DANIEL 1200 Series User manual

OCTOBER 2022
DANIEL
®
LIQUID TURBINE METER
USER MANUAL
SERIES 1200 LIQUID TURBINE METER
NPS 1 THROUGH 4
Decades Proven. Field Chosen.
™

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SERIES 1200 LIQUID TURBINE METER
Contents
Part I Plan
Chapter 1 Introduction.............................................................................................................. 7
1.1 Purpose of this manual................................................................................................................ 7
1.2 Hazard messages.........................................................................................................................7
1.3 Personnel qualifications...............................................................................................................7
1.4 Warranty restrictions................................................................................................................... 9
1.5 Assistance....................................................................................................................................9
1.6 Description of the Series 1200 Liquid Turbine Meter (LTM)........................................................ 10
1.7 Agency certifications for the Series 1200 LTM............................................................................27
Chapter 2 Operating conditions and specifications...................................................................29
2.1 Operating conditions for the liquid turbine meter......................................................................29
2.2 Specifications for the LTM ......................................................................................................... 33
Chapter 3 Turbine meter handling............................................................................................39
3.1 Receive the turbine meter..........................................................................................................39
3.2 Store the turbine meter............................................................................................................. 39
Chapter 4 Prepare the turbine meter for use.............................................................................41
4.1 Lifting conditions.......................................................................................................................41
4.2 Lifting requirements for personnel.............................................................................................42
4.3 Configuration of the turbine meter............................................................................................45
Part II Install
Chapter 5 Installation prerequisites......................................................................................... 53
5.1 Pre-start checks......................................................................................................................... 53
5.2 Torque information................................................................................................................... 53
5.3 Tools required for LME disassembly/assembly............................................................................53
Chapter 6 Installation procedure..............................................................................................55
6.1 Cathodic protection...................................................................................................................55
6.2 Mechanical components assembly............................................................................................ 55
6.3 Assemble the electronic components........................................................................................ 56
Chapter 7 Testing.....................................................................................................................59
7.1 Test the turbine meter...............................................................................................................59
Part III Operate
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Chapter 8 Operation parameters..............................................................................................63
8.1 Operation overview................................................................................................................... 63
8.2 Turbine meter normal operation................................................................................................63
8.3 Back pressure calculation for the LTM........................................................................................ 63
Part IV Maintain
Chapter 9 Planned maintenance...............................................................................................67
9.1 Maintenance considerations......................................................................................................67
9.2 Tools required for mechanical components............................................................................... 67
9.3 Prepare for mechanical disassembly.......................................................................................... 68
9.4 Mechanical assembly................................................................................................................. 78
9.5 Electronics enclosure disassembly............................................................................................. 88
9.6 Electronics enclosure assembly..................................................................................................88
9.7 Replace the preamplifier............................................................................................................89
9.8 Planned maintenance tasks....................................................................................................... 90
Chapter 10 Corrective maintenance........................................................................................... 91
10.1 Turbine meter troubleshooting............................................................................................... 91
10.2 Verify the return to operational condition................................................................................91
Chapter 11 Spare parts...............................................................................................................93
11.1 Recommended spare parts...................................................................................................... 93
Chapter 12 Decommission the turbine meter............................................................................. 95
12.1 Shut down the turbine meter...................................................................................................95
12.2 Turbine meter disassembly/assembly......................................................................................95
12.3 Shipment of the meter.............................................................................................................96
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SERIES 1200 LIQUID TURBINE METER
Part I
Plan
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USER MANUAL
1
1.1
1.2
Introduction
Purpose of this manual
Daniel designed this manual to guide owners and personnel in the installation, operation
and maintenance of the Daniel Series 1200 Liquid Turbine Meter Manual,
3-9008-513. It is imperative that product owners and operation personnel read and follow
the information contained in this manual to ensure that the turbine meter is installed
correctly and is operating according to the design, certifications and safety considerations.
Hazard messages
This document uses the following criteria for hazard messages based on ANSI standards
Z535.6-2011 (R2017).
DANGER
Serious injury or death will occur if a hazardous situation is not avoided.
WARNING
Serious injury or death could occur if a hazardous situation is not avoided.
CAUTION
Minor or moderate injury will or could occur if a hazardous situation is not avoided.
NOTICE
Data loss, property damage, hardware damage, or software damage can occur if a
situation is not avoided. There is no credible risk of physical injury.
Physical access
NOTICE
Unauthorized personnel can potentially cause significant damage and/or misconfiguration
of end users' equipment. Protect against all intentional or unintentional unauthorized use.
Physical security is an important part of any security program and fundamental to
protecting your system. Restrict physical access to protect users' assets. This is true for all
systems used within the facility.
