Installation & Parts Manual
MS-Series Spherical Two-Case Meters
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Installation: M100-20 |
www.lcmeter.com |
|
Table of Contents
Description |
Page Number |
|
Safety Precautions .............................................. |
|
3 |
How LC Meters Work .......................................... |
|
4 |
Owner’s Information Packet ................................ |
|
5 |
Installation Requirements ................................... |
|
6 |
System Design Considerations .......................... |
|
7-10 |
Operation Requirements .................................... |
|
11 |
Meter Start Up and Operation ............................ |
|
12-14 |
Reversing the Meter Registration .......... |
13 |
|
Setting the Standard Adjuster ................ |
|
14 |
Meter Maintenance ............................................ |
|
15-16 |
Servicing the Drive Components ........................ |
|
17-20 |
Removing the Dust Cover ..................... |
|
17 |
Removing the Adjuster |
|
|
& Adjuster Driver Assembly ................... |
|
17-19 |
Servicing the Packing Gland ................. |
|
19 |
Packing Gland Components .................. |
|
20 |
The Retaining Plate ............................... |
|
20 |
Disassembling the Meter .................................... |
21-26 |
Draining Fluid from the Meter ................ |
21 |
Opening the Weldment Assembly ......... |
21-22 |
Removing Rotor Gears .......................... |
22-24 |
Removing the Bearing Plate & Rotors ... |
24-25 |
Removing Meter Housing Assembly...... |
25 |
Universal Joint Assembly ...................... |
26 |
Reassembling the Meter .................................... |
27-30 |
Installing the Meter ................................ |
27 |
Assembling the Meter ............................ |
27-28 |
Rotor Gear Timing ................................. |
29 |
Reassembling Weldment Assembly ...... |
30 |
Bolt Tightening Sequence .................................. |
31 |
Wrench and Socket Size Chart .......................... |
31 |
Fastener and Torque Chart ................................ |
32 |
Identification of Bolt Grades ............................... |
33 |
Troubleshooting.................................................. |
33-34 |
How to Order Replacement Parts ...................... |
35 |
Parts Breakdown ................................................ |
36-39 |
Publication Updates and Translations
The most current English versions of all Liquid Controls publications are available on our website, www.lcmeter.com. It is the responsibility of the Local Distributor to provide the most current version of LC Manuals, Instructions, and Specification Sheets in the required language of the country, or the language of the end user to which the products are shipping . If there are questions about the language of any LC Manuals, Instructions, or Specification Sheets, please contact your Local Distributor.
!WARNING
•Before using this product, read and understand the instructions.
•Save these instructions for future reference.
•All work must be performed by qualified personnel trained in the proper application, installation, and maintenance of equipment and/or systems in accordance with all applicable codes and ordinances.
•Failure to follow the instructions set forth in this publication could result in property damage, personal injury, or death from fire and/or explosion, or other hazards that may be associated with this type of equipment.
Please have the following information available when making inquiries, ordering replacement parts, or scheduling service. If a specific meter accessory is involved, please provide the model and serial number of the meter in question (see page 5).
Meter Serial Number |
________________________________________ |
|
Full Service Distributor |
|
________________________________________ |
Full Service Distributor Phone Number |
________________________________________ |
|
2
Safety Precautions
NOTICE:
This manual provides warnings and procedures that are intended to inform the owner/operator of the hazards present when using the Liquid Controls Meter on LPG and other products. The reading of these warnings and the avoidance of such hazards is strictly in the hands of the owner/operator of the equipment. Neglect of that responsibility is not within the control of the manufacturer of the meter.
SAFETY PROCEDURES:
Remember to relieve internal pressure before disassembly or inspection of the strainer, vapor eliminator, valves, POD pulser, and the front or rear covers. See “Meter Maintenance” on Page 15 for the steps to relieve internal pressure in your system.
BE PREPARED:
•Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation, and fire management.
