KROHNE OPTIMASS 6000 User manual

Sensor for mass flow
OPTIMASS 6000
OPTIMASS 6000OPTIMASS 6000
OPTIMASS 6000 Handbook
HandbookHandbook
Handbook
© KROHNE 02/2016 - 4001894004 - MA OPTIMASS 6000 R04 en
The documentation is only complete when used in combination with the relevant
documentation for the signal converter.
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All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without
the prior written authorisation of KROHNE Messtechnik GmbH.
Subject to change without notice.
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Copyright 2016 by
KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5 - 47058 Duisburg (Germany)
:IMPRINT :::::::::::::::::::::::::::::::::::::::
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CONTENTS
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OPTIMASS 6000
1 Safety instructions 5
1.1 Intended use ..................................................................................................................... 5
1.2 CE certification ................................................................................................................. 5
1.3 Associated documents ..................................................................................................... 5
1.4 Insulation case.................................................................................................................. 6
1.5 Pressure Equipment Directive (PED)............................................................................... 6
1.6 Dirty gas............................................................................................................................ 7
1.7 Safety instructions from the manufacturer ..................................................................... 7
1.7.1 Copyright and data protection ................................................................................................ 7
1.7.2 Disclaimer ............................................................................................................................... 8
1.7.3 Product liability and warranty ................................................................................................ 8
1.7.4 Information concerning the documentation........................................................................... 8
1.7.5 Warnings and symbols used................................................................................................... 9
1.8 Safety instructions for the operator................................................................................. 9
2 Device description 10
2.1 Scope of delivery............................................................................................................. 10
2.1.1 Meters with hygienic connections ........................................................................................ 11
2.2 Nameplates .................................................................................................................... 11
2.3 Dual Seal........................................................................................................................ 11
2.4 Temperature differential and thermal shock ................................................................ 12
3 Installation 14
3.1 General notes on installation ......................................................................................... 14
3.2 Storage ........................................................................................................................... 14
3.3 Handling.......................................................................................................................... 15
3.4 Installation conditions ....................................................................................................16
3.4.1 Supporting the meter............................................................................................................ 16
3.4.2 Mounting the meter .............................................................................................................. 17
3.4.3 Gas / liquid build up .............................................................................................................. 18
3.4.4 Side mounting ....................................................................................................................... 18
3.4.5 Cross talk .............................................................................................................................. 19
3.4.6 Flange connections............................................................................................................... 19
3.4.7 Maximum pipework forces (end loadings) ........................................................................... 20
3.4.8 Pipework reducers................................................................................................................ 20
3.4.9 Flexible connections ............................................................................................................. 21
3.4.10 Hygienic installations.......................................................................................................... 21
3.4.11 Heating and insulation ........................................................................................................ 22
3.4.12 Purge ports ......................................................................................................................... 23
3.4.13 Burst discs .......................................................................................................................... 23
3.4.14 Zero calibration................................................................................................................... 24
3.4.15 Sunshades........................................................................................................................... 24
4 Electrical connections 25
4.1 Safety instructions.......................................................................................................... 25
4.2 Electrical and I/O connections ....................................................................................... 25
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CONTENTS
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OPTIMASS 6000
5 Service 26
5.1 Spare parts availability...................................................................................................26
5.2 Availability of services .................................................................................................... 26
5.3 Returning the device to the manufacturer..................................................................... 26
5.3.1 General information.............................................................................................................. 26
5.3.2 Form (for copying) to accompany a returned device............................................................ 27
5.4 Disposal .......................................................................................................................... 27
6 Technical data 28
6.1 Measuring principle (twin tube) ..................................................................................... 28
6.2 Technical data................................................................................................................. 30
6.3 Measuring accuracy ....................................................................................................... 37
6.4 Guidelines for maximum operating pressure................................................................ 37
6.5 Dimensions and weights ................................................................................................ 42
6.5.1 Flanged versions................................................................................................................... 42
6.5.2 NAMUR dimensions .............................................................................................................. 53
6.5.3 Hygienic versions .................................................................................................................. 54
6.5.4 Heating jacket version .......................................................................................................... 57
6.5.5 Purge port option .................................................................................................................. 58
6.5.6 Burst discs ............................................................................................................................ 58
6.5.7 Burst disc option ................................................................................................................... 59
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SAFETY INSTRUCTIONS 1
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Safety instructions
1.1 Intended use
This mass flowmeter is designed for the direct measurement of mass flow rate, product density
and product temperature. Indirectly, it also enables the measurement of parameters like total
mass, concentration of dissolved substances and the volume flow. For use in hazardous areas,
special codes and regulations are also applicable and these are specified in a separate
documentation.
