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Honeywell Enraf Small Volume Prover Installation, Operation

1. b 2 B a 1 24VDC log Ar CONVERTER 24VDC SEE NOTES FOR 120VAC 60Hz OR 1 FOR 220VAC Ei NEUTRAL FOR 120VAC 60Hz pu OR HOT 2 FOR 220VAC i22 iog fA E OU EFE DWF a NOTES 1 2 3 AVAILABLE MOTOR VOLTAGES FOR 1 PHASE 120 220 THE NEUTRAL IS NOT FUSED ON 120VAC FUSES CAN BE SUBSTITUTED WITH MOTOR PROTECTOR WHEN THE INSTRUMENT POWER SOURCE IS AN AC SUPPLY USE AN AC DC CONVERTER TO CONVERT TO DC A CONVERTER IS NOT NEEDED ON DC SOURCES LEGEND TERMINAL BLOCK ONLY NECESSARY IF A WATER DRAW KIT IS PURCHASED Figure 7 1 Wiring Diagram 1 Phase CUSTOMER CONNECTION BOX 1 WATER DRAW SV1 2 WATER DRAW SV2 3 WATER DRAW COMMON 4 FLOWMETER 1 POWER 5 FLOWMETER 1 PULSE A 6 FLOWMETER 1 COMMON 7 FLOWMETER 1 PULSE B 8 FLOWMETER 1 COMMON 9 FLOWMETER 2 POWER 10 FLOWMETER 2 PULSE A 11 FLOWMETER 2 COMMON 12 FEED FLOW COMPUTER 13 RUN PERMISSIVE 14 RUN PERMISSIVE 15 COMMON FLOW COMPUTER 16 VOLUME PULSE 17 VOLUME PULSE 18 EMR CONTACT A 19 EMR CONTACT B 20 ALARM CLEAR 21 ALARM CLEAR 41 TXIRX 42 TXRX GROUND 0V COMM SHIELD 23 BAR TEMP XMITTER 24 BAR TEMP XMITTER LOOP 25 BAR TEMP XMITTER LOOP GROUND BAR TEMP XMITTER SHIELD 26 SVP TEMP XMITTER 4 27 SVP TEMP XMITTER LOOP 28
2. 1 11 Figure 2 1 Process Connections and General Arrangement 2 2 Figure 2 2 Prover Lifting Diagram 2 3 Figure 2 3 Prover Service Clearance Diagram 2 4 Figure 2 4 Designated anchor points plates located on the bottom side of the prover frame a eat a AUR RR RR RR RA a 2 5 Figure 2 5 Electrical 2 6 Figure 2 6 Customer Connection 2 7 Figure 2 7 Power ee m hm UR 2 7 Figure 2 8 SVP Controller Box with 2 8 Figure 3 1 The Local Access Device LAD and its system overview 3 2 Figure 3 2 Main Menu icc ceed ang eet eee errar RR UD RR pee REG NR EORR RR RR 3 3 Figure 3 3 Text Input Screen ee ends RR RR UR RR RD RR RR DR 3 4 Figure 3 4 Numeric Input 3 4 Figure 3 5 Enumeration Input Screen 3 5 Figure 3 6 Status ER RR add ee 3 5 Figure 3 7 Menu Structure 3 6 Figure 3 8 Device Locking 3 7 Figure 3 9 Password Input 3
3. FLOW RATE Position 2 3 4 Prover Maximum Displaced Maximum Displaced Displaced Shipping Shipping Model Flow Volume Flow Volume Volume Weight Weight PD Coriolis PD Coriolis PD Coriolis Turbine Ultrasonic Turbine Ultrasonic Turbine Ultrasonic Meters Meters Meters Meters Meters Meters Gallons Liters LB KG BPH BPH GPM GPM m h m h 05 715 715 500 500 114 114 5 18 9 1 200 544 15 2 140 1 719 1 498 1 203 340 273 20 15 7 3 500 1 588 25 3 570 1 719 2 499 1 203 568 273 20 75 7 4 350 1 973 35 5 000 4 671 3 500 3 270 795 743 25 94 6 5 250 2 381 5 0 7 200 5 783 5 040 4 048 1 145 919 40 151 4 7 850 3 561 85 12 500 11 267 8 750 7 887 1 987 1 791 25 283 9 12 500 5 670 120 17 500 15 922 12 249 11 145 2 782 2 531 120 454 2 14 500 6 577 Table 2 Prover Flow Range Part No 44200002 Revision 2 Small Volume Prover Installation 1 3 Honeywell Enraf 44200002 indd 3 Operation amp Service Manual 4 23 2014 7 27 03 PM Introduction Wetted Parts Honeywell Enraf small volume provers can be supplied with wetted parts from 304 or 316 Stainless Steel material as specified in the Table 3 below Note Materials choice should be based on product MSDS and application information supplied by the end user Wetted Parts Position 5 304 Stainless Steel flow tube with chrome plated bore 304SS piston end flanges amp shafts 316 Stainless Steel flow tube with chrome plated bore 31655 piston flanges amp shaft
4. 6 2 6 2 4 Service QUO mas em e 6 2 6 3 DiagnosticS na eee eee eee eee 6 2 6 3 1 Dashboard a ea m Ret ter RR rnm ar en ig 6 2 6 3 2 System Health 9533 hana 6 3 6 3 3 Active Alarms utet xc EEEE Rt dence 6 3 6 4 Troubleshooting 6 3 CHAPTER 7 Electrical Schematics amp Drawings 7 1 7 1 Schematics for prover Wining 7 1 7 2 Connections to Flow Computers 7 4 7 2 4 Omni iY RY er i ne nr ee ee Ee 7 4 7 2 2 Gondat CIU RR Sad 7 5 7 2 9 Daniels iu oh RR GR RR RG A R 7 5 TOP e 7 6 CHAPTER 8 Prover Maintenance 8 1 8 1 Portable Prover irruere Rx a angie ree anum aed 8 1 8 2 Stationary provers sou rur rr eee eee cee ee 8 1 8 3 General Prover Maintenance Information 8 1 8 4 Downstream Shaft Seal 8 2 8 5 Prover Piston Assembly Seal 8 5 8 6 Upstream Shaft Seals Replacement 8 10 8 7 Bolt Torque Specifications 8 12 8