•Provide easy access to the appropriate fire extinguishers for your product. Consult with your local fire department, state, and local codes to make sure that you are adequately prepared.
•Read this manual as well as all the literature provided in your “Owner’s Information Packet”. If you have any questions, consult your full-service distributor or call the Service Department at Liquid Controls.
IN THE EVENT OF A GAS LEAK:
In the event of a large gas leak:
Evacuate the area and notify the fire department.
In the event of a small, contained gas leak:
1.Stop the leak.
2.Prevent accidental ignition.
3.Prevent entrance of gas into other portions of the building. Some gases, such as LPG, seek lower levels, while other gases seek higher levels.
4.Evacuate all people from the danger zone.
5.See that the gas is dispersed before resuming business and operating motors. If in doubt, notify your local fire department.
IN THE EVENT OF A GAS FIRE:
In the event of large fires or fires that are spreading:
1.Evacuate the building and notify your local fire department.
2.Stop the leakage only if the equipment can safely be reached.
In the event of small, contained fires that you can safely control:
1.Stop the leakage only if the equipment can safely be reached.
2.Use the appropriate extinguisher: Class B fire extinguisher, water, fog, etc., depending on the materials. If in doubt, call your local fire department.
! WARNING
All internal pressures must be relieved before disassembly of the meter, strainer, vapor eliminator, any valves in the system, the pulse output device, or the front and rear covers. LINE PRESSURE MUST BE 0.0 PSI. See “Meter Maintenance” on Page 15 for the procedures to relieve internal
3
How LC Meters Work
Liquid Controls MS-Series meters are positive displacement flowmeters. They are designed for liquid measurement in both custody transfer and process control applications. Because of their simple design, they are easy to maintain, and can easily be adapted to a variety of systems.
The meter element (1) is designed with three cylindrical bores (2). A Blocking rotor (3) and two Displacement rotors (4,5) turn in a synchronized relationship within the bores. The three rotors are supported by bearing plates (6,7). The ends of the rotors protrude through the bearing plates. Blocking rotor gear (8) is placed on the end of the blocking rotor (3). Displacement rotor gears (9,10) are placed on the ends of the displacement rotors (4,5). These gears create the synchronized timed relationship between the three rotors.
As fluid moves through the meter element, the rotor assembly turns. The liquid is segmented into uniform sections by the turning rotors. Fluid displacement happens simultaneously. As fluid enters, another portion of the fluid is being partitioned and measured. At the same time, the fluid ahead of it is being displaced out of the meter and into the discharge line. Since the volume of the bores is known, and the same amount of fluid passes through the meter during each revolution of the blocking rotor, the exact volume of liquid that has passed through the meter can be determined.
This true rotary motion is transmitted through either the pulse output device (POD) to the encoder, or the face gear and drive shaft to the counter/register. True rotary motion output means consistent accuracy since the register indication is in precise agreement with the actual volume throughput at any given instant.
At any position in the cycle, the meter body, the blocking rotor, and at least one of the displacement rotors form a continuous capillary seal between the un-metered upstream product and the metered downstream product.
Capillary seals mean no metal-to-metal contact within the metering element. This means no wear. No wear means no increase in slippage, and no increase in slippage means no deterioration in accuracy.
Throughout the metering element, the mating surfaces are either flat surfaces or cylindrical faces and sections that are accurately machined. These relatively simple machining operations, plus the fact that there is no oscillating or reciprocating motion within the device, permit extremely close and consistent tolerances within the LC meter.
The product flowing through the meter exerts a dynamic force that is at right angles to the faces of the displacement rotors. The meter is designed so that the rotor shafts are always in a horizontal plane. These two facts result in no axial thrust. Therefore, with no need for thrust washers or thrust bearings, the rotors automatically seek the center of the stream between the two bearing plates eliminating wear between the ends of the rotors and the bearing plates.
