Siemens SITRANS F US SONOFLO SONOKIT User manual

Manual, amendment
Order no.: FDK:521H1050
SFIDK.PS.029.Y1.02 - A5E00253229
SITRANS F US SONOFLO


Ultrasonic flowmeter
Type SONOKIT hot-tap mounted
1- and 2-track DN 200 - DN 4000
Amendment to product manuals for SONOKIT 1- and 2-tracks
[]
*085R9429*
s

SFIDK.PS.029.Y1.022
SITRANS F US SONOFLO


Contents Preface ................................................................................................................................................ 3
Location ............................................................................................................................................... 3
Construction of the sensor ............................................................................................................... 4
Measuring the SONOKIT .................................................................................................................... 8
Drilling ................................................................................................................................................. 11
Installation of the transducers ............................................................................................................. 12
Mounting of transducer ........................................................................................................................ 13
SONOKIT installation with tapping band ........................................................................................... 18
Introduction .......................................................................................................................................... 18
Installation ........................................................................................................................................... 18
Tools for hot-tap installation .............................................................................................................. 23
Description of hot-tap drilling adaptor ................................................................................................. 23
Description of hot-tap alignment tool for pipe sizes DN 300 - DN 1200 ............................................. 24
Description of angle measuring instrument ........................................................................................ 25
Description of lock tool for inserting or replacement of ultrasonic transducers .................................. 26
Ordering .............................................................................................................................................. 27

SFIDK.PS.029.Y1.02 3
SITRANS F US SONOFLO


To ensure optimum performance of the measuring equipment it is essential that the following
instructions are followed.
Location The SONOKIT sensor can be installed both indoors and
outdoors, even in exposed surroundings.
The space requirements around the pipe for retrofitting
a SITRANS F US SONOFLOultrasonic flowmeter type
SONOKIT are given in picture:
In case of large temperature differences between the
medium and the environment the sensor must be iso-
lated to avoid 2-phase flow which will result in inaccurate
measuring results.
Preface This manual describes how to install SONOKIT on filled and pressurized steel pipes (hot-tap installation).
The manual is meant as an amendment to the current SONOKIT manuals delivered with the kit and contains
only special instructions on the hot-tap installation.
Siemens Flow Instruments recommends that you are familiar with the ordinary installation on empty pipes
before getting on with a hot-tap installation and that you know how to use the special tools used with the
hot-tap installation.
It is also important that you know the limitations e.g. maximum pressure, temperature and required space.
If you have any questions, please contact Siemens Flow Instruments A/S.

SFIDK.PS.029.Y1.024
SITRANS F US SONOFLO


Construction of the
sensor
The construction of
the sensor is done
in 4 steps:
1. Marking up the
pipe
2. Installating of the
alignment tool
3. Measuring the
pipe geometry
4. Drilling and
inserting trans-
ducers
Step 1
Mark up a paper drawing as described in
product manual describing the empty pipe
installation.
Mark the centre of the top line X1 – X2 with
a centre punch. This point must form the
centre of the centre point of the alignment
tool.
Also punch points to show the transducer
holder position.
Remove the (drawing/measurement)
paper.
Step 2
Place the cradle from the alignment tool
on top of the pipe. Place the supplied awl
through the centre point of the cradle so
that the cradle is centered in the middle of
the top line X1 – X2.
Use a spirit lever to check that the cradle
is positioned horizontally on/to the pipe-
line. Move e.g. the cradle sideways no
matter whether the centre is moved a little
away from the top line. It is important for
the further installation that the alignment
tool is balanced in horizontal and vertical
positions as the adjustment takes place
by means of a spirit lever.
Spot weld the cradle 3 – 4 places, but see
to it that it can always easily be reposi-
tioned.

SFIDK.PS.029.Y1.02 5
SITRANS F US SONOFLO


Mount the alignment tool as shown. It is
recommendable to finish one sound track
at a time and when installing a two-track
meter, it is recommendable to start with
the lowest track.
Use a spirit level to control that the upper
guiding beam is positioned horizontally
and make sure that it is thoroughly fasten-
ed.
Use a spirit level to control that the vertical
guiding beams are plumb.
Shorten the transducer holder according
to the actual pipe wall thickness (t). The
shortening can be done with a grinder or
a saw. Cut parallel to the angle of the
transducer holder.
•At an angle of 45° the transducer
holder is shortened by t x 1.4.
•At an angle of 60° the transducer
holder is shortened by t x 1.15.

SFIDK.PS.029.Y1.026
SITRANS F US SONOFLO


Mount the adaptor on the shortened trans-
ducer holders. Then mount guiding
beams as shown.
Adjust the guiding beams until the trans-
ducer holders follow/aim at the marking-
out.
Make sure that the distance between the
two horizontal guiding beams are the
same on both sides of the pipe.
If not, the lower guiding beams with the
transducer holders must be adjusted.
Check that transducer holders and guid-
ing beams run parallel to the upper guid-
ing beam. A visual control or a control by
means of plumb lines will do. Both meth-
ods require that you stand on the pipe.
Tack weld the transducer holders in 3
places and check that also after the tack
welding they are positioned correctly. If
so, the complete welding can be made.
Please note that with hot-tap installations
no mounting plates are needed like is the
case with empty pipe installations.
If during the welding the transducer holder
has bended, it can be adjusted by means
of a hammer and the supplied 1½” end
cap. Check with spirit level.

