Spirax Sarco TVA DN100, Installation And Maintenance Instructions Manual

Page 1: ...y 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 ...

Page 2: ...th 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 p...

Page 3: ...he 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 Grou...

Page 4: ... 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 loc...

Page 5: ...mal 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 whic...

Page 6: ...rax Sarco TVA flowmeter 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 Ifit...

Page 7: ... MI Issue 2 7 Fig 1 TVA flowmeter TVA flowmeter body Flowmeter stem Electronics housing Sensor cable Pressure sensor U syphon assembly Items required for superheat operation Flow Earth cable Earth cable NPSM boss ...

Page 8: ...39 C 333 psi g 462 F Saturated steam 32 bar g 239 C 464 psi g 462 F Vertical flow 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 PM...

Page 9: ...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 1160 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 Maximu...

Page 10: ...mum rated flow 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 S...

Page 11: ...allows Standard cable length is 1 m F 2 8 Dimensions weights approximate in mm and kg Size A Flowmeter 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 X D A G ...

Page 12: ...l of the TVA flowmeter for maintenance or calibration Closing valves V1 and V2 and opening valve V3 will allow the TVA flowmeter 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 sat...

Page 13: ...ty adversely effect the performance and may damagethe TVA flowmeter see Figure 6 Other considerations Be sure to allow sufficient 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 ex...

Page 14: ...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 flowmeter must be installed in a horizontal pipe with the electronics housing below the body see Figure 9 Note The TVA flowmeter operates with flow in one direction only It is not intended for use with bi directional flow The TVA flowmeter is clearly marked with a direction o...

Page 15: ...0 to enable sufficient clearance for installation To rotate the electronics housing loosen the 6 mm grub screw located on the rear of the electronics housing seeFigure10 Theelectronicshousing can now be rotated to the required position When the electronics housing has been located intothecorrectpositionretightenthegrubscrew to a torque of 1 3 N m 11 5 lbf in Warning Do not loosen remove the stem f...

Page 16: ...nal diameter It is recommended that slip on flanges 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 ...

Page 17: ...gurations are present upstream of the TVA flowmeter 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 ...

Page 18: ...In configurations where there is more than one rapid acting pressure reducing valve close coupled the TVA flowmeter 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 ...

Page 19: ...ting 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 ...

Page 20: ...uding into the pipe It is important that the TVA flowmeter is located centrally in the pipework as any eccentricity may cause inaccurate readings The TVA flowmeter 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 superh...

Page 21: ...IM P192 02 MI Issue 2 21 Fig 18 Gaskets and pipe offline fitting incorrectly Fig 17 Gaskets fitted incorrectly ...

Page 22: ...l be required on the pipe for the connection of the U syphon and pressure sensor It should be sited as close to the upstream flange as practicably possible see Figure 19 and take into account dimension X in Section 2 8 Note The TVA must only be used for superheated steam application when the pipe is in a horizontal plane Fig 19 TVA flowmeter TVA flowmeter body Flowmeter stem Electronics housing Se...

Page 23: ...he electronics housing When using the RS232 485 port PVC covered steel conduit should be used All cables that run through conduit should be screened The screens must be earthed at the far end of the installation and not at the flowmeter If using the loop and switch pulse ports Either combine both port outputs to one screened four core cable which is terminated with an EMC gland or use flexible con...

Page 24: ...display unit with 4 20 mA active input supplying current loop 1 Power 0 Volts R Or R 10 k EIA 232 RS 232 Communication port RJ11 socket Pulse Loop Remote PNP input maximum 28 V Power 0 Volts R 2 3 4 5 N L 230 V 50 Hz Fuse 1A Loop powered 4 20 mA display unit or chart recorder 9 28 Vdc Superheat pressure sensor pin header connection ...

Page 25: ...ssue 2 25 Fig 21 TVA with EIA 485 RS485 Communications wiring diagram Power supply 24 Vdc 19 28v 50 mA maximum GND data B data A data Note Do not reconnect loop power supply to these terminals when RS485 board fitted ...

Page 26: ...ph Figure 22 shows the range of power supply voltages and loop resistances over which the TVA flowmeter is capable of operating The loop resistance includes all the wiring Cable length Generally the maximum cable length between the TVA flowmeter and the power supply is 300 m 984 ft However the actual cable length is governed by the number of network devices the total resistance of the network and ...

Page 27: ...nnector from the display 4 1 Run mode Normally the TVA flowmeter will operate in the run mode displaying the total flow flow power pressure or temperature of the fluid passing through the pipeline After initial power up the TVA flowmeter will automatically enter the run mode and all commissioning menus can be accessed from this mode See Section 4 2 Commissioning mode for details on how to commissi...

Page 28: ...ys will scroll through the following data total flow power pres imp temp total flow power pres imp temp total flow power pres imp temp total flow power pres imp temp total flow power pres imp temp total flow power pres imp temp total flow power pres imp temp Fig 25 Pressure Flow 4 1 1 Run mode data sequence Temperature Power Total flow Temp C POWER Flow Pressure Pressure bar g or psi g depending i...