Liquid Controls meters are made of a variety of materials to suit a variety of products. Because of our no-wear design, capillary seals, and unique rotary metering, LC meters provide unequalled accuracy, long operating life, and unusual dependability.
4
Owner’s Information Packet
Is all the documentation included with the meter? LC meters come in many variations. The information sent depends on the accessories ordered with the meter. Make an inventory of the “Owner’s Information Packet”. First, find the LC packing slip with the computer printout. Locate the serial number and the meter model number on this printout. Cross-reference the packing slip with the actual meter serial numbers.
Included in the “Owner’s Information Packet” are the following:
•Installation, Operation & Parts Manuals (for all elements supplied such as LectroCount Register, Valves, Air Eliminators, etc.)
•Bill of Materials
Record the meter serial number in the space provided on Page 2 of this manual. This page also provides a space for the full-service distributor’s name and telephone number, if applicable. Fill in this information and keep it handy. The meter serial number and model number will be required when calling for service or parts. See “How to Order Replacement Parts” on Page 35 in this manual.
Serial Plates
5
Installation Requirements
! WARNING
All internal pressures must be relieved before disassembly of the meter, strainer, vapor eliminator, any valves in the system, the pulse output device, or the front and rear covers. LINE PRESSURE MUST BE 0.0 PSI. See “Meter Maintenance” on Page 15 for the procedures to relieve internal pressure.
•Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation, and fire management.
•Provide easy access to the appropriate fire extinguishers for the product. Consult with the local fire department and state and local codes to make sure that you are adequately prepared.
•Read this manual as well as the literature provided in the “Owner’s Information Packet”. If there are any questions, consult with the full-service distributor or call the Service Department at Liquid Controls.
•Install the meter and accessories in conformance with all applicable federal, state, local, construction, electrical, and safety codes.
•Class 10 meters for LPG must be installed in accordance with the requirements of ANSI-NFPA 58 in addition to all other state and local codes.
•Before shipment, protective thread caps were placed in all meter and accessory openings. They should remain in place until ready to attach piping.
•Prior to meter installation, the entire piping system should be thoroughly flushed of all debris, with a liquid that is compatible with the construction of the meter.
•Keep all external surfaces of the meter clean.
•The meter must always be securely bolted to a platform or supporting member, regardless of the mounting position of the meter. Never “hang” a meter on the connecting pipe.
•Prevent pipe strain or stress from occurring when making meter or accessory repairs. Pipe strain and stress occur when the pipes are not supported or are not aligned correctly to the meter. The weight of the pipes must always be supported independent of the meter. This means that the meter and accessories can easily be removed without affecting the pipes or the pipe alignment. Never leave any of the pipes hanging.
•Apply pipe compound to male threads only.
•Install the meter down stream of the pump.
•Position the meter with service in mind. Provide ample work space. Removing covers can be difficult when work space is not available. Always supply a platform or support for the meter mounting.
•A meter is metallurgically designed to be physically compatible with a given type of liquid, as originally specified by the customer, and as indicated on the Serial Number Plate. A meter should not be used with a liquid different from the liquid originally specified, unless the physical characteristics and pH rating are similar and the application has been checked with Liquid Controls Sales or Engineering.
NOTE: Always request up-to-date, engineering approved, dimensional drawings before starting any construction. Do not rely on catalog pictures or drawings which are for reference only. After receiving prints, check to see that all equipment ordered is shown and that any extra pressure taps, plugs, etc. are noted and their size specified.
6
System Design Considerations
Flowmeters must be installed properly if accuracy and repeatability of measurements are to be sustained over long periods of time. The system in which the meters are to be used must have provisions for controlling flow, transitional, and no flow conditions. Pressure, both hydrostatic and hydrodynamic, must be an integral part of the variables controlled in the flowing system. Systems in which meters are to be installed must be designed to eliminate transient pressure conditions, eliminate thermally induced pressure increases, and to exclude air or vapor.