SFIDK.PS.029.Y1.02 7
SITRANS F US SONOFLO


Step 3
Before proceeding it is a good idea to
measure Lmax. of the sound track just
finished. By means of a plumb line the
ends of the transducer holders are
transpositioned to the upper guiding
beam.
Lmax. can now be measured with a meas-
uring tape on the upper guiding beam.
Enter the values in the measuring report.
* Valid for standard 160 mm transducers.
With other transducer lengths, set in dimensions correspond-
ing to these lengths.
*
*
Step 1
The distance between the transducer
windows (L) is calculated based on Lmax
as shown.
The standard transducer length is
160mm. If other lengths have been or-
dered, use the new values in the calcu-
lation.

SFIDK.PS.029.Y1.028
SITRANS F US SONOFLO


Measuring the
SONOKIT
To allow theoretical calibration by the SONO
3000 signal converter the sensor geometry must
be measured.
The following sensor data must be known:
⇒θ= Angle between sound track and longi-
tudinal axis of the pipe
⇒L = Distance between transducer windows
⇒Di = Inner diameter of the pipe
⇒h = Distance between sound track and
centre axis of the pipe
∆θDN 400-3000 0.1°
∆L DN 400-1000 0.8 mm
DN 1000-2000 2.0 mm
DN 2000-3000 4.0 mm
∆Di DN 400-1000 0.8 mm
DN 1000-2000 2.0 mm
DN 2000-3000 4.0 mm
∆H DN 400-1000 0.8 mm
DN 1000-2000 2.0 mm
DN 2000-3000 4.0 mm
The table shows the required measuring accu-
racy:
Measuring the inner diameter (Di)
The inner diameter Di can be calculated
on the basis of the circumference C ac-
cording to the following formula:
(t = wall thickness)
Di = (C / π)π)
π)π)
π) - (2 x t)
Measure the angle (
θ
) of each trans-
ducer holder. To get the most accurate
value, it is recommended to take several
measurements and calculate the aver-
age of these. Then calculate the average
angle for each sound track. Enter the
values in the measuring report.
To make sure that angle meter and pipe-
line are level you may place a spirit level
on the angle meter.
Measuring the distance h between sound
track and centre axis
To determine h measure Ha and Hb with
a measuring tape or a sliding gauge and
calculate h using the formula:
Ha + Hb
h = 4
Enter h into the measuring report.

SFIDK.PS.029.Y1.02 9
SITRANS F US SONOFLO



SFIDK.PS.029.Y1.0210
SITRANS F US SONOFLO


s

SFIDK.PS.029.Y1.02 11
SITRANS F US SONOFLO


Drilling Step 4
Prepare to drill through the pipe wall with
the hot-tap drill adaptor. At first mount the
ball valve from the lock tool. Make sure
that the valve is open.
Mount the hot-tap drill adaptor on the ball
valve by means of the hook spanners
from the lock tool. Make sure that flat
gaskets and o-rings have been mounted
in the drill adaptor.
Lubricate the drill with oil. Do not use
grease as it can be difficult to flush out
and will pick up drill chips which may
damage the transducer o-ring.
Mount a standard hand-held drilling
machine on the hot-tap drill adaptor. A
drilling machine of 700 – 1000 W is
sufficient. Remember to open the valve
before drilling. Once the drilling is fin-
ished pull the drill back passed the ball
valve. Close the ball valve and demount
the drill adaptor.
It is recommended to open the ball valve
for a moment to flush out possible drill
chips and/or the drill core.
To determine the exact inside diameter
of the pipe, measure the width of the core
(t) with a sliding gauge.

SFIDK.PS.029.Y1.0212
SITRANS F US SONOFLO


Installation of the
transducers
Prepare a transducer for mounting in the
drilled transducer holder.
Demount the spring clips with the spring
clips gripper.
Remove the silicone plug and carefully
put the wires into the transducer.
To avoid liquids penetrate into the trans-
ducer during installation, mount the brass
adaptor from the lock tool on the trans-
ducers. Be careful when putting the wires
into the transducer so that they will not be
damaged when screwing on the adap-
tor.
Be careful with the mounting of the trans-
ducer. Make sure that the gasket is
mounted and not damaged.

SFIDK.PS.029.Y1.02 13
SITRANS F US SONOFLO


Mounting of trans-
ducer
Mount the transducer on the mandrel of
the lock tool.
Push the snap coupling forward until the
2 teeth of the coupling snaps in place on
the transducer.
Make sure that the lock tool is turned
back to rear position, i.e. maximum length.
Place the mandrel with transducer in the
lock tool.