1.2 CE certification
This device conforms with the following EC directives:
•EMC Directive 2004/108/EC
•ATEX Directive 94/9/EC
•Low Voltage Directive 2006/95/EC
•Pressure Equipment Directive 97/23/EC
The manufacturer declares conformity and the device carries the CE mark.
1.3 Associated documents
This handbook should be read in conjunction with relevant documents in relation to:
•hazardous areas
•communications
•concentration
•corrosion
CAUTION!
Responsibility for the use of the measuring devices with regard to suitability, intended use and
corrosion resistance of the used materials against the measured fluid lies solely with the
operator.
INFORMATION!
This device is a Group 1, Class A device as specified within CISPR11:2009. It is intended for use in
industrial environment. There may be potential difficulties in ensuring electromagnetic
compatibility in other environments, due to conducted as well as radiated disturbances.
INFORMATION!
The manufacturer is not liable for any damage resulting from improper use or use for other than
the intended purpose.
CE marking
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1SAFETY INSTRUCTIONS
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1.4 Insulation case
On meters fitted with an insulation case, the case will be filled with one of the following
materials:
Cryogenic meters
Cryogenic metersCryogenic meters
Cryogenic meters (-200°C...+40°C / -364°F...+104°F)
Block grade EPS 1112A (Polystyrene) containing flame retardant additive (FRA)
Standard meters
Standard metersStandard meters
Standard meters (-70°C...+230°C / -94°F...+446°F)
Glass mineral wool
High temperature meters
High temperature metersHigh temperature meters
High temperature meters (-50°C...+400°C / -58°F...+752°F)
Silicon dioxide based mineral wool
Do not open the insulation case. Some, or all, of the above materials can cause:
•skin irritation
•throat and lung irritation
•eye irritation
Install the meter so that water cannot get into the insulation case. Water will damage the
insulation material and reduce performance.
1.5 Pressure Equipment Directive (PED)
To ensure the PED integrity of the meter, you MUST check that the serial numbers on the
converter nameplate and the sensor nameplate are the same.
To comply with the requirements of the Pressure Equipment Directive (PED) the manufacturer
provides all the relevant technical data in the technical data section of this handbook. Secondary
pressure containment is NOT supplied on this meter.
LEGAL NOTICE!
The Pressure Equipment Directive places legal requirements on both the manufacturer and the
end user. Please read this section carefully!
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SAFETY INSTRUCTIONS 1
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Tube failure
Where the meter is being used to measure high pressure gasses and / or gasses kept as liquids
by high pressure and / or where there is a risk of tube failure because of the use of corrosive or
erosive fluids, frequent pressure and / or thermal cycling, seismic or other shock loading, the
burst disc option MUST be purchased. For more information, please contact your nearest
representative.
1.6 Dirty gas
Dirty gas is gas that carries sand or other solid particles. Dirty gas causes excessive wear to the
primary measuring tube that can eventually result in complete tube failure. In some situations
tube failure where gas is being measured, can be very dangerous.
1.7 Safety instructions from the manufacturer
1.7.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.
The contents and works in this document are subject to copyright. Contributions from third
parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.
The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.
We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.
DANGER!
If it is suspected that the primary measuring tube has failed, de-pressurise the meter and
remove it from service as soon as it is safe to do so.
