Petrol 212 Installation and operating instructions

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POSITIVE
DISPLACEMENT
FLOWMETERS
MOD.
212 - 612 - 114
INSTALLATION OPERATION AND MAINTENANCE
PETROL INSTRUMENTS S.r.l. - 04011 APRILIA (LT) - ITALY

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INSTALLATION OPERATION AND MAINTENANCE MANUAL
ED. 03
REV. 10
P.O. No. _____________
Mod. _____________
Ser. No. _____________
C. _____________
 2001 Pe rol Ins rumen s S.r.l. - Via della Tecnica, 5 - 04011 Aprilia - La ina
I is forbidden any reproduc ion of his documen , even par ial, wi hou a previous wri en approval by Pe rol Ins rumen s
S.r.l.
Pe rol Ins rumen s S.r.l. has he righ o make all he necessary changes o his documen s wi hou any advance no ice.

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Sect. Description Pag.
1. eneral 4
2. Construction 5
3. Special Conditions
(MID Measuring System) 6
4. Disposal
(MID Measuring System) 7
5. Applicable Standards
(MID Measuring System) 9
6. Limits of use,
Special Conditions and Atex Marking 10
7. Installation Instruction 11
8. Start-up and Operating Instructions 12
9. Failures Analysis 13
10. Inspection Procedures 14
11. Inner Housing Ass’y Maintenance 15
12. Spare Parts 17
13. Storage 18
14. Troubleshooting table 19
15. Drawings 21
A. Spare Parts List 24

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1
eneral
"PETROL" PD flowme ers are ins rumen s capable of measuring he volume of
flowing liquids wi h a s andard accuracy of ± 0,5% of reading for general purposes
and of ± 0,15% of reading for fiscal ransac ions.
“PETROL” PD flowme ers have been employed since many years by differen
indus ries (such as ship-building, s eel making, power genera ion plan s, refineries
and depo s, chemical, pharmaceu ical, ex ile indus ries e c.) of many coun ries
and have always sa isfied he users for heir good performances and dependable
service during he years.
This manual has been prepared for people responsible of heir ins alla ion and, a
he same ime, for people responsible of heir main enance and service.
This documen includes specific aspec s of ins alla ion, use and main enance aimed
a mi iga ing he risk of explosion associa ed wi h use in hazardous areas.
Personnel involved in ins alla ion, es ing and main enance mus possess he
qualifica ions required by Annexes F of EN 60079-14: 2014 and EN 60079-17: 2014.
The equipmen supplied already has he me allic con inui y of all i s par s. Once i
reaches i s des ina ion, he equipmen mus be connec ed o he pro ec ion sys em
by connec ing he equipmen 's grounding conduc or o he ins alla ion si e's ground
sys em. I is he responsibili y of he final ins aller o verify he correc equipo en ial
connec ion wi h he dispersan sys em of he ins alla ion si e
INVOLVED PERSONNEL ARE KINDLY REQUESTED TO READ CAREFULLY THE
PRESCRIPTIONS CONTAINED IN THIS MANUAL, MAINLY THOSE RELEVANT TO
PD FLOWMETERS INSTALLATION BEFORE THEIR START-UP.

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Construction
PD flowme ers are mainly composed of he measuring uni assembly and of he
reading uni (see dwg.1).
The reading uni , available in differen models, is ha required for he specific
applica ion.
The measuring uni assembly is composed of hree main sub-assemblies, namely:
•The ou er housing;
•The inner housing assembly;
•The coupling assembly.
The ou er housing is he par ha wi hs ands he liquid pressure and i s
cons ruc ion is in accordance o maximum expec ed pressure of flowing liquid.
The inner housing assembly is he par ha accura ely measures he volume of
flowing liquid hrough he revolu ions of he ro ors (“roo s” ype mechanism).
The coupling assembly is he par hrough which he number of ro ors revolu ions
is ransmi ed o he reading uni where are displayed he volumes me ered.

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Special Conditions
(MID Measuring System)
The measuring sys em has been evalua ed o he 2014/32/UE direc ive, and found
o be sui able for measuring liquids o her han wa er wi h an accuracy class of 0,3
according o he Annex VII of direc ive.
The me er and accessories mus remain full of produc a all imes. Ups ream lines
mus remain full o preven air from en ering he measuring sys em componen s.
If ups ream or inle lines are cons ruc ed in a manner which allows reverse flow,
foo valves or back checks mus be ins alled.
To ensure proper me er and accessory ins alla ion, adhere o he following:
Flush he en ire piping sys em prior o componen ins alla ion o rid he sys em of
all debris. Use a liquid compa ible wi h he cons ruc ion of he Pe rol Ins rumen s
componen s.