Page 29: ...nuous error will reinstate itself 2 seconds after it has been cancelled and will be indicated by a flashing exclamation mark Certain errors will also cause the 4 20 mA alarm signal to be initiated The error messages are displayed over two screens and are Power interrupted No signal from sensor This can also activate the 4 20 mA alarm Signal from sensor constant This can also activate the 4 20 mA a...

Page 30: ...will flash After a period of five minutes without any keys being pressed the TVA flowmeter will automatically default to the run mode For a full commissioning flow chart see Section 4 3 To enter the commissioning mode press and hold down the OK key for 3 seconds The display then shows Followed by The leading digit will flash indicating that this is the position of the cursor The default factory se...

Page 31: ...rom the commissioning mode at any stage continually pressing the left key will return to the run mode Pressing the up and down buttons scrolls through the various first level menus Pressing the right arrow button enters a particular sub menu PRES SENSR tESt ALARM SWVER SEt PASS ...

Page 32: ...tware version no SEt PASS xxxx OFF ON CONSt ALARM OFF ON MEtER PRES SENSR tESt SAt ALARM dELAy XX POWER OUt NO SIGNL SENSR CONST HIGH FLOW The 4 20 mA alarm can also be activated Shows when flow exceeds maximum No signal from sensor The 4 20 mA alarm can also be activated Power interrupted Flow above maximum Signal from sensor constant Error Messages Thesealternatewiththenormalrunmodedisplay They ...

Page 33: ...LSE PULSE WIDTH SORCE CHECK 4 mA CHECK 20 mA SEt4 mA SORCE SEt20 mA in kg or lbs MJ or kBtu tOtAL xxxxx xxxmS ENRGy Connect a DVM and use the up and down keys to set 4 or 20 mA in kg h or lb h kW or kBtu h FLOW POWER OP 4 mA xxxxx xxxxx OP 20 mA CLEAR tOtAL COMMS bAUD tyPE ASCII 1200 9600 MOdbuS UNItS IMP MEt Add XXX Press OK to select yES NO 0CAL 25CAL SH MARGN XXXXX XXXXX ON OFF PRES ALARM yES N...

Page 34: ... g F Select either MEt or IMP and press the OK button to confirm 4 4 3 CLEAR tOtAL This function is used to clear the total by pressing and holding the OK key for 3 seconds Note The total is backed up every 8 minutes in the TVA flowmeter s non volatile memory If power is lost the TVA flowmeter could lose up to 8 minutes worth of totalised steam 4 4 4 AtMOS PRES This value compensates the flowrates...

Page 35: ...olate the pipeline where the flowmeter is installed and ensure that there is no flow The line temperatures should be above 5 C 41 F and below 30 C 86 F Press and hold the OK button for three seconds On completion the display will step back to S N If ZErO ErrOr is displayed check to ensure that the line is isolated with no flow If tEMP ErrOr is displayed the line temperature is below 5 C 41 F Allow...

Page 36: ...e to be re calibrated A digital volt meter multimeter should be connected in series with the 4 20 mA output Pressing the right arrow button will display OP 4 mA and the TVA flowmeter will output a steady 4 mA If the multimeter does not read 4 mA the up and down arrow buttons can be pressed to alter this current until 4 mA exactly is indicated Pressing the OK button confirms the setting 4 6 6 CHECK...

Page 37: ...E WIDTH This allows the width of the pulse to be set The width can be set in 0 01 second increments from 0 02 seconds to a maximum of 0 2 seconds 4 6 12 COMMS This allows the connection to other communications protocols PULSE NUM PULSE PULSE WIDTH SORCE yES NO xxxmS xxxxx tOtAL ENRGy COMMS bAUD tyPE ASCII 1200 9600 MOdbuS Add xxx Press OK to select 4 6 13 bAUD This allows the communication speed t...

Page 38: ...that are required to be entered into this menu When the bits values for the 25CAL have been entered press the OK button to confirm This will automatically display the SH MARGN menu 4 7 3 SH MARGN The SH MARGN menu enables the configuration of the superheat alarm the superheat limit in degrees C and delay before the alarm is triggered LIMIt Number of degrees of superheat have dropped before alarm i...

Page 39: ...ontinue to be transmitted for five minutes unless the cancel option is chosen 4 8 3 PULSE OUt This allows the pulsed output to be tested By selecting ON or OFF the desired test state of the pulsed output can be selected Once the OK button is pressed the pulsed output will remain in the selected state for five minutes or until the cancel option is chosen 4 8 4 CANCEL This allows the 4 20 mA output ...

