Spirax Sarco TVA Series User manual

IM-P192-02 MI Issue 2 1
IM-P192-02
MI Issue 2
1920050/2
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Maintenance
6. Spare parts
7. Fault finding
8. Settings table
© Copyright 2016
Printed in GB
TVA Flowmeter
for Saturated and Superheated Steam Service
Installation and Maintenance Instructions

IM-P192-02 MI Issue 22
Safe operation of this unit can only be guaranteed if it is properly installed,
commissioned and maintained by a qualified person (see Section 1.11) in compliance
with the operating instructions. General installation and safety instructions for
pipeline and plant construction, as well as the proper use of tools and safety
equipment must also be complied with.
Manufacturer:-
Spirax Sarco Ltd
Charlton House
Charlton Kings
Cheltenham
Glos
GL53 8ER
The product is designed and constructed to withstand the forces encountered
during normal use.
Use of the product for any other purpose, or failure to install the product in
accordance with these Installation and Maintenance Instructions, could cause
damage to the product, will invalidate the marking, and may cause injury or
fatality to personnel.
1. Safety information
Certain computer programs contained in this product [or device] were developed
by Spirax-Sarco Limited ('the Work(s)').
Copyright © Spirax-Sarco Limited 2016
All rights reserved
Spirax-Sarco Limited grants the legal user of this product (or device) the right to
use the Work(s) solely within the scope of the legitimate operation of the product
(or device). No other right is granted under this licence. In particular and without
prejudice to the generality of the foregoing, the Work(s) may not be used, sold,
licensed, transferred, copied or reproduced in whole or in part or in any manner
or form other than as expressly granted here without the prior written consent of
Spirax-Sarco Limited.

IM-P192-02 MI Issue 2 3
EMC directive
The product complies with the Electromagnetic Compatibility Directive
2004 / 108 / EC. A technical file with a reference number of 'UK Supply TVA flowmeter'
supports the Spirax Sarco claim that the product complies with the requirements of
the Directive and the product can be used in Class A (heavy industrial) and Class B
(domestic / commercial areas).
The following conditions should be avoided as they may create interference above
the heavy industrial limits if:
-The product or its wiring is located near a radio transmitter.
-Cellular telephones and mobile radios may cause interference if used within
approximately 1 metre (39") of the product or its wiring. The actual separation
distance necessary will vary according to the surroundings of the installation
and the power of the transmitter.
If this product is not used in the manner specified by this IMI, then the protection
provided may be impaired.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical
Information Sheet, check that the product is suitable for the intended use/ application.
The product listed complies with the requirements of the European Pressure
Equipment Directive 97 / 23 / EC, carries the mark when so required.
The product falls within the following Pressure Equipment Directive categories:
Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
TVA flowmetering
system DN50 to DN100 - 1 - -
i) The product has been specifically designed for use on saturated and superheated
steam only which is in Group 2 of the above mentioned Pressure Equipment
Directive.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being fitted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature occurrence, ensure
a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may
be induced by any system to which they are fitted. It is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise
them.
v) Remove protection covers from all connections and protective film from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.

IM-P192-02 MI Issue 24
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns
and consider whether protective clothing (including safety glasses) is required.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and /or others in the vicinity require any protective clothing to
protect against the hazards of, for example, chemicals, high / low temperature,
radiation, noise, falling objects, and dangers to eyes and face.

IM-P192-02 MI Issue 2 5
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the product
according to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and /or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of some products
may reach temperatures of 250 °C (482 °F).
Many products are not self-draining. Take due care when dismantling or removing the
product from an installation (refer to 'Maintenance instructions').
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost
damage in environments where they may be exposed to temperatures below freezing
point.
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product
is recyclable and no ecological hazard is anticipated with its disposal providing due
care is taken.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment
Law, when returning products to Spirax Sarco they must provide information on
any hazards and the precautions to be taken due to contamination residues or
mechanical damage which may present a health, safety or environmental risk. This
information must be provided in writing including Health and Safety data sheets
relating to any substances identified as hazardous or potentially hazardous.