1.3 Personnel qualifications
Read and follow all instructions, dangers, warnings, and cautions to avoid personal
injury or property damage during system operation. Daniel is not responsible for
damage or injury resulting from unsafe use of products, lack of maintenance, incorrect
installation of equipment or system operation. If in doubt about any applications and
safety precautions described in this document, contact Daniel.
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SERIES 1200 LIQUID TURBINE METER
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. For further questions
about training requirements, contact your local Daniel representative.
Operations risk assessment must be used and followed in conjunction with this
document when performing all online retrieval operations.
Ensure that all end user and installation specific safety requirements are read,
understood and adhered to.
Ensure that any operator that is conducting work on the equipment, is following end
user guidelines on the use of protective equipment including, but not limited to:
•Safety helmet or hard hat
•Steel-toed shoes
•Safety glasses
•Working gloves (suitable for mechanical operations)
•Chemical resistant latex gloves or the equivalent
•Long-sleeved, fire-retardant shirt and fire-retardant trousers or full-length fire
retardant coveralls
Additional PPE may be required depending on facility requirements and MSDS
requirements, if applicable. Failure to comply may result in personnel injury.
WARNING
RISK TO PERSONNEL AND EQUIPMENT
Failure to follow the installation, operation or maintenance instructions for a Daniel
product could lead to serious injury or death from explosion or exposure to dangerous
substances. To reduce the risk:
•Comply with all information on the product, in this manual, and in any local and
national codes that apply to this product.
•Do not allow untrained personnel to work with this product.
•Use Daniel parts and work procedures specified in this manual.
NOTICE
Observe all precautionary signs posted on the equipment to avoid serious injury.
WARNING
RISK TO PERSONNEL AND EQUIPMENT
Operation of this product on pressurized lines may potentially imply operational risk for
personnel and equipment from the potential escape of hot gas or liquid, which could
result in serious injury.
Observe all precautionary signs on the equipment.
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WARNING
RISK TO PERSONNEL AND EQUIPMENT
The operation of the Daniel product involves heavy equipment handling. Observe the
following guidelines to avoid potentially serious injury:
•Be aware of your limitations and ask for assistance if needed.
•Do not attempt to lift weight beyond your capacity.
•Lift with your legs, not your back.
Note
Mechanical lifting tools may also be used in some locations to reduce risk.
NOTICE
Attending the training course for this product is not considered sufficient for operating
the tool on pressurized lines. Daniel requires a two-man crew with formal training.
Additionally, at least one of the operators must have a record of extensive field
experience and be certified for this work.
1.4
1.5
Daniel assumes no responsibility for incidents, or consequences of incidents,
occurring as a result of the use of this product by others than Daniel or its designated
personnel, and have no liability whatsoever for any such work.
Consult Daniel for more details on both training and certification.
Warranty restrictions
Visually inspect all components for shipping damage. If shipping damage is found, notify
the carrier at once. Shipping damage is not covered by the warranty. The carrier is
responsible for all repair and replacement costs resulting from shipment damage.
Assistance
The Daniel Global Service Center is organized through a network of service centers
worldwide, and supports all service requirements or technical queries. For the Product
Support Help Desk, go to: http://www.Daniel.com or contact your nearest Daniel
service provider.
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SERIES 1200 LIQUID TURBINE METER
1.6 Description of the Series 1200 Liquid Turbine
Meter (LTM)
1.6.1 General features of the turbine meter
The Daniel Series 1200 Liquid Turbine Meter (LTM) is a volumetric flow metering and
transmitting device used extensively in the petroleum industry for the accurate
measurement of liquid hydrocarbons. The turbine meter's simple configuration ensures
higher flow rates, extended flow range and sustained performance capability. This meter is
specifically designed for loading rack service where a vital characteristic is repeatability.
The turbine meter is designed for use within the guidelines of API Manual of Petroleum
Measurement Standards (MPMS), Chapter 5.3 and test procedures of API MPMS, Chapter 4
(Prover systems).
The meter consists of two main parts: Local Mounted Enclosure (LME) assembly and the
meter body housing assembly.
The LME is an explosion-proof, weather-resistant housing for dual pickoffs, as well as an
encapsulated preamplifier. It also serves as the mechanical mounting connection
necessary for local and remote accessories.
Note
Daniel offers electronic enclosures with different housing materials and electronic
configurations.
Local Mounted Enclosure (LME)
The LME consists of an electrical enclosure and a solid cover made of stainless steel. This
configuration contains a mounting bracket and a preamplifier which works with two
standard pickoff coils mounted into the meter housing.
The electrical enclosure contains an external and an internal grounding lug. The two
enclosure openings are plugged with stainless steel plugs. Refer to Operating conditions
and specifications for more specifications.