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Disposal
(MID Measuring System)
The measuremen sys em is sui able for measuremen s of liquids o her han wa er
having he charac eris ics and environmen al condi ions shown on he pla e of he
measuring sys em.
Me rological seals guaran ee he measuremen sys em from he volun ary or
involun ary al era ion of he correc func ioning and calibra ion condi ions. The seals
mus no be removed. Removal can be carried ou by he manufac urer and/or
personnel of Surveillance Bodies.
The pla e of he measuremen sys em con ains he following informa ion:
II 2G
This equipmen has been evalua ed o he Equipmen
For Po en ially Explosive A mospheres Direc ive,
2014/34/EU, and found o be sui able for use in surface
(no mines) loca ions where a high level of pro ec ion is
provided agains flammable gases, vapours, or liquids
which may exis during normal opera ion.
This equipmen has been evalua ed o he 2014/32/UE
direc ive, Annex VII and found o be sui able for
measuring liquids o her han wa er by a No ified Body
iden ified wi h number 0476.
FLUID The in ended process fluid.
FLOW MIN./MAX. The minimum flow range for which he me er is
designed o opera e.
PS MIN./MAX. The minimum and maximum working pressure o which
he equipmen should be subjec ed on a normal basis.
MMQ
Weigh s & Measures field indica ing he minimum
measured quan i y. This is he smalles volume ha can
be accura ely delivered.
VISC. MIN./MAX. The minimum and maximum viscosi y of fluid o which
he accuracy is guaran eed.
FLOW MAX. The maximum flow range for which he me er is
designed o opera e.
TEMP. MIN./MAX. Maximum empera ure for Weigh s & Measure purpose.
0476
MX
X

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ACCURACY Weigh s & Measures field for ca egory of approval.
DENS. MIN./MAX. The minimum and maximum densi y of fluid o which
he accuracy is guaran eed.
ENV.
MECH./EM./HUM. CL.
Environmen al condi ions class for mechanical, EMC and
humidi y which he me er is designed o opera e and he
accuracy is guaran eed.
PED. CAT.
This equipmen has been evalua ed o he Pressure
Equipmen Direc ive 2014/68/EU and found o be
sui able for he ca egory no ed wi h regards o volume-
pressure limi a ions found wi hin he equipmen i self.
The measuremen sys em mus be used according o he ins ruc ions and
condi ions con ained in his manual. Inspec ion, main enance and repair opera ions
mus be performed following he ins ruc ions given in his manual by qualified
personnel o guaran ee he me rological conformi y of he measuremen sys em.

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Applicable Standards
(MID Measuring System)
Direc ive 2014/32/EU - Harmoniza ion of he laws of he Member S a es rela ing o
he making available on he marke of measuring ins rumen s
Direc ive 2014/34/EU - Equipmen For Po en ially Explosive A mospheres Direc ive
Direc ive 2014/68/EU - Pressure Equipmen Direc ive
Direc ive 2014/30/EU — EMC Direc ive
OIML R117-1 - Dynamic measuring sys ems for liquids o her han wa er

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Limits of use,
Special Conditions and Atex Marking
The PD Flowme ers mus be used only and exclusively wi hin he limi s shown on
he name pla e, so only and exclusively for ype of liquid, flow ra e, empera ure,
max pressure and viscosi y specified on he namepla e (dwg. 1 ). IT IS NECESSARY
TO CAREFULLY CHECK THE DATA ON THE NAMEPLATE BEFORE STARTING
THE METER.
SPECIAL CONDITIONS FOR A SAFE USE
1. i is forbidden o use he equipmen wi h an emp y pipe
2. he ins aller/user mus ensure ha he ins alla ion posi ion is respec ed as
declared by he manufac urer for he equipmen for which a specific posi ion is
envisaged
ATEX/CE MARKING on he PD flowme ers:
II 2G Exh IIC T6 … T3 X
II -/2D
: I ’s he symbol of EC marking and i represen s ha he equipmen is
complian wi h 2014/34/UE direc ive. An EC declara ion of conformi y is included in
he documen a ion
: I ’s he symbol of Ex, and i represen s ha he equipmen is according o IEC
60079, and he ATEX guideline
II: I ’s in ended as Group II, elec rical equipmen for use wi h an explosive gas
a mosphere o her han mines suscep ible o firedamp.
2G: I iden ifies he equipmen ca egory; 2G is sui able for use in zone 1 in
presence of explosive gas and vapours inside he equipmen bu , ou side, i is no
sui able for a ex zones
2D: I iden ifies he equipmen ca egory; 2D is sui bale for use in zone 21 and 22 in
presence of dus
Exh: I iden ifies he pro ec ion for mechanical cons ruc ion
IIC: I ’s a subdivision of Group II, i iden ifies he na ure of explosive gas
a mosphere. In his case he ypical gas is hydrogen.
T6 … T3 I indica es he range of he maximum surface empera ure, which shall
be be ween 85 °C and 200 °C
Ambien Tempera ure is: -20°C ≤ Tamb. ≤ +40°C