IM-P192-02 MI Issue 26
2. General product information
T h i s m a n u a l e x p l a i n s h o w t o i n s t a l l , c o m m i s s i o n a n d m a i n t a i n t h e S p i r a x S a r c o T VA  o w m e t e r
for use on saturated and superheated steam.
2.1 Product description
The Spirax Sarco TVA owmeter is designed to reduce the cost of owmetering and is used
as an accurate means to measure steam owrates and record total ow.
For saturated steam installations the TVA owmeter is a stand alone device and requires no
o t h e r e q u i p m e n t , s u c h a s d i f f e r e n t i a l p r e s s u r e t r a n s m i t t e r s , p r e s s u r e s e n s o r s , e t c . t o c a l c u l a t e
mass owrates of saturated steam.
With superheated steam installations, the addition of the pressure sensing kit is required to
ena ble mass ow r ates to be measur ed w here the relat i on b et ween pr essure and te mperat ure
has been lost (steam saturation curve).
2.2 Equipment delivery and handling
Factory shipment
Prior to shipment, the Spirax Sarco TVA owmeter is tested, calibrated and inspected to
ensure proper operation, including the wired communications.
Receipt of shipment
Each carton should be inspected at the time of delivery for possible external damage. Any
visible damage should be recorded immediately on the carrier’s copy of the delivery slip.
Each carton should be unpacked carefully and its contents checked for damage.
I f i t i s f o u n d t h a t s o m e i t e m s h a v e b e e n d a m a g e d o r a r e m i s s i n g , n o t i f y S p i r a x S a r c o i m m e d i a t e l y
and provide full details. In addition, damage must be reported to the carrier with a request
for their on-site inspection of the damaged item and its shipping carton.
Storage
If a owmeter is to be stored prior to inst allation, the environmental storage conditions should
be at a temperature between 0 °C and 55 °C (32 °F and 131 °F), and between 10% and 90%
relative humidity (non-condensing).
2.3 Sizes and pipe connections
DN50, DN80 and DN100
The TVA owmeter is of a wafer design, suitable for tting between the following anges:
EN 1092 PN16, PN25 and PN40
BS 10 Table H
ASME B 16.5 Class 150 and 300
Korean Standard KS 20.

IM-P192-02 MI Issue 2 7
Fig. 1 TVA flowmeter
TVA owmeter body
Flowmeter stem
Electronics housing
* Sensor cable
* Pressure sensor
* 'U' syphon assembly
* Items required for superheat operation
Flow
Earth
cable
Earth
cable
¼"
NPSM
boss

IM-P192-02 MI Issue 28
2.4 Pressure / temperature limits
Temperature °C
Pressure bar g
The product should not be used in this region due to the limitations of the software.
PMA Maximum allowable
pressure @ 239 °C (462 °F)
Saturated steam 32 bar g (464 psi g) otherwise as
the specied ange rating
TMA Maximum allowable temperature 239 °C (462 °F)
Minimum allowable temperature 0°C (non-freezing) (32 °F non-freezing)
PMO
Maximum
operating
pressure for
saturated
steam service
Horizontal
ow
Superheated
steam 23 bar g @ 239 °C (333 psi g @ 462 °F)
Saturated
steam 32 bar g @ 239 °C (464 psi g @ 462 °F)
Vertical
ow
Saturated
steam only 7 bar g @ 170 °C (101 psi g @ 338 °F)
Minimum operating pressure 0.6 bar g (8.7 psi g)
TMO Maximum operating temperature 239 °C (462 °F)
Minimum operating temperature 0°C (non-freezing) (32 °F non-freezing)
Maximum electronics ambient temperature 55 °C (131 °F)
Maximum electronics humidity level 90% RH (non-condensing)
PMX
Maximum
differential
pressure
The pressure drop across the TVA owmeter at the maximum
rated ow is nominally 750 m bar (300 inches wg) for the DN50,
and 500 m bar (200 inches wg) for the DN80 and DN100
Cold hydraulic test pressure of: 52 bar g (754 psi g)
Pressure psi g
Temperature °F
*
Steam
saturation
curve