5. Slotted precision optical switches are utilized to define volume displaced These switches are reliable fast b X 10s and precise showing a maximum deviation of 0 0005 on repeatability of linear measurement For maximum fluid compatibility the only seals in contact with the flowing fluid in the Honeywell Enraf small volume prover are filled PTFE A static leak detector is provided with the prover This consists of a device to generate a differential pressure across the piston When filled with fluid and the blocking valves closed the operator simply provides a differential pressure gauge or transmitter to monitor any leakage while differential is applied Refer to static seal leak test The latest version of the Honeywell Enraf small volume prover incorporates a hazardous area intelligent controller utilizing state of the art microprocessor technology and a display to provide a window to the operation of the prover When used with its associated Local Access Device LAD you are able to view the status of the calibration and perform diagnostics The contents of this manual provide general information and operational characteristics for the Honeywell Enraf small volume prover This manual does not include information regarding auxiliary equipment for unique applications Consult your factory approved service center for this information Part No 44200002 Revision 2 Small Volume Prover Installation 1 1 Honeywell Enraf Operati
6. Motor Voltage Supply Position 10 D 24 VDC Portable 05 35 Only A 120 VAC 60 Hz 05 35 Only G 120 VAC 50 Hz 05 35 Only B 220 VAC 60 Hz 1 Phase 05 35 Only 220 VAC 50 Hz 1 Phase 05 35 Only H 220 240 VAC 60 Hz 3 phase Required 50 120 Sizes N 220 240 VAC 50 Hz 3 phase Required 50 120 Sizes R 380 400 415 VAC 60 Hz 3 phase Required 50 120 Sizes L 380 400 415 VAC 50 Hz 3 phase Required 50 120 Sizes E 460 480 VAC 60 Hz 3 phase Required 50 120 Sizes 460 480 VAC 50 Hz 3 phase Required 50 120 Sizes Table 6 Motor Voltage Supply Part No 44200002 Revision 2 Small Volume Prover Installation 1 5 Honeywell Enraf Operation amp Service Manual 44200002 indd 5 4 23 2014 7 27 03 PM Introduction Electrical Agency Approvals amp Certifications The SVP provers has electrical agency approval for hazardous area classification installation that cover the industry requirements Electrical hazardous classification Position 11 3 CSA UL Class 1 Division 1 Group D T2C CSA 1011011 LR 84500 4 CSA UL Class 1 Division 1 Group C T3B CSA 1011011 LR 84500 5 ATEX certified for ll 2 G Ex d ia ia IIB T4 Gb and ll 2 Gc IIB T4 Table 7 Electrical hazardous classification Prover Finish The prover comes standard with a brushed finish to enhance the stainless steel materials There is also an option for a white paint seal coat for a higher level of enviro
7. Note When setting the clock first set the controller to 24 hour mode then set the time This will allow the proper AM or PM to be displayed when 12 hour mode is selected Date This entity selects the actual date and will be used for time stamping of transactions calibrations and alarms Time This entity selects the actual time and will be used for time stamping of transactions calibrations and alarms 3 3 6 2 5 Motor These parameters are set at the factory and must not be changed without consulting Honeywell Enraf experts or damage to the prover may occur Motor switch timeout Configurable time interval by which piston puller must have reached motor stop switch before detection of a motor timeout error Covers retraction of piston from parked position to Configurable range is from 5 seconds to 120 seconds factory recommended settings per model are shown below S05 16 S35 38 120 62 motor stop switch Units are in seconds 515 14 550 26 525 22 585 58 Motor off delay Configurable delay which controls when motor Configurable range is from O to 60 seconds turns off after piston puller has retracted to factory recommended settings per model are motor stop switch Can be adjusted to affect shown below optimal positioning of puller in preparation for S05 0 S35 2 120 2 next retraction sequence Units are seconds S15 B S50 5 525 1 585 2 3 3 6 2 6 Sensor Pair Standa
8. REN AND BLEED SM eee VALVE OD FLOW METER SIGNAL CONDITIONER SIGNAL STRAINER FLOW METER UNDER TEST THE HONEYWELL SMALL VOLUME PROVER MAY BE INSTALLED UPSTREAM OR DOWNSTREAM OF THE METER UNDER TEST AS THE DISPLACED VOLUMES ARE EQUAL P PRESSURE TRANSMITTER D TEMPERATURE TRANSMITTER Figure 2 1 Process Connections and General Arrangement A Warning Do not exceed the maximum working pressure of the prover as detailed on the nameplates It is the customer s responsibility to install the prover a system that is protected by correctly sized over pressure protection Process lines should be cleaned thoroughly by flushing before installation to eliminate potentially damaging foreign material from entering the prover A correctly specified strainer should be installed upstream of the prover to protect it from the introduction of foreign material 2 2 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 2 4 23 2014 7 27 08 PM Installation A Caution Be certain that all flanges bolts dry break couplers hammerlock fittings hoses loading arms and pressure containing components have sufficient pressure rating Also be absolutely certain that the flow direction through the prover is correct The Honeywell Enraf small volume prover is