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Installation Instruction
PRECAUTIONS
The majori y of flowme er failures are caused by infil ra ion of solid par icles from
ou er housing flanges during "inopera ive condi ions". I is herefore very impor an :
•o remove he flanges pro ec ions only immedia ely before he ins rumen
ins alla ion;
•o absolu ely preven he en ering of solid par icles in o measuring uni ass'y
during ins alla ion.
INSTRUCTIONS
During flowme er ins alla ion avoid ha deforma ion and/or s resses are induced
in o ou er housing from he connec ing pipes. IF THE PD FLOWMETER IS
EQUIPPED WITH ANCHORING PLATES, BOLT THEM STRONGLY TO AVOID
VIBRATIONS.
1. Check ha ac ual flow direc ion is he same indica ed by he arrow on he
flowme er ou er housing and/or in accordance o he "in" and "ou " name-pla es
a ached o inle and ou le flanges of he flowme er.
2. For he measure of very viscous liquid a ambien empera ure i is
recommended o provide hea ing for bo h line and flowme er (if necessary
jacke ed ype PD flowme ers are available).
4. I is recommended o provide enough space over he flowme er for op-cover
removal as well as for inner housing ass'y removal.
5. I is good prac ice o ins all a s rainer direc ly before he flowme er. However if
plan configura ion does no permi he direc coupling of flowme er and s rainer
i is impera ive o clean hroughly, before flowme er ins alla ion, he spool pipe
used for s rainer and flowme er connec ion.
6. In case of new lines and expecially in case of new and long lines flush
comple ly he lines hemselves, by pumping liquid in he piping, before
flowme er ins alla ion or, should such opera ion be imprac ical, remove he inner
housing ass'y from ou er housing when flushing he lines.
INSTALLATION EXAMPLES
1. Wherever possible ins all he flowme er on a by-pass as shown in drawing 2 for
i s easier disassembly and inspec ion.
2. When an appreciable quan i y of solid par icles is expec ed o be presen in he
flowing liquid, ins all s rainers in parallel for al erna e use or ins all wo s rainers
as shown in drawing 3.
3. In case gas bubbles are expec ed in flowing liquid, ins all a sui able deaera or as
shown in drawing 4.

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Start-up and Operating Instruction
1. For new lines le liquid flow hrough he by-pass in order o comple ely wash
away any scale races (scale remaining in he lines migh cause unusual wear of
bearings and of iming gears).
2. In he case ha PD flowme er is no ins alled on a by-pass or in he case ha he
line has no a by-pass, remove he inner housing ass'y from he PD flowme er
ou er housing flanged o he piping and le liquid flow hrough he line un il he
line i self is comple ly clean and any race of scale has been washed away.
Af er such kind of line flushing has been comple ed, ins all he inner
housing ass`y in o he ou er housing and proceed wi h he PD flowme er s ar -
up.
3. To s ar he flowme er open firs he inle valve i.e. pressurize he PD flowme er
and hen open slowly he ou le valve.
In his phase loosen he ven screw of he upper cover o remove he air /gas
even ually remained in o he flowme er.
Once he upper cover is comple ly filled wi h liquid igh en he ven screw and
proceed wi h he s ar -up.
AVOID TOO HIGH FLOW RATES AS WELL AS TOO SHORT OPENING
AND/OR CLOSING CYCLES.
4. During ini ial service periods check frequen ly he s rainer screener, even ually
cleaning i , o avoid clogging.
5. PD flowme ers main ain an high accuracy for long periods of ime when
opera ed wi hin he flow ra e range for which hey have been realized. I is
recommanded o opera e he flowme er only wi hin he flow ra e limi s
specified in he name-pla e.
6. In case flowme ers are ins alled in cold places and expecially in case of me ering
wa er in such cold places i is recommended, once measuring cycle has been
comple ed, o drain comple ly, hrough he proper drain plugs, he liquid
remained in o he flowme er o avoid damages o he housing and/or ro ors
deforma ions due o liquid (wa er) freezing.
7. Should he line where PD flowme er is ins alled be subjec o periodic flushing
wi h high empera ure s eam and/ or vapor, i is s rongly recommended,
during he flushing phase, ha inner housing ass'y is removed from he ou er
housing flanged o piping, o avoid ha sudden mechanic and hermic
shocks may damage he componen s of he measuring mechanism.