IM-P192-02 MI Issue 2 9
CAUTION:
If the electronic housing is mounted at
an angle of more than 45° from the
vertically downward position the PMO
(maximum operating pressure) must
be limited to 7 bar g (101 psi g) and
saturated steam applications only.
The electronic housing must be
mounted vertically downward for all
superheated applications.
Fig. 2 Installation limiting conditions
Important note
*
Limited to
7 bar g (101 psi g)
and
saturated steam
applications
only
For saturated steam
applications
over 7 bar g (101 psi g)
to 32 bar g (464 psi g) and all
superheated applications up to
23 bar g (333.5 psi g).
High pressure syphon tube assembly
Maximum design pressure 80 bar g (1 160 psi g)
Maximum design temperature 450 °C (842 °F)
Maximum working conditions 60 bar g @ 450 °C (870 bar g @ 842 °F)
Pressure sensing kit
Maximum operating temperature 125 °C (257 °F)
Minimum operating temperature 0°C (non-freezing) (32 °F non-freezing)
Maximum operating pressure 50 bar g (725 psi g)
Maximum ambient temperature
(cable+connector) 70 °C (158 °F)

IM-P192-02 MI Issue 210
2.5 Technical data
IP rating IP65 with correct cable glands.
Power supply Loop powered nominal 24 Vdc
Outputs
4-20 mA (proportional to mass ow)
Pulsed output Vmax 28 Vdc,
Rmin 10 kW, Von 0.7 Vmax
Communication port
EIA 232C 15 m limit - See Section 4.12
RS485 for longer distances
(conversion from RS232)
Performance System uncertainty to ISO 17025
(95% condence to 2 STD)
±2% of reading over the range of 10%
to 100% of maximum rated ow
±0.2% FSD from 2% to 10% of
maximum rated ow
Turndown: up to 50:1
2.6 Electrical connections
Electrical connections M20 x 1.5
2.7 Materials
Unit Part Material
TVA
Flowmeter body Stainless steel S.316 1.4408 CF8M
Internals 431 S29 / S303 / S304 / S316
Spring Inconel X750 or equivalent
Flowmeter stem Stainless steel 300 series
Electronics housing Aluminium LM25
Pressure
sensing kit
Cable Polyvinyl chloride (PVC)
Sensor housing AISI 304 Stainless steel 1.4301
Sensor AISI 630 Stainless steel 1.4542
'O' ring Nitrile Butadiene Rubber (NBR)
Adaptor AISI 431 Stainless steel 1.4057
High pressure
syphon tube
assembly
Tube Carbon steel BS 3602: Part.1 1987 CFS 360
(zinc plated / passivated).
Valve Body Carbon steel
Seat PEEK/ Polymain

IM-P192-02 MI Issue 2 11
Fig. 3
Note: Dimension 'X' is a recommended minimum distance between the pressure tapping
and the flowmeter. However it can be installed at any distance provided the cable allows
(Standard cable length is 1 m).
F
2.8 Dimensions/weights (approximate) in mm and kg
Size AFlowmeter
OD
C D E F G X Weight
TVA Superheat
kit
'U'
syphon
DN50 35 103 322 125 65 250 160 300 2.67 0.3 0.5
DN80 45 138 334 115 65 270 160 300 4.38 0.3 0.5
DN100 60 162 344 155 65 280 160 300 7. 28 0.3 0.5
Caution:
Any free hanging cable must be
secured to prevent contact with the
steam pipe.
E
C
XD
A
G