9. 5 from the upstream piston shaft 7 Remove the upstream seal retainer assembly Figure 8 7 52101 from the upstream flange by first removing the shock absorbers Figure 8 7 52108 and then removing the hex socket cap screws Figure 8 7 52107 holding the seal retainer to the end flange Then remove the upstream seal retainer assembly 8 With sufficient personnel and or a hoist or crane at the downstream end of the prover lift the piston assembly and pull it out of the flow tube see Figure 8 4 Be extremely careful to remove the piston assembly in such a manner to not cause damage to the piston or to the precision bore flow tube Note Lift the piston assembly with a nylon strap wrapped through piston support to prevent damage or injury NEVER lift the piston assembly with the strap positioned far away from the piston support Figure 8 5 54002 9 For piston disassembly on most models use procedure Ya for older models use 9b 9a Referring to Figure 8 5 disassemble the piston by first removing the downstream shaft 54005 from the poppet valve 54003 Then remove the piston support 54002 from the piston body by placing the piston body 54001 face down on a clean surface and hold pressure to keep the spring 54009 compressed and removing the 54020 hex head cap screws The poppet assembly may now be removed from the piston body Remove poppet seal 54014 from piston body 54001 Remove the main piston seals 54013 and riders 54008
10. 8 17 Figure 8 12 Grounding the 8 18 Figure 8 13 Guide Block 5 8 19 Figure 8 14 Stud 8 20 Figure 8 15 Correctly Seated Optical Switch Bottom and Side View 8 21 Figure 8 16 Switchbar Position e ee da eee RR EREA 8 22 Figure 8 17 Pipe Clamp 8 23 Figure 8 18 Puller Alignment 8 24 Figure 8 19 Adjustment Blocks 8 25 Figure 8 20 Shaft Loctite 8 26 Part No 44200002 Revision 2 Small Volume Prover Installation vii Honeywell Enraf Operation amp Service Manual 44200002 indd 7 4 23 2014 7 27 02 PM Table of Contents Figure 8 21 Chain Support 8 27 Figure 8 22 Recommended Chain Sag 8 28 Figure 8 23 Shock Installation 8 29 Figure 8 24 Correct Optical Switch Installation Bottom ViewW 8 30 Figure 8 25 Correct Optical Switch Installation Side 8 31 Figure 8 26 Improper Optical Switch Installation Side View 8 31 Figure 8 27 Improper Opti
11. Enraf provers It depends on the prover model but in general an 05 uses 0 5hp 35kW electric motor 15 25 35 amp 50 use a 1hp 75kW electric motor 85 uses a 2hp 1 5KW electric motor 120 uses 5hp 3 7kW electric motor What are the installation considerations for a Honeywell Enraf prover Correct installation of the Honeywell Enraf prover is vital to a long and trouble free operation Critical elements include suitable foundations pipe stress and load analysis on provers inlet and outlet ports adequate upstream filtration and thermal pressure relief If you have any questions please consult the factory How is the installed base of Honeywell Enraf provers supported Honeywell Global Technical Support GTS is the focal point for all Honeywell Enraf related after sales support questions and GTS is supported by a network of Honeywell service centers and strategically positioned service partners How can receive information and support for the Honeywell Enraf prover Contact your local sales specialist There is a Honeywell Enraf specialist located in each global region Americas Asia Pacific and Europe Middle East amp Africa EMEA Table 18 Frequently Asked Questions Part No 44200002 Revision 2 Honeywell Enraf 44200002 indd 33 Small Volume Prover Installation Operation amp Service Manual 8 33 4 23 2014 7 27 50 PM Honeywell Enraf Americas Inc 2000 Northfield Court
12. Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 4 4 23 2014 7 27 03 PM Introduction Inlet and Outlet Configuration For easy installation and connection to the end user s piping system Honeywell Enraf small volume prover can be configured per Table 5 below INLET AND OUTLET CONFIGURATION Position 8 and 9 0 nlet both sides amp Outlet flange left side 1 nlet amp Outlet flanges opposite inlet right side nlet amp Outlet flanges same side right side Flanges at 90 Inlet on right side Outlet on top nlet amp Outlet flanges same side left side nlet amp Outlet flanges both sides double set nlet amp Outlet flanges both on top nlet amp Outlet flanges opposite Inlet left side J et flanges both sides amp Outlet on top 5 et flange on top amp Outlet on left wy k et flange on top amp Outlet on right a a Flanges at 90 Inlet on right side Outlet on top 12 5 et on right Outlet on left Outlet on top Table 5 Inlet and Outlet Configuration Motor Voltage Supply Options The SVP motor sizes have been established to satisfy the industry needs globally for all possible facility needs Note The DC power was designed for use with our portable provers for the PO5 to the P35 sizes only