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Failure Analysis
Failures of flowme er's coun er may be caused by:
1. Solid par icles inside inner housing ass'y;
2. Ro ors in erference due o excessive wear of bearings and of iming gears;
3. Failure of coupling ass'y due o excessive wear of ransmission gears.
4. Failure of indica or uni .
In case of flowme er's coun er failure i is necessary o inspec he ins rumen
following s ep by s ep he inspec ion procedures lis ed under i em 7 and replacing,
where needed, damaged par s wi h new par s.

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Inspection Procedures
To check he inner housing ass'y i is as firs necessary o con rol whe her ro a ion
of iming gears is regular or no .
I is herefore necessary o remove he op cover of PD flowme er ou er housing
(see drawing 1) un-screwing he relevan fixing bol s and nu s.
The op cover of ou er housing may be removed oghe er wi h coun er uni .
During such an opera ion par icular care mus be used o avoid any damage of he
"fork ype" coupling sys em exis ing be ween he inner housing ass'y and coun er
uni i self.
Once removed he op-cover, he iming gears of inner housing ass'y may be
inspec ed and heir ro a ion may be checked by hands or wi h an adegua e wrench.
•Should he ro ors ro a ion be normal or uniform i is necessary o check he
movemen ransmission sys em be ween inner housing ass'y and coun er uni .
The ransmission sys em componen s are in egrally moun ed wi h he op-
cover and in he ac ual si ua ion may be easily inspec ed wi hou par icular
ins ruc ions.
•A con rary, should he ro ors ro a ion be no normal or uniform i is necessary o
pull-ou he inner housing ass'y from he ou er housing o proceed o relevan
inspec ion and main enance.

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Inner Housing Ass’y Maintenance
The inner housing ass'y is shown in drawing 5 as an ass'y and in drawing 6 as an
exploded view.
The numbers prin ed in he wo (2) above men ioned drawings, and which will be
referred o hereinaf er, are hose iden ifying he componen es lis ed in he legenda
of drawing 6.
To disassembly he ro ors i is recommended o proceed in he following way.
1. remove he inner cover (50), iming gears side, aking-ou he relevan fixing
screws (66).
2. remove he shaped ro ors pla e (48) aking-ou he relevan fixing screws (49). To
do ha i is necessary o sligh ly push upward he ro ors o avoid ha he pla e
may damage by blowing he cen ering pins be ween body and cover (13).
3. mark he rela ive posi ion of iming gears by making a recognizing sign on hem.
Such marking is necessary for he correc re-assembly of ro ors.
4. pull-ou he ro ors from inner housing ass'y, using he iming gears as pullers.
Once ro ors have been removed he ac ual condi ions of ro ors hemselves and
he wear condi ions of iming gears and of bearings may be properly evalua ed. I
is jus he case o men ion ha he rear cover is disassembled following he same
procedures men ioned under i em 1).
•TIMING GEARS
The purpose of iming gears is o synchronize he ro ors and heir rele ive
posi ion is es ablished by he cen ering pins (34). Should iming gears be
replaced i is recommended o use par icular care in he re-posi ioning of he
new gears. The iming gears are removed by unscrewing he relevan fixing
screws (37).
•BEARINGS
Should be necessary o replace he bearings (22, 59), hose la ers mus be
removed from relevan covers (14, 50), oghe er wi h he bearing holders (23,
60). To facili a e such an opera ion i is recommended o moun a screw on he
hreaded holes of he bearing holders and use hem o remove he sys em
bearing/bearing-holder.
Inner housing uni re-assembly procedures are jus he reverse of ro ors
disassembling procedures above men ioned.
However he u mos care and a en ion mus be placed o he following poin s.