Page 40: ...ic electronics determine that the sensor output has been constant for a period of time or is not giving out a signal it will set the 4 20 mA output to 22 mA LOW If the self diagnostic electronics determine that the sensor output has been constant for a period of time or is not giving out a signal it will set the 4 20 mA output to 3 8 mA OFF This disables the 4 20 mA alarm function 4 9 2 POWER ALAR...

Page 41: ...t pressure which may indicate a stuck cone due to debris If the system that the TVA is fitted to has long periods where there is zero flow but the line is kept at a constant pressure it is advisable to turn the alarm off to avoid unwanted alarm messages ON This enables the saturated steam alarm OFF This disables the saturated steam alarm dELAy This enables the time duration before alarm is display...

Page 42: ...cho off Response time The TVA will start responding within 500 msec The actual time to fully receive a response from the TVA is baud rate dependent for example a Modbus poll of 12 registers 1200 baud rate could take 5 24 bytes x 10 ms byte 500 ms 800 ms to complete The polling frequency can be faster if the polling algorithm is set to poll immediately after receiving a valid response to a poll 4 1...

Page 43: ... 4 12 3 Using RS485 Communications The TVA is available with RS485 communications This is achieved by converting the communication from RS232 by an additional PCB The PCB is fitted at the factory when the TVA is ordered with RS485 communications However the RS485 communications board is available if ordered with a replacement electronics front panel Note RS232 4 20mA outputs are not available if t...

Page 44: ...Register data 2 x Quantity of registers MSB first low register address first Error check CRC 2 bytes Total 5 2 x Quantity of registers bytes Format Response frame error Address 1 byte Error code 1 byte error code function code plus 0x80 Exception code 1 byte 01 or 02 see below Error check CRC 2 bytes Total 5 bytes Note Only Read holding registers function code 03 is currently supported 4 14 1 ModB...

Page 45: ...re x100 PSIg 40025 24 Temperature x10 F 40026 25 Water equivalent flowrate x10 Lbs hour 40027 26 Power x1 KBTU h 40028 27 Energy low 16 bits x1 kBTU Energy Energy high x 65536 Energy low 40029 28 Energy high 16 bits x1 kBTU Note Modbus protocol requires that Modbus addresses start at offset 0 not 1 Register addresses start from 1 in description but 0 in binary Most parameters are 16 bits and few p...

Page 46: ... has latched Bit 10 0x0400 No signal from sensor alarm is latched Bit 11 0x0800 Power failed alarm has latched nothing Bit 12 0x1000 Low superheat Low S HT alarm Bit 13 0x2000 Over pressure alarm OVEr PRES Bit 14 0x4000 Bit 15 0x8000 A maximum of 12 Modbus registers can be polled together at the same frame It has to be noted that only a poll with a valid start address and quantity that falls withi...

Page 47: ...ew electronics and carefully replace Replace the mounting screws and reconnect the power supply Note Electrostatic discharge ESD procedures should be followed while installing the new electronics Do not force the electronics display unit into position Important note The TVA is a loop powered device It requires the CTS and DTR terminals to be wired and enabled to power the communications interface ...

Page 48: ... TVA flowmeter is given at the time of ordering Example 1 off Spirax Sarco display and electronics panel for a DN100 TVA flowmeter having the following Serial number D______ This can be found on the product label on the stem 2 Superheated steam conversion kit This comprises of a new electronics front panel complete with pressure sensor and syphon Please note the serial number of the existing TVA m...

Page 49: ...e cause Action Display is blank dc voltage is not within the range of 9 28 Vdc Supply connected with reverse polarity Electronics faulty Check power supply current connections See Section 3 3 Change polarity Refer to Spirax Sarco Limited Display shows NO SIGNL Insufficient supply voltage Current loop resistance is greater than Rmax Electronics faulty Check supply voltage is between 9 and 28 Vdc Ch...

Page 50: ...of the pipe bore Signal falsified due to bi phase medium Insufficient upstream downstream pipe lengths Flow direction reversed The axis of the flowmeter bore should be aligned with that of the pipe See Section 3 Figures 16 17 and 18 for proper installation of gaskets Pipe bore should be free of irregularities Bi phase media are not permitted Use a separator for wet steam droplets from the steam Se...

Page 51: ...ected powered Connect CTR DTS terminals Additional fault finding for versions with RS485 conversion board fitted Symptom Possible cause Action No power and no diodes lit up No power to terminals 4 and 5 Check power supply Power to terminals 4 and 5 wrong way round Connect to terminals 4 and 5 correct way round No communication Green diode lit only No query received from computer system Check commu...

Page 52: ...re changes be required Sub menu Changeable settings Factory settings Customer settings Further changes Basic data Dryness fraction 1 0 Units Metric Nominal pressure Atmospheric pressure 1 01 bar a Outputs 4 20 mA Source data Flow 4 mA setting 0 20 mA setting Flowmeter maximum 32 bar g Pulse ON Source data Total Number of pulses 1 per kg Pulse width 50 mS Error High Pass code 7452 8 Settings table ...