The complete system must be kept full of product at all times. The photograph below is a typical fuel delivery gantry designed for loading rail tank wagons. This particular gantry has provisions for loading 152 rail tank wagons at one time. Four different fuels are supplied to the gantry through 16 inch pipe lines which are approximately ½ mile long. The pumps are centrifugal type and are located between 100 and 300 yards from the storage tanks.
The next photograph shows a typical gantry position. From left to right, there is a supply line attached to an isolation valve, a second isolation valve and piping leading vertically to the loading arm. The meter is equipped with a dual channel, quadrature pulse
Strainer/Air
Eliminator
Supply Side
Isolation Valve
transmitter connected directly to a batch controller. The batch controller provides preset batch capability, flow rate control, and slow flow start and stop. There is one batch controller for each metering position.
MS Series Meter
Outlet Side
Isolation Valve
Pulse Output
Device (POD)
7
System Design Considerations
Design For Calibration
Field calibration of meters is essential. Calibration conducted during meter production is to confirm the meter is capable of attaining the required accuracy/linearity and repeatability.
Typically, the meter characteristics are:
Mechanical Registration
•Repeatability: Capable of .02% or better at any flow rate over entire range
•Linearity: ± .125% over a 5:1 range
•Linearity: ± .22% over a 10:1 range
•Linearity: ± .5% over a 40:1 range
Electronic Registration
•Repeatability: Capable of .02% or better at any flow rate over entire range
•Linearity: ± .1% over a 5:1 range
•Linearity: ± .1% over a 10:1 range
•Linearity: ± .15% over a 40:1 range
The meters are normally tested against a master meter that has been proven against a Weights & Measures certified, volumetric prover.
The pictures below show a properly configured meter installation and mobile master prover. The prover connections are at the right. The two valves to the left of the meter are for connecting the volumetric prover or
Proper Meter Installation
Volumetric Prover
master meter to be used for calibration. The valve mounted in the vertical line between the two horizontally mounted valves is a double-block, bleed valve used to ensure there is no leakage through the valve during calibration.
Mobile Master Proving Trolley
8
System Design Considerations
Design for Standard Mounting Arrangements
(straight through flow)
Regardless of meter mounting configuration, accessories such as the air/vapor eliminator must always be mounted in a vertical orientation to permit proper operation of the float-actuated apparatus.
Design for Special Mounting Arrangements
Special flange arrangements are available as shown.
Contact the factory for details or additional information.
Design for Hot Oil/Steam Jacket Options
Heating a meter can be accomplished by hot oil/steam jacketing the meter’s rear cover and/or packing gland boss. A heat jacketed meter does not preclude the necessity for insulating the meter and surrounding piping.
Design for Ensuring the System Remains Full of Product
The first consideration is merely filling the piping for the first time. The filling of the system must take place slowly in order to avoid pressure “spikes” or transients caused by rapid acceleration or deceleration of the liquid. Under gravity flow conditions, pressure transients in orders of magnitude larger than the available head pressure are possible.
At this time, air must be removed from the system. Make sure that a positive head condition is always present in the system (which should be designed into the system). Air or vapor in the system contributes to error in measurements while metering. Once air is removed from the system, ensure that the system design does not allow for air to re-enter the system once it is full of product.
9
System Design Considerations
Design for Thermal Shock or Expansion
Temperature considerations in system design should not be ignored. Care must be taken in the design so that zones are not created where fluid can be trapped or locked between two closed valves. For every 1°F increase in temperature, pressure in the trapped zone will increase by an amount depending on the product in the system (70 psi for LPG). A few degrees increase in ambient temperature may create a serious problem if thermal expansion pressure relief is not included in regions where the product may be trapped. Typically, the pressure setting in a thermal relief valve is set approximately 10% higher than the nominal operating pressure.