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5) check and even ually adjus hrough he screw 40 he dis ance be ween he
ro ors and he bo om cover of measuring uni .
6) check ha he "clearances", i.e., he dis ances be ween he ro ors and he
dis ances be ween hose la ers and he inner uni body are uniform;
7) check ha ro or posi ion is ha corresponding o he recognizing marks
previously made on iming gears.
The PD flowme er re-assembly procedures are jus he reverse of disassembly
procedures above men ioned for inner uni ass'y check.
The u mos care mus however be pu in re-moun ing he op-cover o avoid
damages o he "fork ype" coupling (43, 44, 45) be ween inner uni ass'y and
coun er.

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Spare Parts
To order spare par s reference mus always be made o he a ached exploded-
view drawing. (see dwg. 6)
When placing order specifiy:
a) flowme er model, prin ed on name-pla e (see dwg. 1)
b) flowme er serial number, prin ed on name-pla e (see dwg. 1)
c) i em number and descrip ion of par s as specified in he a ached exploded-view
drawing (see dwg. 6)
.

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Storage
PD flowme ers are normally supplied packed inside wooden cases ha may be
easily handled wi hou damaging he ins rumen s.
For cases handling all ypes of mo or machinery and/or hand machinery generally
available a s orage houses may be used.
I is however recommended o avoid he superimposing of cases excep in case of
equal dimensions and similar gross weigh .
No special precau ions have o be aken for shor periods of s orage. I is however
recommended ha cases are possibly s ored in a closed warehouse and anyway
no lef in open areas exposed o rain, sand and wind.
In case of long periods of s orage, cases mus be s ored in a closed warehouse. In
addi ion, PD flowme ers main enance procedures mus be s ric ly followed
immedia ely af er equipmen unpacking and/or immedia ely before heir ins alla ion
and/or s ar -up.
I is in any case impera ive ha a leas he measuring uni is removed from he
ou her housing and duly checked according o i s specific main enance procedures,
before PD flowme er s ar -up.

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Troubleshooting Table
FAILURES FOR PD FLOWMETERS WITH MECHANICAL COUNTER
FAILURE CAUSE SOLUTION
The liquid flows regularly
bu he PD flowme er
does no coun
Mechanical coun er failure
Check he correc opera ion
of he mechanical coun er
Connec ion be ween
magne ic ransmission
and mechanical coun er
Check he correc opera ion
of he reduc ion gear
assembly
Connec ion be ween PD
flowme er and reduc ion
gear assembly
Check he correc opera ion
of he magne ic
ransmission
The liquid does no flow
hrough he PD flowme er
Ro ors failure Disassemble and inspec
he ro ors
Foreign bodies s uck
be ween he surfaces of
he ro ors
Remove foreign bodies and
res ore he surface of he
ro ors.
Timing gears blocked Check he correc opera ion
of he iming gears
S rainer clogged Clean he s rainer
The liquid leaks from he
junc ion be ween he fron
cover and / or rear and he
body
O-ring damaged; cover
screws no properly
screwed
Replace he O-ring and
igh en he screws of he
covers
Lack of accuracy Bushings and / or iming
gears worn
Replace he bushings and /
or iming gears

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FAILURES FOR PD FLOWMETERS WITH ELECTRONIC COUNTER
FAILURE CAUSE SOLUTION
The liquid flows regularly
bu he PD flowme er
does no coun
Elec ronic coun er failure Check he correc opera ion
of he mechanical coun er
Connec ion be ween
magne ic ransmission
and mechanical coun er
Check he correc opera ion
of he pulse ransmis er
Connec ion be ween PD
flowme er and reduc ion
gear assembly
Check he correc opera ion
of he magne ic
ransmission
The liquid does no flow
hrough he PD flowme er
Ro ors failure Disassemble and inspec
he ro ors
Foreign bodies s uck
be ween he surfaces of
he ro ors
Remove foreign bodies and
res ore he surface of he
ro ors.
Timing gears blocked Check he correc opera ion
of he iming gears
S rainer clogged Clean he s rainer
The liquid leaks from he
junc ion be ween he fron
cover and / or rear and he
body
O-ring damaged; cover
screws no properly
screwed
Replace he O-ring and
igh en he screws of he
covers
Lack of accuracy Bushings and / or iming
gears worn
Replace he bushings and /
or iming gears