13. Revision 2 Small Volume Prover Installation 4 3 Honeywell Enraf Operation amp Service Manual 44200002 indd 3 4 23 2014 7 27 20 PM Operations Intentionally left blank 4 4 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 4 4 23 2014 7 27 21 CHAPTER 5 CALIBRATION 5 1 General It is recommended that prior to doing any volumetric calibration that the personnel involved read the API Manual of Petroleum Measurement Standards MPMS Chapter 4 Proving Systems sec 4 8 and the MPMS Chapters 4 3 7 1 and 12 2 4 pertaining to the calculation for the volume of provers Although the prover may be calibrated with procedures traceable to the National Institute of Standards and Technology NIST by a number of techniques only two techniques for volume determination will be described here a volumetric calibration and a gravimetric mass calibration The gravimetric calibration method requires collecting the volume of water displaced by the prover during a prove pass and determining its mass by weighing it with a precision scale or balance Corrections are made for the density of the water and the buoyancy of the air displaced by the volume of water per API 14 6 and applying various other correction factors such as the temperature and pressure effects on the flow tube and the volume switch position De ionized or distilled water should be
14. Service Manual Honeywell Enraf 44200002 indd 10 4 23 2014 7 27 02 PM The Honeywell Enraf Prover Series A Warning For information on the dimensions of the flameproof joints contact Honeywell Enraf A Warning Risk of injury Honeywell Enraf recommends mains power to be shut off including lockout tagout at that mains switch to ensure safety during maintenance and related work being performed on the inside of the drive end cover A Warning Risk of injury Ensure that the motor drive end and downstream shaft covers are always in place before operating the device to guard against human injury A Warning Risk of injury Pressurize system slowly to avoid a hydraulic shock which could result in damage to prover personnel and or piping systems A Warning Risk of injury Ensure that the unit is fully depressurized and drained prior to disassembly or service Commissioning The commissioning of the instrument shall be conducted by qualified engineers trained by Honeywell Enraf and with knowledge of the local and national requirements for electrical equipment in potentially explosive atmospheres Operation After commissioning the Honeywell Enraf SVP and its associated SVP Controller can be used for its intended purpose After connecting to the SVP Controller the LAD can be used for its intended purpose The memory card can be removed and inserted also in hazardous areas but be aware that the device is then no
15. detailed consult Honeywell Enraf and the flow computer manufacturer If equipped with CONDAT or Prove lt prover control systems refer to the operators manual for instructions for installation and operation The Honeywell Enraf small volume prover must be correctly earth grounded prior to electrical service connection 2 4 1 Field wiring Field wiring at hazardous voltage levels needs to be provided with insulation rated for a minimum of 300V with a rated temperature of a least 105 C and with a conductor size of at least 0 5mm2 or AWG 18 2 4 2 Breaker A readily accessible disconnecting breaker device shall be incorporated external to the equipment 2 4 3 Enclosures The picture below shows the three electrical enclosures mounted on the Small Volume Prover The connections to the SVP Controller Box are made at the factory and must not be modified All of your connections are to be made in the Power Box and the Customer Connection Box Figure 2 5 Electrical Enclosures 2 6 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 6 4 23 2014 7 27 14 PM Installation 2 4 3 1 Customer Connection Box The picture below shows the Customer Connection Box where you can connect your flow computer and other signals to the SVP gt NS SES NAA CON NIST KRI WER NUSSSSENS