IM-P192-02 MI Issue 212
3. Installation
Note: Before actioning any installation observe the 'Safety information' in Section 1.
To meet its specified accuracy and performance it is essential that the following installation
guidelines are followed carefully. For steam applications sound steam engineering practices
should be followed, including the use of separators. The installation must conform to all
relevant construction and electrical codes.
Fig. 5 Typical installation
TVA
owmeter with
Superheat kit
tted
Steam
Spool
piece
V3
V1
A bypass line will enable safe removal of the TVA owmeter for maintenance or calibration.
Closing valves V1 and V2 and opening valve V3 will allow the TVA owmeter to be isolated
for re-zeroing (temperature to be <20 °C).
Trap set
Separator
Strainer
CAUTION:
If the electronic housing is mounted
at an angle of more than 45° from the
vertically downward position the PMO
(maximum operating pressure) must
be limited to 7 bar g (101 psi g) and
saturated steam applications only.
The electronic housing must be
mounted vertically downward for all
superheated applications.
Fig. 4 Installation limiting conditions
Limited to
7 bar g (101 psi g)
and
saturated steam
applications
only
For saturated steam
applications
over 7 bar g (101 psi g)
to 32 bar g (464 psi g) and all
superheated applications up to
23 bar g (333.5 psi g).
V2

IM-P192-02 MI Issue 2 13
3.1 Environmental conditions
The owmeter should be located in an environment that minimises the effects of heat,
vibration, shock and electrical interference. (Pressure / temperature limits are detailed in
Section 2.4).
CAUTION: Do not lag (insulate) the TVA flowmeter or mating flanges as this may result
in excessive temperatures in the electronics. Exceeding specified temperature limits
will invalidate the warranty, adversely effect the performance and may damagethe TVA
flowmeter, see Figure 6.
Other considerations
Be sure to allow sufcient clearance for:
-Installation of conduit / wiring.
-Removal of the electronics enclosure cover.
-Viewing of the display. Note electronics housing and display can be rotated.
-Do not allow the earth cable to touch the steam pipe or damage to the sheath will occur.
Tie up any loose (excess) cable.
Warning: Do not install the flowmeter outdoors where it can be subjected to adverse
weather conditions like driving rain or where it can freeze.
Flow
Do not
insulate the anges of the TVA owmeter
Fig. 6 Pipeline insulation

IM-P192-02 MI Issue 214
Fig. 8
Horizontal flow limited to 7 bar g (101 psi g)
and saturated steam applications only
Fig. 7
Vertical flow limited
to 7 bar g (101 psi g)
and saturated steam
applications only
Flow
Flow
Flow
3.2 Mechanical installation
Warning: Do not alter the adjustment nut at the back of the TVA flowmeter shaft, as
this will affect the flowmeters calibration.
Orientation
The TVA owmeter can be installed in any orientation when used on saturated steam
applications and when the pressure is below 7 bar g (101 psi g), see Figures 7, 8 and 9.
When the pressure is above 7 bar g (101 psi g) or used on a superheated steam application
the TVA owmeter must be installed in a horizontal pipe, with the electronics housing below
the body, see Figure 9.
Note: The TVA owmeter operates with ow in one direction only. It is not intended for use
with bi-directional ow. The TVA owmeter is clearly marked with a direction of ow arrow.
Caution: If the electronic housing is
mounted at an angle of 45° (or more) from
the vertically downward position the PMO
(maximum operating pressure) must be
limited to 7 bar g (101 psi g) and saturated
steam applications only.
The electronic housing must be mounted
vertically downward for all superheated
applications.

IM-P192-02 MI Issue 2 15
Flow
Fig. 9
Horizontal flow up to
32 bar g (464 psi g)
for saturated steam applications
and
23 bar g
(333.5 psi g)
for superheated steam applications
Note: The 'U' syphon and pressure sensor
must be used for superheated steam
applications.
Rotating the electronics enclosure
The electronics housing can be rotated 270°to
enable sufcient clearance for installation. To
rotate the electronics housing, loosen the 6 mm
grub screw located on the rear of the electronics
housing (see Figure 10). The electronics housing
can now be rotated to the required position.
When the electronics housing has been located
into the correct position retighten the grub screw
to a torque of 1.3 N m (11.5 lbf in).
Warning: Do not loosen / remove the stem
from the main body of the unit.
6 mm grub screw
Warning: Do not loosen /
remove the stem from the
main body of the unit.
Fig. 10
Earth
cable