DANGER!
If the meter is being used to measure gas and there is a risk that the gas might be dirty, you
must fit a filter upstream of the meter to catch solid particles.
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1SAFETY INSTRUCTIONS
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1.7.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect or incidental and consequential damages.
This disclaimer does not apply in case the manufacturer has acted on purpose or with gross
negligence. In the event any applicable law does not allow such limitations on implied warranties
or the exclusion of limitation of certain damages, you may, if such law applies to you, not be
subject to some or all of the above disclaimer, exclusions or limitations.
Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer reserves the right to alter the content of its documents, including this
disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable
in any way for possible consequences of such changes.
1.7.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation or operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.7.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of icons as shown below.
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SAFETY INSTRUCTIONS 1
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1.7.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
• HANDLING
HANDLINGHANDLING
HANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
i RESULT
RESULTRESULT
RESULT
This symbol refers to all important consequences of the previous actions.
1.8 Safety instructions for the operator
DANGER!
This warning refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat or hot surfaces.
DANGER!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.
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2DEVICE DESCRIPTION
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Device description
2.1 Scope of delivery
If any items are missing, please contact the manufacturer.
If your meter has flange connections, the flange specification is stamped on the outer edge of the
flange. Check that the specification on the flange is the same as your order.
Compact version
1 Mass flowmeter.
2 Carton.
3 Documentation.
4 2.5 mm and 5 mm hex head tools.
5 CD-ROM and calibration certificate.
Remote version
1 Mass flowmeter.
2 Converter. This will be either: field (as shown), wall or rack.
3 Carton.
4 2.5 mm and 5 mm hex head tools.
5 CD-ROM and calibration certificate.
6 Documentation.
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DEVICE DESCRIPTION 2
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2.1.1 Meters with hygienic connections
Inspect the condition of all seals between the meter and the process line (including seals
supplied as part of the hygienic adapter) at regular intervals and replace them as necessary.
The time between inspections must be based on the seal material and the process conditions.
2.2 Nameplates
2.3 Dual Seal
To comply with the requirements of ANSI/ISA -12.27.01-2011 “Requirements for process Sealing
Between electrical systems and Flammable or Combustible process Fluids”a secondary seal is
incorporated into all OPTIMASS / GAS products. If the primary seal fails, the secondary seal will
prevent escaping fluid reaching the electronic compartment.
Pressures and / or temperatures are limited by tube, temperature, connection and Ex limits.
Check the meter nameplates and relevant documentation for full details. On all meters
operating on gas measurement, the casing of the meter is fitted with a burst disc. If the primary
seal (tube) fails leakage will occur from the burst disc. Install the meter so that the burst disc is
pointing away from personnel.
Liquids
LiquidsLiquids
Liquids (Example model code: OPTIMASS 6000F S50 - LIQUID
Pressure and temperature data:
Pressure and temperature data:Pressure and temperature data:
Pressure and temperature data:
OPTIMASS 6000 / 6000F / 6400C -200°C...+230°C and 100...10000 kPa (Stainless Steel)
OPTIMASS 6000 / 6000F / 6400C -50°C...+230°C and 100...20000 kPa (Hastelloy®/ duplex)
OPTIMASS 6000 / 6000F - HT -50°C...+400°C and 100...10000 kPa
If the primary seal fails, the casing of the meter will fill with liquid and the meter will stop
working. The meter will notify the operator by displaying the status message "Sensor: Sensor
signal low" on the converter or PLC display. This is an indication that the primary seal (tube) has
failed and the status of the meter should be checked.
As soon as it is safe to do so, de-pressurise the process line and remove the meter. Please
contact customer service for servicing or replacement of the meter.
1 Fully welded - the O-rings between the meter and the process pipework are not supplied as standard but can be or-
dered.
2 DIN 11864-2 Form A - the O-rings between the Form A and Form B parts of the connection are not supplied as standard
but can be ordered.