16. enough time to stabilize and generate accurate repeatable readings What is Run up time The run up time is the time it takes from the release of the piston to reach the start measurement switch 1st Optical Switch Why is the upstream and downstream volume the same The Honeywell Enraf flow Prover has a piston shaft on both sides of piston body therefore the displaced volume is the same How does the flow prover measure volume pulses The Honeywell Enraf prover does not measure anything It is a very accurate but simple instrument that waits for a start signal from the flow computer and sends back the pulses as it passes the volume switches Can the fluid flow through the prover all the time How much pressure drop does the Honeywell Enraf Flow Prover Have Yes many Honeywell Enraf provers are installed in Standby Mode but it is recommended to consider the more durable elastomer option when operating a prover in this way This is the best practice for fluids that are at temperatures higher or lower than ambient continuous to allow for faster warm up time Under normal operating conditions the prover will generate 28 69 kPa 4 10 psi pressure drop at maximum flow rate This is based on water and is applicable to refined products such as diesel jet gasoline etc Products such as heavy crude oil can generate pressure drops of up to 20psi in some cases What motor sizes are used on Honeywell
17. ipsc PN 44100375 momo CABLE FROM SOLENOID VALVES 22342524 20 TO ENCLOSURE POWER ENCLOSURE e h POWER SUPPLY CONNECTION ee Welelerelelek H 22 23 24 cc PN 10601197 LEER WATER DRAW 1 PLUMBING ASSY T pil Mel 5 6 y l gt E o all IAN O Pee J TUBING TO TUBING TO WASTEWATER TEST CATCH CONTAINER MEASURE Water Draw SV1 Water Draw SV2 Water Draw Common INCLUDED IN WATER DRAW KIT 1 2 SS BRAIDED HOSE CONNECT TO PROVER DOWNSTREAM SIDE Customer Connection Enclosure Figure 5 6 Water Draw Kit Part No 44200002 Revision 2 Honeywell Enraf 44200002 indd 5 Small Volume Prover Installation Operation amp Service Manual 4 23 2014 7 27 24 PM Calibration Procedure Water draw notes Perform steps 12 17 at least twice prior to taking data to purge the system of air assure the temperature is stable and to get familiar with the procedure Repeat the water draw procedure until at least consecutive draws repeat within 0 02 or other repeatability criteria that the certifying parties agree upon The flow rate on at least one run must vary by 25 to assure integrity of prover seals and absence of leakage Failure to achieve the necessary repeatability may be caused by leaking valves air in the system varying pressure leaking sea
18. volumetric water draw technique 4 Connect water supply to prover refer to Figure 5 7 Make sure that the water draw kit is wired to the customer connection enclosure as specified in the Figure 5 6 6 Turn water supply on and open valves V1 V2 and V3 After all air is bled off close V2 and V3 Open V5 valve and allow water to circulate until the temperature has stabilized and is not changing 5 6 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 6 4 23 2014 7 27 24 PM Calibration 7 Valve V2 may be opened slightly to allow just a very small stream of water to flow this will bleed off air which may be in the water supply At the end of the temperature stabilization close the V5 valve 8 Place properly wetted and drained test measure under the water draw valves 9 Ensure power is applied to the prover Navigate to Calibration screen from the Main Menu as shown below Prover Calibration Enter Calibration Mode Run Calibration Exit Calibration Enter Average Volume Abort Calibration Press OK to choose Stop 10 Enter the prover calibration mode using Enter Calibration Mode submenu Notification to user after selecting Enter Calibration Mode will show up on the SVP Controller screen see below Please note that permissive signal from the flow computer will be ignored while in prover calibration mode Enteri
19. 2 xvi Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 16 4 23 2014 7 27 03 PM Installation Procedure 14 15 16 17 18 18 20 21 22 23 When connecting prover to pipeline be certain that a Flow direction is correct Flow must go through the prover in the proper direction Severe damage may occur if flow direction is not correct b Bolts flanges and piping of sufficient strength are to be used for all pressure retaining connections All connection bolts are tightened to correct torque specifications d No foreign bodies i e weld slag will be introduced into the prover Carry out the removal and replacement of transit seals with the operation seals as supplied prior to introducing liquid into the Honeywell Enraf small volume prover Pressurize system slowly to avoid shock which could result in damage to prover personnel and or lines Be certain that ALL applicable electrical codes are met when connecting and using the Honeywell Enraf small volume prover especially in hazardous area locations The Honeywell Enraf small volume prover is certified by one of the following CSAVUS certified for Class 1 Group D T2C CSA US certified for Class 1 Group C T3B ATEX certified for ll 2 G Ex d ia ia IIB T4 Gb and Il 2 Gc IIB T4 It is the responsibility of the user to satisfy the relevant electrical