IM-P192-02 MI Issue 216
Upstream / downstream pipework
The TVA owmeter should be installed in pipework manufactured to BS 1600, ASME B 36.10
Schedule 40 or EN 10216-2 / EN 10216-5 equivalent, which corresponds to the following
pipeline internal diameters:
For different pipe standards / schedules,
if the owmeter is being operated at the
extreme of its published maximum
range, and maximum accuracy is
required, downstream spool pieces
manufactured from pipe to the above
standard should be used.
It is important that the internal upstream and downstream diameters of pipe are smooth.
Ideally seamless pipes should be used and there should be no intrusive weld beads on the
internal diameter. It is recommended that slip-on anges be used to avoid any intrusive weld
beads on the internal diameter of the pipe.
Note: See Figures 11 to 14 for other considerations which need to be noted before
determining the correct installation location.
Rotating the electronics front panel
To rotate the electronics front panel loosen the four retaining screws and rotate the front
panel to the orientation, required.
Note: Take care not to damage or strain any of the wiring.
A B C D
For applications with
steam above 7 bar g
and all superheated
applications.
Note:
Fitting the TVA
in this orientation
when the RS485
board is fitted
ensures that the
display can be read
easily.
For vertical flow applications. For saturated steam
applications below
7 bar g.
Retaining screws Retaining screws
Nominal diameter Nominal internal diameter
50 mm 52 mm
80 mm 77 mm
100 mm 102 mm

IM-P192-02 MI Issue 2 17
Fig. 12
Fig. 11
Flow
Flow
The TVA flowmeter normally
only requires a minimum of 6
pipe diameters upstream and
3 downstream of clear straight
pipe. These dimensions
assume a measurement
from a single 90° bend (see
Figure 11).
If any of the following congurations are present upstream of the TVA owmeter:
-Two right angled bends in two planes.
-Pressure reducing valve.
-Partly open valve.
Then it is recommended that the minimum upstream clear pipework is doubled to 12 diameters
(See Figure 12).
3D Minimum
6D Minimum 3D Minimum
6D Minimum
3D Minimum
12D Minimum
Note: The 'U' syphon
and pressure sensor
must be used for
superheated steam
applications.
Note: The 'U' syphon and
pressure sensor must be used for
superheated steam applications.

IM-P192-02 MI Issue 218
Fig. 13
Flow
Avoid installing the TVA owmeter downstream of an actuated valve as rapid cycling of
the valve could give rise to inaccurate results or damage the flowmeter. See Figure 13. In
configurations where there is more than one rapid acting pressure reducing valve close
coupled, the TVA owmeter should be installed with a minimum of 25 upstream and 3
downstream pipe diameters away from the valves.
Safety valves should also be as far away as possible from the flowmeter - at least 25D.
25D
Minimum
3D
Minimum
Note: The 'U' syphon and
pressure sensor must be
used for superheated steam
applications.

IM-P192-02 MI Issue 2 19
Fig. 14
Spool piece
Flow
To install the TVA owmeter pipeline unit into existing pipework and for aiding possible
flowmeter removal, a spool piece can be fabricated locally to the dimensions given below
(see Figure 14).
Size DN50 DN80 DN100
Dimension A
180 mm 240 mm 300 mm
7.1 in 9.5 in 11.8 in
A
Note: The 'U' syphon and
pressure sensor must be
used for superheated steam
applications.

IM-P192-02 MI Issue 220
Fig. 16 Gaskets fitted correctly
Location in pipework
Bolt ring gaskets having the same internal diameter of the pipework are recommended.
This will prevent possible inaccuracies being created by the gasket protruding into the pipe.
It is important that the TVA owmeter is located centrally in the pipework as any eccentricity
may cause inaccurate readings. The TVA owmeter has integral centering webs, which locate
on the internal diameter of the pipework (see Figure 15).
Integral centering webs
Fig. 15 Integral centering webs
Integral centering webs
Note: The 'U' syphon and
pressure sensor must
be used for superheated
steam applications.
Earth cable