SFIDK.PS.029.Y1.0214
SITRANS F US SONOFLO


Mount the hex screw nut in the end of the
mandrel.
Mount the spring clip through the nut and
mandrel.
Make sure that the gasket is mounted
and not damaged.
Mount the lock tool on the ball valve. It is
essential that both lock tool and ball
valve have been thoroughly tightened
by means of the hook spanners.

SFIDK.PS.029.Y1.02 15
SITRANS F US SONOFLO


Slowly open the valve to avoid pressure
surge.
Turn the tripod of the lock tool clockwise.
Turn the tripod of the lock tool to stop. The
tripod must be turned clockwise right to
the end. If this is not possible, the trans-
ducer may have knocked against an
edge on its way through the valve.
Use a spanner key to turn the screw nut
at the end of the mandrel approx. 10
rounds clockwise. When you feel a stop,
the transducer has been correctly
mounted.

SFIDK.PS.029.Y1.0216
SITRANS F US SONOFLO


Demount ball valve and lock tool from
the transducer holder.
Remove ball valve and lock tool from the
transducer holder.
When the transducer has been correctly
mounted, open the air nozzle to remove
the pressure in the lock tool. Close the air
release valve again. If the pressure re-
establishes, the transducer has not been
correctly mounted or the gaskets are
damaged.
Remove spring clips and screw nut.

SFIDK.PS.029.Y1.02 17
SITRANS F US SONOFLO


Pull back the snap coupling and remove
the mandrel.
Tighten the transducer by means of the
pipe wrench.
Remove the brass adaptor from the trans-
ducer by means of a fork spanner.
Mount spring clips and silicone plug.
The hot-tap installation of this transducer
is now finished. Continue with the re-
maining transducers following the same
procedure.

SFIDK.PS.029.Y1.0218
SITRANS F US SONOFLO


SONOKIT installa-
tion with tapping
band
The Siemens Flow Instruments
SONOKIT Tapping band is an ultrasonic
flow meter designed to be fitted to pipe of
circumference, pipe wall thickness and
pressure rating nominated at the time of
ordering.
The Siemens Flow Instruments
SONOKIT Tapping band is recom-
mended for installation of SONOKIT ul-
trasonic flow meters on non weldable
pipes, such as: Cast iron, Plastic pipes,
Glass reinforced plastic pipes (GRP) or
Concrete pipes.
The Siemens Flow Instruments
SONOKIT Tapping band is designed for
installation on pipes under pressure (hot-
tap) and on empty pipes.
Introduction
Installation
Unpack the Tapping band and check that all components are included. Some small items can be
misplaced during shipping and Customs inspection. If the list below does not check out, please contact
Siemens Flow Instruments.
•Each band has an associated Data Sheet with information unique to that band. If more than one band
of the same size are delivered, ensure that each Data Sheet can be identified individually with its band.
•The number of segments in the band depends upon the band circumference and pressure rating.
Check that the gap numbers stamped on the solid strips at the edge of each segment form a full
sequence.
•A set of small packets is included containing lubricant. The material embedded in the tissues is Pipe
Joint Lubricant.
Handle the segments carefully at all times, paying attention to the feathered edges of the rubber mats.
Curling or tearing of these edges can compromise the seal.
Step 1
Prepare the segments for installation by
unwinding the nuts almost off the end of
each stud.
The Fish plate which spans several studs
must be inserted between the washers
and opposing tension plate at installa-
tion.
Ensure that these fish plates are free to
move along the studs and can be cor-
rectly placed with ease.

SFIDK.PS.029.Y1.02 19
SITRANS F US SONOFLO


Step 2
Completely expose the pipe and clean
the surface for a distance equal to the
length of the band plus approx. 200 mm
each side.
Ensure all loose flakes of paint and rust
are removed. Old paint and pipe-wrap
can be retained if not forming a hard
edge which the rubber mat could not
closely follow and seal completely along.
Step 3
Spread the lubricant across the whole
surface of the rubber mat on each Tap-
ping band segment. A liberal amount
ensures adequate slip between the mat
and the pipe surface, and will not at all
degrade the sealing properties of the
band. Spread lubricant on the upper
side of the feathered edge of each mat to
promote good overlap slip.
Step 4
Place the segments in sequence start-
ing at the top of the pipe and evenly
distributing the weight on either side.
Ensure that the alignment spikes are
correctly interleaved with the studs and
the studs are in their correct slots.

SFIDK.PS.029.Y1.0220
SITRANS F US SONOFLO


The feathered edges of each mat is flat
against the pipe and not curled or caught.
The fish plates shall be correctly placed
against the tension plates and the folded
edge can be hooked beneath them.
Step 5
Run the nuts to about half-way down
each stud when a segment is placed to
ensure that the later alignment stage can
proceed easily. The work can be done
easily with a hand held drilling machine.