1.6.2 Operation overview of the turbine meter
Metering systems combine turbine meters and electronic instrumentation to measure
volumetric total flow and/or flow rate. Metering systems are used to provide
measurement information in fluid transport, petroleum and chemical processing, custody
transfer of liquids, blending systems, in product batching and in field or plant operations.
•Each turbine meter is comprised of a cylindrical housing that contains a precise turbine
rotor assembly. The magnetic pickoffs are mounted in a boss on the turbine meter
body.
•As fluid passes through the turbine meter, it causes the rotor to revolve with an angular
velocity proportional to flow.
•The rotor blades passing through the magnetic field of the pickoff generate a pulsing
voltage in the coil of the pickoff assembly. Each voltage pulse represents a discrete
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volume. The total number of pulses collected over a period of time represents the total
volume metered.
•The sinusoidal signal from each pickoff has a low amplitude and is not normally relied
upon for transmission distances over 6 meters (20 feet). The signal must, therefore, be
amplified. This is achieved with a preamplifier contained within the LME that is
mounted on the turbine meter.
•These pulse signals are typically transmitted to control room instrumentation, such as
flow computers, and may also be required to transmit to prover computers which
calculate, display, transmit, control or record the flow sensed by the rotor. The results
may be displayed as pulse-counts or standard engineering units, such as gallons, liters,
barrels, etc.
•All Daniel Series 1200 Liquid Turbine Meters have, as standard, the LME which is fitted
with two pickoffs and a dual channel preamplifier.
•The pickoff mountings are oriented so that the outputs from the pickups are 90º
electrically out of phase.
•Each turbine meter is precisely flow calibrated before shipment.
1.6.3 Parts lists for the Series 1200 LTM, Nominal Pipe Size
(NPS) 1-4
This section includes the necessary parts required to assemble a standard unit described in
this manual.
Configuration for LME assembly - Standard enclosure is shown below.
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SERIES 1200 LIQUID TURBINE METER
LME assembly - Standard enclosure
Figure 1-1: Part identification for a standard enclosure
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Table 1-1: Part description for a standard enclosure
Item
number
Description Part number Quantity
required
1(1) End cap solid 1-360-00-025 1
2 (1) Electronics enclosure 899-10-110-60 1
3 Plug pipe hex socket 154717-019 2
4 Grounding clamp B18934-004 2
5 Mounting bracket 899-10-230-50 1
6(2) Socket head screw 899-10-230-52 4
7 Warning tag-Hazard 899-00-228-04 1
8 Socket head screw 899-10-230-61 2
10 (3) 2818 Dual channel preamplifier 1-504-05-550 1
11 Socket head screw 899-10-230-65 2
12 Wiring diagram for 2818 Dual channel
preamplifier
899-10-228-07 1
13 O-ring NBR 2-4-9163-245 1
14 O-ring FKM 1500093-022 1
15 Washer plastic 1-562-01-827 1
16 Clamp cover 1-504-90-165 1
17 Socket head screw 1-555-27-001 1
(1) Enclosure housing and end cap material: stainless steel.
(2) Screw length varies on LTM sizes. The screws are not included in the part number package.
(3) 2818 Dual channel shown. For other preamplifier options refer to Interface parameters.
NOTICE
The joint between the LME cover and housing is a threaded joint. The joint between the
LME housing and Sensor housing is a spigot joint with a minimum axial length of 26.16
mm (1.030 in), radial length of 3.18 mm (0.125 in), and a clearance of 0.07 mm (0.0028
in).
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SERIES 1200 LIQUID TURBINE METER
LME assembly - Internal Totalizer
Figure 1-2: Part identification for the LME with Internal Totalizer
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Table 1-2: Part description for the LME with Internal Totalizer
Item
number
Description Part number Quantity
required
1(1) Cover (SS/ALUM) 899-10-230-60/70 1
2 Electronics enclosure (SS/ALUM) 899-10-110-60/70 1
3 Plug pipe hex socket 154717-019 2
4 Grounding cap B18934-004 2
5 Mounting bracket 899-10-230-50 1
6 (2) Socket head screw 899-10-230-52 4
7 Warning tag-Hazard 899-00-328-04 1
8 Socket head screw 899-10-230-61 4
10 2818 Dual channel preamplifier 1-504-05-550 1
11 Socket head screw 899-10-230-65 2
12 Wiring diagram for 2818 Dual channel
preamplifier
899-10-230-69 1
13 O-ring NBR 2-4-9163-245 1
14 O-ring FKM 1500093-022 1
15 Washer plastic 1-562-01-827 1
16 Clamp cover 1-504-90-165 1
17 Socket head screw 1-555-27-001 1
19 Display and terminal block 899-10-230-30/32 1
20 Female standoff 899-10-230-63 4
21 Machine screw 899-10-230-64 4
(1) Enclosure housing and cap material: aluminum. Optional: stainless steel.
(2) Screw length varies on LTM sizes. The screwa are not included within the part number package.