3 The 11864-2 Form B is not supplied as part of this connection but it can be ordered.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
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2DEVICE DESCRIPTION
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Meter status:
Meter status:Meter status:
Meter status:
The meter will also display the mesage "Sensor: Sensor signal low" if the measuring tubes are
not completely filled with fluid. For example, if the meter is drained or re/filled.
To check the status of the meter, drain and re/fill with fluid and note the converter or PLC
display. See the relevant section of the converter handbook for a list of status messages and
diagnostics information.
If the meter continues to display the message: "Sensor: Sensor signal low" you MUST assume
that the primary seal (tubes) has failed and the appropriate action MUST be taken.
Gases
GasesGases
Gases (Example model code: OPTIMASS 6000F S50 - GAS)
Pressure / temperature data:
Pressure / temperature data:Pressure / temperature data:
Pressure / temperature data:
OPTIMASS 6000 / 6000F / 6400C -200°C...+230°C and 500... 10000 kPa (Stainless Steel)
OPTIMASS 6000 / 6000F / 6400C -50°C...+230°C and 500...20000 kPa (Hastelloy®/ duplex)
OPTIMASS 6000F - HT -50°C...+400°C and 500...10000 kPa
Pressures and/or temperatures may be further limited by tube, temperature, connection and Ex
limits. Consult the meter nameplate and relevant documentation for full details.
On all meters operating on gas measurement the casing of the meter is fitted with a burst disc. If
the primary seal (tube/s) fails leakage will occur from the burst disc. Install the meter so that the
burst disc is pointing away from personnel.
Regular maintenance of the burst disc:
Regular maintenance of the burst disc:Regular maintenance of the burst disc:
Regular maintenance of the burst disc:
Carry out regular maintenance checks on burst discs for leakage and/or blockages. On all
OPTIMASS meters, the primary seal is considered to be the measuring tube of the meter. The
materials of construction of the measuring tube/s are described within the relevant sections of
this handbook and the customer’s product and any other fluid flowing through the tube must be
compatible with the material of construction. If failure of the primary seal is suspected then the
process line should be de-pressurised and the meter removed as soon as it is safe to do so.
Please contact customer service for servicing or replacement of the meter.
2.4 Temperature differential and thermal shock
Temperature differential
Temperature differentialTemperature differential
Temperature differential
The maximum difference between ambient temperature and process (operating) temperatures
are:
INFORMATION!
At high pressures, process fluid may also leak from the meter casing. This is also an indicatioin
that the primary seal has failed.
Meter temperature range Maximum temperature differential
-200°C...+40°C / -328°F...+104°F 210°C / 410°F
-70°C...+230°C / -94°F...+446°F
-50°C...+400°C / -58°F...+752°F 380°C / 716°F
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DEVICE DESCRIPTION 2
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Thermal shock
Thermal shockThermal shock
Thermal shock
Thermal shock occurs when there is a sudden and extreme change (shift) in process
temperature. To prevent thermal shock on this meter, the manufacturer recommends that you
avoid a temperature shift greater than 100°C / 212°F, at a maximum of 40% of the nominal flow
rate.
These limits will give a minimum calculated life span for the meter of 3500 cycles for meter sizes
08...150, 2000 cycles for meter size 200 and 1000 cycles for meter size 250. Thermal shocking
below this temperature will increase the life span of the meter. For more information, please
contact your nearest representative.
Maximum temperature rate rise
Maximum temperature rate riseMaximum temperature rate rise
Maximum temperature rate rise
If the change in temperature (rate rise) is greater than 100°C / 212°F, the temperature rise must
be over a period of time. Calculate the time required for the whole temperature rise using the
table below.
These limits will provide a minimum calculated life span for the meter of 2000 cycles for meter
sizes 08...200 and 1000 cycles for meter size 250. Temperature rises below 100°C / 212°F, or
temperature rises over a longer period of time, will increase the life span of the meter.