20. 36 6 1500 59 1500 59 1530 60 3 1870 73 8 2110 83 2250 88 4 FLANGE SIZES 3 inch 6 inch 6 inch 8 inch 8 inch 12 inch 16 inch NOTES 1 All dimensions are in mm inches 2 Dimensions C and F may vary according to model type configuration 3 dimensions vary according to pressure rating 4 All dimensions are subject to change Table 11 Prover Dimensions Part No 44200002 Revision 2 1 9 Honeywell Enraf Small Volume Prover Installation Operation amp Service Manual 44200002 indd 9 4 23 2014 7 27 07 PM Introduction Pressure drop Pressure drop measured between inlet and outlet of the prover is specified in the Table 12 see below The drop is obtained at maximum flow rate using water as a fluid Honeywell Enraf SVP MODEL FLOW RATE BPH PRESSURE DROP S05 785 69 kPa 10 0 psig 515 2 140 28 kPa 4 0 psig 525 3 570 52 kPa 7 5 psig S35 5 000 69 kPa 10 0 psig S50 8 000 69 kPa 10 0 psig S85 12 500 69 kPa 10 0 psig 120 17 500 55 kPa 8 0 psig Table 12 Maximum pressure drop per prover size 1 4 Tests and Certifications The Honeywell Enraf small volume provers are factory tested on the following before shipment Electrical Tests Dielectric strength and ground bond test Hydrostatic Pressure Test Hydrostatic pressure test is done per ASME Section 8 Pressure Vessel Code Prover wetted parts are pressurized for four hours and th
21. 4 Menu Structure scs 3 5 3 3 5 Device Locking Menu acinar eae gee nie ee eg 3 7 3 3 6 Configuration RY UR 3 9 3 3 6 1 Using the Configuration 3 9 3 3 6 2 3 11 3 3 0 2 1 Identificatiori ee ERR eens RR ERE 3 11 3 9 6 2 2 UhitS Ru chee eee eee eee 3 11 3 3 6 2 3 5 2 st nn Rena anam e Grated 3 11 3 9 6 2 4 e a RR ees GR dees eee 3 12 cR UR Mj EP 3 12 3 3 6 2 6 Sensor Pair 3 12 3 9 6 3 VO Sets E a tls saca bcn dun 3 13 3 3 6 3 1 Alarm Relay 3 13 3 3 0 4 AlarmS ee eat es es 3 13 3 3 7 Prover Calibration iY YG sees 3 14 3 3 8 System 3 14 3 3 0 L0gS8 ieee ie teed 3 16 3 3 9 1 Transaction LOGS 6 de EE Ren 3 16 3 3 9 1 1 Transaction information 3 17 3 3 9 2 Calibration LOGS ee ee tre geen 3 17 3 3 9 3 Alarm 095 ia aes 3 17 3 9 10 DiagriosliCS 3 18 3 3 11 Transfer GG LLYFR 3 20 3 3 12 LAD Settings Rn Rr en Rr epee arlene seed en 3 21 C
22. 7 Figure 3 10 Configuration 3 9 Figure 3 11 Configuration Menu 3 10 Figure 3 12 Prover Calibration Slate quai 3 14 Figure 3 13 System 3 14 Figure 3 14 System Information Menu 3 15 Figure 3 15 LOgS 5 maar RR RR RR RR 3 16 Figure 3 16 Logs Menu Tree seg ema iid 3 16 Figure 3 17 Diagnostics 3 18 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 6 4 23 2014 7 27 02 PM Table of Contents Figure 3 18 Diagnostics Menu 3 19 Figure 3 19 Transfer 2 08 082s hr 3 20 Figure 3 20 Transfer Menu 3 20 Figure 3 21 LAD 5 3 21 Figure 3 22 LAD Settings Menu 3 21 Figure 5 1 Static Leak Detection 5 3 Figure 5 2 Gauge with HI amp LOW 5 3 Figure 5 3 Differential pressure creator inserted in
23. A mie Main Menu icon Configuration Name of selected item Selected item focus rectangle Only available if LAD is connected Configuration Figure 3 2 Main Menu Part No 44200002 Revision 2 Small Volume Prover Installation 3 3 Honeywell Enraf Operation amp Service Manual 44200002 indd 3 4 23 2014 7 27 15 PM Controller Information 3 3 3 Screen Input Fields 3 3 3 1 Text Input Screen Configuration Lock Device TZ W3H68T s eee Y v w x Z Confirm Type your passcode T Title bar Single line edit field Selected letter Action message Configuration Lock Device Numbers grouped Letters grouped Figure 3 3 Text Input Screen 3 3 3 2 Numeric Input Screen Configuration Display Contrast Number buttons Configuration Blend Str K Factor un oA 0 IL Point button Enter Value Single line edit field Backspace 6 Confirm 3 Figure 3 4 Numeric Input Screen Single line edit field Confirm amp Backspace buttons Configuration Display Contrest 4156 Coirm 3 4 Small Volume Prover Installation Operation amp Service Manual 44200002 indd 4 Part No 44200002 Revision 2 Hone
24. Certificate number ATEX 12ATEX0101 X IECEx DEK 12 0021X CSA 11 2370409 xii Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 12 4 23 2014 7 27 03 PM The Honeywell Enraf Prover Series Additional information specific to the Fusion4 LAD Approvals I 2 G Ex ia IIB T4 Gb Ex ia IIB T4 Gb Certificates Approval Certificate number ATEX KEMA 10ATEX0152 IECEx IECEx KEM 10 0070 CSA 11 2395571 Part No 44200002 Revision 2 Small Volume Prover Installation xiii Honeywell Enraf 44200002 indd 13 Operation amp Service Manual 4 23 2014 7 27 03 PM The Honeywell Enraf Prover Series Intentionally left blank xiv Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 14 4 23 2014 7 27 03 PM INSTALLATION PROCEDURE A Warning Please read this section carefully before installing using or maintaining your Honeywell Enraf small volume prover Failure to follow directions may result in personal injury and or property damage Honeywell Enraf is not responsible for injury damages losses as a result of deviation from installation procedure The Honeywell Enraf small volume prover is fitted with transit seals in both the up amp downstream shaft seal retainers upon its shipment from the factory It is important to replace these seals dur