NOTICE
The joint between the LME cover and housing is a threaded joint. The joint between the
LME housing and sensor housing is a cylindrical joint which has an axial length of 25.4 mm
(1 in) and a clearance of 0.038 mm (0.0015 in).
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SERIES 1200 LIQUID TURBINE METER
Meter housing internal components - NPS 1
The information below identifies and describes the NPS 1 meter housing components.
Figure 1-3: Part identification for an NPS 1 LTM
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Table 1-3: Part description for an NPS 1 LTM
Item
number
Description Part number Quantity
required
25 Rotor 798-10-019-00 1
28 O-Ring 1500093-022 1
29 Clip 1-504-05-520 1
30 Sleeve 797-10-500-60 1
31 Hanger blade 798-10-080-00 4
32 Hanger hub 798-10-008-00 2
33 Shaft 798-10-018-00 1
34 Bearing 1505024 2
35 Spacer 798-10-073-00 1
39 Pickoff 899-00-201-00 2
54 Meter housing Class 150 799-10-311-61M 1
Class 300 799-10-331-61M 1
55 Anti-rotation bracket clamp 899-10-230-66 1
Note
For alternative materials and NACE, contact Daniel Sales and Service.
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SERIES 1200 LIQUID TURBINE METER
Meter housing internal components - NPS 1.5 through 2
The information below identifies and describes the NPS 1.5 through 2 meter housing
components.
Figure 1-4: Part identification for an NPS 1.5 through 2 LTM
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Table 1-4: Part description for an NPS 1.5 LTM
Item
number
Description Part number for
material 304 SS
Quantity
required
18 Nut 151687 1
19 Washer 151891 1
20 Flow conditioning plate 798-14-301-01 1
21 Hanger blade 798-14-070-00 3
22 Hanger hub 798-14-308-00 1
23 Bearing 155195 2
24 Spacer 798-14-073-00 1
25 Rotor 798-14-019-00 1
26 Downstream cone 798-14-013-00 1
28 O-ring 1500093-022 1
39 Pickoff 899-00-201-00 2
54 Meter housing Class 150 798-14-312-61M 1
Class 300 798-14-332-61M 1
55 Anti-rotation bracket clamp 899-10-230-66 1
Table 1-5: Part description for an NPS 2 LTM
Item
number
Description Part number for
material 304 SS
Quantity
required
18 Nut 151687 1
19 Washer 151891 1
20 Flow conditioning plate 798-16-301-01 1
21 Hanger blade 798-16-070-00 3
22 Hanger hub 798-16-308-00 1
23 Bearing 155195 2
24 Spacer 798-14-073-00 1
25 Rotor 798-16-019-00 1
26 Downstream cone 798-16-013-00 1
28 O-ring 1500093-022 1
39 Pickoff 899-00-201-00 2
54 Meter housing Class 150 798-16-312-61M 1
Class 300 798-16-332-61M 1
55 Anti-rotation bracket clamp 899-10-230-66 1
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Note
For alternative materials and NACE, contact Daniel Sales and Service.
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Meter housing internal components - NPS 3 through 4 -
Stainless steel bearing internals
The information below identifies and describes the NPS 3 through 4 stainless steel meter
housing components.
Figure 1-5: Part identification for an NPS 3 through 4 LTM - Stainless steel bearing internals
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Table 1-6: Part description for an NPS 3 LTM - Stainless steel bearing internals
Item
number
Description Part number Quantity
required
18 Nut 151687 2
20 Flow Conditioning
Plate - Thermoplastic
798-20-301-01 1
20 Flow Conditioning
Plate - Aluminum
798-20-301-02 1
25 Rotor assembly 798-20-319-00 1
28 O-ring 1500093-022 1
36 Washer 151891 1
37 Diffuser 798-20-008-00 1
38 Support fin 798-20-070-00 3
39 Pickoff 899-00-201-00 2
46 Screw (hex head) 1500615 1
47 Retaining ring
(External)
156514 1
48 Ball Bearing 155194 2
49 Retaining Ring
(External, Bowed)
1500733 2
50 Shaft 798-20-010-00 1
51 Roll pin 153569 1
52 Retaining ring 1500616 1
53 Retaining Ring
(External)
1500732 1
54 Meter housing Class 150 798-20-312-61M 1
Class 300 798-20-332-61M 1
55 Anti-rotation bracket clamp 899-10-230-66 1
Table 1-7: Part description for an NPS 4 LTM - Stainless steel bearing internals
Item
number
Description Part number Quantity
required
18 Nut 151685 2
20 Flow Conditioning
Plate - Thermoplastic
798-22-301-01 1
20 Flow Conditioning
Plate - Aluminum
788-22-301-02 1
25 Rotor assembly 798-22-319-00 1
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