Meter size Temp. rate rise Example
DN 08...50 6°C / 10.8°F per minute 20°C...230°C / 68°F...446°F = 35
minutes
20°C...400°C / 68°F...752°F = 80
minutes
DN 80...250 3°C / 5.4°F per minute 20°C...230°C / 68°F...446°F = 70
minutes
20°C...400°C / 68°F...752°F = 140
minutes
CAUTION!
Operation outside these limits may result in shifts in density and mass flow calibration. Repeated
shocking and / or rapid heating, may also result in premature failure of the meter. However,
higher thermal shocks and / or an increased number of cycles are possible at lower working
pressures. For more information, please contact your nearest representative.
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3INSTALLATION
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Installation
3.1 General notes on installation
3.2 Storage
•Store the device in a dry and dust-free location.
•Avoid direct exposure to the sun.
•Store the device in its original packing.
•Do not allow the ambient temperature to fall below -50°C / -58°F or rise above +85°C /
+185°F.
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
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INSTALLATION 3
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3.3 Handling
1 Use a well maintained sling to lift the meter by the spigots.
2 DO NOT lift the meter by the converter housing or the electronics stem.
3 DO NOT lift the meter by the meter body.
4 DO NOT lift the meter using the flange bolt holes.
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3INSTALLATION
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3.4 Installation conditions
3.4.1 Supporting the meter
1 Support the weight of the meter on the process pipework.
2 DO NOT leave a long pipe run between the meter and the support. This can cause damage to the meter, especially on
larger meter sizes.
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INSTALLATION 3
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3.4.2 Mounting the meter
Mounting positions
1 The meter can be mounted at an angle but it is recommended that the flow is uphill.
2 Avoid mounting the meter with the flow running downhill because it can cause siphoning. If the meter has to be mount-
ed with the flow running downhill, install an orifice plate or control valve downstream of the meter to maintain back-
pressure.
3 Horizontal mounting with flow running left to right.
4 Avoid mounting meter with long vertical runs after the meter as it can cause cavitation. Where the installation includes
a vertical run after the meter, install an orifice plate or control valve downstream to maintain backpressure.
5 The meter can be mounted vertically but it is recommended that the flow is uphill.
6 Avoid mounting the meter vertically with the flow running downhill. This can cause siphoning. If the meter has to be
installed this way, install an orifice plate or control valve downstream to maintain backpressure.
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3.4.3 Gas / liquid build up
In certain applications, the design of the meter can cause either gas or liquid to build up in the
measuring tube.
3.4.4 Side mounting
The meter can be installed with the converter (or remote junction box) on the side of the meter
so that the measuring tubes are sitting one above the other. Avoid this method of installation
where there is a two phase process flow, or where the process fluid contains gas. If this situation
cannot be avoided, please contact the manufacturer for advice.
1 Where liquids are being measured, mount the meter as shown. This will prevent gas building up in the measuring tube,
when there is no flow.
2 Where gases are being measured, mount the meter as shown. This will prevent liquids building up in the measuring
tube, when there is no flow.
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INSTALLATION 3
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3.4.5 Cross talk
Where more than one meter is being installed, a very high level of immunity to cross talk means
that the meters can be mounted within close proximity to each other. The meters can be
mounted either in series or parallel, as shown.
3.4.6 Flange connections
Tighten the flange bolts evenly and in turn.
INFORMATION!
Where the meters are installed in series, it is strongly recommended that the process pipe
diameter remains constant. For more information, please contact the manufacturer.
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Use a regular pattern to tighten the bolts evenly
3.4.7 Maximum pipework forces (end loadings)
Mass flowmeters have a maximum level of force (negative or positive) that can be applied to the
ends of the meter. Refer to the table below for permitted forces.
Please refer to the table in the technical data section of this Handbook for the maximum end
loadings.
3.4.8 Pipework reducers
Always avoid extreme step changes in pipe size. Use pipework reducers, where there is a large
difference between pipework size and meter flanges.
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