25. Figure 8 3 position 4 with the rubber bumper Figure 8 3 position 5 on the upstream piston shaft Note It is recommended to replace existing rubber bumper with the new one at this time Make sure to clean the surface on the mechanical stop prior to gluing the rubber bumper to it Use Loctite 422 or equivalent 10 Carefully slide the guide block Figure 8 3 position 2 over the threads of the dimple stud and secure it using the washer standard hexagonal nut and locking nut Figure 8 3 position 1 Note Make sure to clean the threads on the dimple stud and be careful not to damage the optic switches 8 10 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 10 4 23 2014 7 27 41 PM Prover Maintenance p YV 52106 52205 52202 4X SEE DETAIL D DETAIL A DETAIL B AND DETAIL D BELLEVILLE WASHER 52202 ORIENTATION DETAIL C ITEM NO DESCRIPTION 52201 UPSTREAM FLANGE 52202 BELLEVILLE SPRING 52203 WASHER BELLEVILLE RETAINER 52204 RETAINING RING 52205 UPSTREAM FLANGE O RING SEAL 52206 SOCKET HEAD CAP SCREW 52207 HEX HEAD CAP SCREW 52101 UPSTREAM SEAL RETAINER 52102 SHAFT SEAL UPSTREAM OUTER 52103 IGUS BUSHING 52104 SHAFT SEAL 52106 RETAINING RING 52107 SOCKET HEAD CAP SCREW 52108 SHOCK ABSORBER 52109 TEFLON O RING SEAL 52110 RYTON WASHER 52111 SHAFT SEAL UPSTREAM MIDDLE 52112
26. Honeywell Enraf 44200002 indd 8 4 23 2014 7 27 18 PM Controller Information gt gt Cannot apply configuration path is Transfer Configuration Apply Configuration gt gt Cannot see and acknowledge or reset alarms path is Diagnostics Active Alarm or Diagnostics Prover Service Test Clear Task gt gt Cannot upgrade any firmware path is LAD Functions Firmware update The following tasks can be performed even if the controller is locked 1 Navigate to Calibration and Enter Run Exit Enter Average Volume and Abort Calibration 2 Navigate and see System Info 3 Navigate to Logs and see and retrieve Transaction Calibration and Alarm logs 4 Retrieve configuration path is Transfer Configuration Retrieve Configuration 5 Navigate and view Diagnostics Dashboard menu and activate or deactivate alarm output 6 Navigate and view storage info path is Diagnostics Storage Info 7 Navigate to Diagnostics Prover Service Test Run Prover Service Test to activate the prover test 8 Navigate to LAD Function and view LAD information 9 Navigate to LAD Function and Format SD card 3 3 6 Configuration 3 3 6 1 Using the Configuration Menu Main Menu re 2 Configuration Figure 3 10 Configuration Menu Part No 44200002 Revision 2 Small Volume Prover Installation 3 9 Honeywell Enraf Operation amp Service Manual 44200002 indd 9 4 23 2014 7 27 18 PM Controller Infor
27. ID E WT Part No 44200002 Revision 2 Small Volume Prover Installation 5 19 Honeywell Enraf Operation amp Service Manual 44200002 indd 19 4 23 2014 7 27 25 PM Calibration CPLp Correction for effect of pressure on liquid water 1 1 0 0000032 Pp WDz Average of all WD s sum WDz Fill 1 WDz Fill5 n Volume of Prover at 60 deg and 1 atm WDz CPSp CPLp Gravimetric Water Draw Calculations Gravimetric Water Draw technique is completed in accordance with API 4 9 4 Volume correction factors are based on API Manual of Petroleum Measurement Standards API chapters 4 2 4 9 and 12 2 4 Corrections and representations WDzb Given Td Temperature of detector bar deg Tp Temperature of prover deg F Temperature of ambient air deg Pp Pressure in prover psig Ww Weight of water grams h Elevation above sea level feet Dtw Density of test weights gm cc Ga Area coefficient of expansion for flow tube API 12 2 4 Gl Linear coefficient of expansion for detector API 12 2 4 E Modulus of elasticity for flow tube material API 12 2 Appendix WT Thickness of flow tube wall inches ID Diameter of flow tube inches Calculate Calculation of Air Density in USC Units pA 0 001223068 1 0 032 x h 1000 519 67 Tf 459 67 Where pA is the density of air gm cc Per API 4 9 4 h is the elevation above sea level ft Tf is the test temper
