or normally
low).
[ENTER] to read display.
“Switchpt1” “0.0000000” the current set point.
“Change? (Y/N)>” enter Y [ENTER] and enter #______ . Set Point Value , i.e. 50 (value is in same units as the flow and
must be within the calibrated range). [ENTER]. The next prompt is,
“Sink state: ” “High to Low” Change to “Low to High?>”. Set the output signal to be normally “High” or
normally “Low.” Pressing [Y] [ENTER] toggles the current setting. Pressing [ENTER] resumes normal operation.
same units as the flow
or temp.
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PDA IR Communication Interface
The IR interface software is an optional accessory kit and can ordered using FCI part number 019819-01. The software is compatible
with PALM OS 4.1 or greater. If the software was ordered with the instrument, a CD should be located with the instrument documentation.
The factory has verified the following 3 PDA models. All commands meet their intended purpose and function properly.
1. Palm, Tungsten E, E2:Palm OS 5.2.1, 5.4.7
2. Palm, Zire 71, Palm OS 5.2.1
3. ecom instruments, m 515-EX, Intrinsically-safe. Palm OS 4.1
Procedure:
1. Down load the software into the target PDA. When complete, a yellow and blue FCI icon will be available.
2. Verify JP5 jumper is set in the PDA IR interface position, see Figure H.
3. Select FCI icon on PDA device.
4. The opening menu is displayed, select start.
5. Five menu groups are displayed.
Process: displays current process variables (Flow and Temperature)
ID-Unit: displays model, firmware version, serial no. …
Set-up: allows access to the following areas
Units K Factor
Line size Temp/Flow min/max
Totalizer Output Cal
LCD Output Config
Diagnostics: A/D values
Utilities: allows access to the following areas
Reset
Parameter memory
Calibration coefficients
Factory restore
Process and System Faults
6. After entering into specific menu areas, point the PDA IR port towards the Instrument display. Begin with the PDA device within
5 feet of the instrument display. Select the “Get All” or “Get” button to retrieve information from the instrument. If a value needs
to be changed, the value must first be retrieved.
Example: reading standard process variable information
1. Verify instrument and PDA are functioning.
2. Select FCI icon on the PDA.
3. Select the start button on the opening screen.
4. Select the “Process” button.
5. Point the PDA at the instrument display, start with the PDA no futher that 5 feet from the instrument.
6. Select the “Get Data” button.
7. Flow and temperature Data will begin streaming to the PDA.
8. If the IR link is interrupted, a “Command response timed out” message will be displayed.
9. Repeat the process if the link is interrupted.
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Maintenance
The FCI instrument requires little maintenance. There are no moving parts or mechanical parts subject to wear in the instrument. The
sensor assembly which is exposed to the process media is composed of 316 SS and Hastelloy C.
Without detailed knowledge of the environmental parameters of the application surroundings and process media, FCI cannot make
specific recommendations for periodic inspection, cleaning, or testing procedures. However, some suggested general guidelines for
maintenance steps are offered below. Use operating experience to establish the frequency of each type of maintenance.
Calibration
Periodically verify the calibration of the output and recalibrate if necessary. FCI recommends every 18 months at a minimum.
Electrical Connections
Periodically inspect cable connections on terminal strips and terminal blocks. Verify that terminal connections are tight and physically
sound with no sign of corrosion.
Remote Enclosure
Verify that the moisture barriers and seals protecting the electronics in the local enclosure is adequate and that no moisture is entering
the enclosure.
Electrical Wiring
FCI recommends occasional inspection of the system’s interconnecting cable, power wiring and flow element wiring on a “common
sense” basis related to the application environment. Periodically the conductors should be inspected for corrosion and the cable
insulation checked for signs of deterioration.
Flow Element Connections
Verify that all seals are performing properly and that there is no leakage of the process media. Check for deterioration of the gaskets
and environmental seals used.
Insertion Type Flow Element Assembly
Periodically remove the flow element for inspection based on historical evidence of debris, foreign matter, or scale build-up and
appropriate plant shutdown schedules and procedures. Check for corrosion, stress cracking, and/or build-up of oxides, salts, or foreign
substances. The thermowells must be free of excessive contaminants and be physically intact. Any debris or residue build-up could
cause inaccurate flow indication. Clean the flow element, as necessary, with a soft brush and available solvents (compatible with
Stainless Steel).
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Troubleshooting
Application Verification
After verifying that the flow meter is functioning, review the application parameters as shown below to verify the calibration matches
the process media.
Equipment Needed
Flow Instrument Calibration Data
Process Parameters and Limits
Check Serial Numbers
Verify that the serial number of the flow element and the flow transmitter electronics are the same. The flow element and the flow
transmitter are a matched set and cannot be operated independently of each other.
Check the Instrument Installation
Verify correct mechanical and electrical installation. Verify the flow element is mounted at least 20 diameters downstream and 10
diameters upstream from any bends or interference in the process pipe or duct.
Check for Moisture
Check for moisture on the flow transmitter. Moisture may cause intermittent operation. Check for moisture on the flow element. If a
component of the process media is near its saturation temperature it may condense on the flow element. Place the flow element where
the process media is well above the saturation temperature of any of the process gases.
Check Application Design Requirements
Application design problems may occur with first time application instruments, although the design should also be checked on
instruments that have been in operation for some time. If the application design does not match field conditions, errors occur.
1. Review the application design with plant operation personnel and plant engineers.
2. Ensure that plant equipment such as pressure and temperature instruments conform to the actual conditions.
3. Verify operating temperature, operating pressure, line size, and gas medium.
Verify Standard Versus Actual Process Conditions
The flowmeter measures the mass flow rate. The mass flow rate is the mass of the gas flowing through a pipe per time. Other flow
meters, such as an orifice plate or a pitot tube, measure the volumetric flow rate. The volumetric flow rate is the volume of gas per
time. If the readings displayed do not agree with another instrument, some calculations may be necessary before comparing them. To
calculate the mass flow rate, the volumetric flow rate, and the pressure and temperature, the point of measurement must be known. Use
the following equation to calculate the mass flow rate (Standard Volumetric Flow rate) for the other instrument:
Equation:
QQ
=× ×
SA
Where: used for pressure and temperature.)
QA= Volumetric Flow QS= Standard Volumetric Flow
PA= Actual Pressure TA= Actual Temperature
PS= Standard Pressure TS=
PSIA and °R are used for pressure and temperature units.
P
T
A
A
T
S
P
S
Standard Temperature
(Metric: Where bar(a) and °K are
Example: (Metric: PS = 1.01325 bar(a)
QA= 1212.7 ACFM QS= 1485 SCFM TS = 21.1°C (294.1K))
PA= 19.7 PSIA TA= 120°F (580°R)
PS= 14.7 PSIA TS= 70°F (530°R)
1212.7 ACFM
(
This page is subject to proprietary rights statement on last page
1
)
(
19.7 PSIA
580° R
12 Doc. No. 06EN003389 Rev. -
)
(
530° R_
14.7 PSIA
)
=1485 SCFM
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