Design for Proper Flow Control
The example on Page 7 shows 152 meters monitoring the delivery of 4 different products. Thirty eight meters are used for delivery of HSD. Assume that one (1) pump is selected to supply product to the meters. Each meter measures 375 gallons per minute (GPM). The total flow capacity of the pump must be:
38 X 375 GPM or 14,250 GPM.
Once the system is in operation, product flows through the first meter when the control valve is opened. If the flow rate is not regulated, 14,250 GPM attempts to flow through the meter. The resulting overspeed will immediately damage the meter. It is critically important that a each meter location be equipped with a digital or hydraulic flow rate controller. These valves must be downstream of the meter to ensure that the meter remains full of product at all times.
Control must also be used when beginning or stopping flow. Proper control will minimize or eliminate transient pressure conditions brought on by rapid velocity changes in the system.
Commissioning
Once the metering system is installed, it is ready for commissioning. Filling the system the first time requires care and time. Ensure that the isolation valve on the inlet side of the meter is closed. Pressure the header by starting the pump. At the meter position to be commissioned, “crack” or slightly open the inlet isolation valve until flow into the meter can be heard. Allow the inlet side to remain in this slightly opened position until flow stops.
At this time, “crack” or loosen the pipe plug on top of the meter case to allow air to bleed out. Once the air is eliminated and product is present, fully tighten the plug. Open the inlet side isolation valve completely. The system must be kept full of fluid to avoid damage to the meter. If air is allowed inside the metering element, significant damage can occur as this air expands or compresses due to system flow and pressure conditions. In extreme cases, the presence of air can cause catastrophic failure of the measuring element as a result of liquid velocities and transient pressure spikes that can bend or break critical measuring elements. The rate at which the system is filled and pressurized must be controlled to eliminate the possibility of creating any pressure transients from excessive liquid velocity. Once the meter and system are filled, pressurized, and free of air, flow may begin.
Care must be taken during the initial flow condition to prevent damage to the meter or strainer due to foreign debris in the piping system. Foreign particles not removed during flushing and hydrotesting will collect in the strainer basket. Monitor the strainer differential pressure for the first month of operation. Clean the strainer basket if needed. Examine the strainer basket carefully and replace if damaged.
Assure that the thermal relief valves are installed and functioning properly.
10
Operation Requirements
The meter must remain full of product at all times.
An easy way to accomplish this is to put the meter assembly in the line below the piping center-line (a sump position). This requires adding elbows and flanges prior to installing the meter. The meter should be installed with a bypass loop, below the pipe center-line, with block valves upstream and downstream. A block valve should be located in the mainstream, labeled as the bypass valve. A word of caution: any portion of pipe system that might isolate or block flow should be provided with a pressure relief to prevent damage from thermal expansion. There are excellent benefits to this type of installation. First, the meter is kept full. Second, this type of installation allows the meter to be isolated for servicing and calibration while continuing flow through the bypass valve.
Upstream lines must be maintained full to prevent air from entering the meter. If the upstream or inlet lines are constructed in a manner which allows reverse flow, foot valves or back checks must be installed.
NOTE: Use soft seats, not cast iron swing checks.
Every meter should be calibrated under actual service and installation conditions per the API Manual of Petroleum Measurement Standards:
Chapter 4: Proving Systems
Chapter 5: Metering
Chapter 6: Metering Assemblies
Chapter 11 Section 2.3: Water Calibration of Volumetric
Provers
Chapter 12 Section 2: Calculation of Petroleum
Quantities
These chapters of the API Manual of Petroleum Measurement Standards supersede the API Standard 1101.
Provide a means of conveniently diverting liquid for calibration purposes.
Give careful attention to your system’s pumping equipment and piping because of their influence on liquid being measured as it enters the meter assembly. Systems should be made free of conditions that cause or introduce entrained air or vapor.
Follow the manufacturer’s recommendations fully when installing pumps. Give particular attention to factors like: use of foot valves, pipe size to the inlet and conformance to net positive suction head (NPSH) conditions when suction pumping is required. Following the manufacturer’s recommendations will minimize air and vapor elimination problems.
For all products, it is desirable to use flooded suctions and piping sized larger than the normal pump size.
Hydraulic shock is harmful to all components of an operating system including valves, the meter and the pump. In particular, meters must be afforded protection from shock because of their need to measure with high precision. Generally the best protection is prevention, which can be readily accomplished by adjusting valve closing rates in such a manner that shock does not occur. Shock pressure and system pressure are independent of each other.
Thermal expansion like hydraulic shock is a phenomenon that can easily damage meters and systems in general. Care should be taken in designing the system to include pressure relief valves in any portion or branch of the system that might be closed off by closure of operating valves or block valves. Note that 1°F is equivalent to an increase amount depending on the product in the system (70 psi for LPG).
! WARNING
Under normal operation, do not expose any portion of the LP-Gas system to pressures in excess of rated working pressures without an automatic safety valve to vent the over pressure discharge to a place of safety away from the operator and other people. Failure to provide such a safety relief may result in leakage or rupture of one or more of the components in the system. This can result in injury or death from the gas, a fire, or pieces of flying debris from the rupture.
When a Back Check Valve is used, an automatic safety valve must be installed to prevent pressure buildup (thermal expansion) in excess of rated working pressure in the meter housing. One automatic safety valve should be installed in each meter. Remove the pipe plug from the front cover or rear cover and insert the appropriate automatic safety valve.
11
Meter Start Up and Operation
Prior to meter start up, use extreme caution. Make sure that:
1.The meter is properly secured
2.All connections are tight
3.All valves are in the closed position
Placing your meter in operation:
Check to determine that all fittings and flanges are tight and liquid lines are closed.
Open the vapor line to the meter. Using vapor pressure only, check each joint with a liquid soap solution to see that no leaks go undetected. When all joints have been checked, admit liquid SLOWLY to avoid operation on vapor at speeds greater than the maximum indicated on the serial number plate and to insure that cover cavities do not contain vapor which can be compressed. Proper slow filling can be done by throttling the system with a valve at the meter OUTLET.
With the valve(s) open between the tank and the meter, go to the valve located down stream of the meter. Open the down stream valve slowly until the meter’s register/ counter starts to move. Do not run the meter any faster than 25% of its maximum rated flow during start-up. Once the product is flowing out the end of your system, the outlet valve can be opened all the way provided that the system is designed not to exceed the flow rate marked on the meter.
NOTE: If the valves are not manual, consult the valve manufacturer for slow flow start-up.
Filling the system with a pump:
Consult the pump manufacturer for proper pump priming. Once the pump is primed with product, proceed.
NOTE: Make sure that your pump can operate against a dead head pressure. If NOT, consult the factory for assistance.
Never operate the meter or system when partially filled with liquid, or with pockets of compressed air or vapor present. If these conditions cannot be avoided, air and vapor elimination systems may be required. If you cannot fill the meter slowly by gravity or by using a valve to throttle back the flow, consult the factory.
•Do not operate the meter at a pressure exceeding that marked on the Serial Number Plate. Under any and all pressure producing circumstances, for instance, thermal expansion and hydraulic shock, the working pressure must not exceed the indicated maximum.
•If the meter is operated at a rate greater than the maximum recommended GPM, excessive wear and premature failure may occur.
The meter can be calibrated for flows below minimum ratings if the flow remains constant and varies within narrow limits or if the product is viscous. A meter should never be run beyond the maximum flow rate determined for that class meter and/or liquid measured.
Electronic Registration
Liquid Controls’ family of LectroCount® electronic registers provide near-perfect metering accuracy over a full range of flow rates and deliver enhanced functions including: automated data collection (i.e., date, time, product, delivery quantity and more), on-site ticket generation, meter linearization, electronic temperature volume compensation, real-time communication capabilities (RF, GPS, CDPD), improved security and more.
12
Loading...