28. OK again in order to stop the motor 6 3 2 System Health The System Health screen allows you to check the status of the various assemblies that are contained in the SVP Controller Contact Honeywell support if there are errors 6 3 3 Active Alarms The Active Alarms screen allows you to see if any alarms have been activated and to re enable the device 6 4 Troubleshooting Chart Prover does not cycle when proving pass is initiated No power to Honeywell Enraf small volume prover Check for continuity of power to prover see Section 7 Interface cable between CIU or flow computer Check connections and integrity of cables see Section 7 and flow and Honeywell Enraf small volume prover is not computer manual properly connected Above checks do not resolve problem See Section 6 for troubleshooting controller optical switches and motor stop switch Honeywell SVP Controller is not in Meter Exit Prover Test Mode Section 4 3 or Prover Calibration Mode Calibration Mode Section 5 3 and 5 4 Unsteady or absence of pulse from flow meter Defective flow meter signal cable or connection Refer to applicable proving computer manual and check cables and connections Defective pickup or pulser Check for electrical or mechanical failure Defective flow meter Observe for pulse width variation and possible noise from meter repair or replace flow meter Defective flow meter signal Test input and output signals prea
29. Revision 2 Honeywell Enraf 4 23 2014 7 27 30 PM Electrical Schematics amp Drawings CUSTOMER CONNECTION BOX DOWN MID UP MOTOR STREAM STREAM STREAM STOP SWITCH SWITCH SWITCH SWITCH T T T 1 WATER DRAW SV1 2 WATER DRAW SV2 3 WATER DRAW COMMON 4 FLOWMETER 1 POWER SEO SEO SEn 5 FLOWMETER 1 PULSE A az as ms 6 FLOWMETER 1 COMMON 7 FLOWMETER 1 PULSE 8 FLOWMETER 1 COMMON 9 FLOWMETER 2 POWER 10 FLOWMETER 2 PULSE A 11 FLOWMETER 2 COMMON 12 FEED FLOW COMPUTER 13 RUN PERMISSIVE 14 RUN PERMISSIVE 15 COMMON FLOW COMPUTER POWER BOX 16 VOLUME PULSE n m A a EN T17 VOLUME PULSE P 19 EMR CONTACT B 9 iCONVERTER 24VDC gt Os TPSEE a S a 7 0229 IHPOWER 24VDC CONVERTER 24VDC 9 4 SEE NOTE 4 FEMME GROUND 0V COMM SHIELD 23 BAR TEMP XMITTER gt 24 BAR TEMP XMITTER LOOP 2 25 BAR TEMP XMITTER LOOP 5 5 GROUND BAR TEMP XMITTER SHIELD ii 26 SVP TEMP XMITTER 126 27 SVP TEMP XMITTER LOOP 28 SVP TEMP XMITTER LOOP ee GROUND SVP TEMP XMITTER SHIELD 29 SVP PRESS XMITTER NOTES 30 SVP PRESS XMITTER LOOP 1 AVAILABLE MOTOR VOLTA
30. SEH SS KX A NYCH RR I RARE Figure 2 6 Customer Connection Box Figure 2 7 Power Box 2 4 3 2 Power Box The picture below shows the Power Box with two separate power connections one for the motor which generates electrical noise during operation and one for clean or instrument power T vaa NCC EX R NN SY X 55 S WE Sm STS ES SSN 9939999 S Lo E E amp 2 OU Part No 44200002 Revision 2 Honeywell Enraf 44200002 indd 7 Small Volume Prover Installation Operation amp Service Manual 2 7 4 23 2014 7 27 14 PM Installation 2 4 3 3 SVP Controller Box All internal electrical connections to the SVP Controller are made at the factory Agency safety approvals prohibit opening the enclosure by non Honeywell employees Connection of the LAD is as shown below Figure 2 8 SVP Controller Box with LAD 2 8 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 8 4 23 2014 7 27 14 PM CHAPTER 3 CONTROLLER INFORMATION 3 1 Initial Power up 3 2 3 2 1 Upon initial power up of the SVP Controller the Prover Status screen will be dis
31. SVP TEMP XMITTER LOOP GROUND SVP TEMP XMITTER SHIELD 29 SVP PRESS XMITTER 30 SVP PRESS XMITTER LOOP 31 SVP PRESS XMITTER LOOP GROUND BAR TEMP XMITTER SHIELD 32 LEAK DETECTOR 1 33 LEAK DETECTOR 1 LOOP 34 LEAK DETECTOR 1 LOOP GROUND LEAK DETECTOR 1 SHIELD 35 LEAK DETECTOR 2 36 LEAK DETECTOR 2 LOOP 37 LEAK DETECTOR 2 LOOP GROUND LEAK DETECTOR 2 SHIELD 38 DENSITY METER 24VDC 39 DENSITY METER GROUND 40 DENSITY METER PULSE INPUT GROUND DENSITY METER SHIELD Part No 44200002 Revision 2 Honeywell Enraf 44200002 indd 1 Small Volume Prover Installation Operation amp Service Manual 7 1 4 23 2014 7 27 27 PM Electrical Schematics amp Drawings DOWN MID UP MOTOR STREAM STREAM STREAM STOP SWITCH SWITCH SWITCH SWITCH CONTROLLER a BLACK oc T POWER BOX r NE POWER FEPTEM 125 68 ESERNOTE 3 NS o an oe 5 gt d 1L IPOWER 24VDC ICONVERTER 24VDC o i L l SEENOTE4 gt 24VDC ive 5 20 24VDC lt IE z 0 gt i26 5 Jed pee o 5 a 1 _ AVAILABLE MOTOR VOLTAGES FOR DC 24 VDC 2 FUSES CAN BE SUBSTITUTED WITH MOTOR PROTECTOR 3 WHEN THE INSTRUMENT POWER SOURCE IS AN AC SUPPLY USE AN AC DC CONVERTER TO CONVERT TO DC ACONVERTER IS NO
32. any lose bolts or parts b Be certain to check the washers on the end of the guide bars If these washers are not thick stainless steel washers replace them even if they appear to be tight standard bolt washers do not work correctly Part No 44200002 Revision 2 Small Volume Prover Installation 8 15 Honeywell Enraf Operation amp Service Manual 44200002 indd 15 4 23 2014 7 27 46 PM Check to see if all six pins have been installed Figure 8 10 PIN 2 PLACES PIN 4 PLACES X 4 SPRING PINS 14 X 14 SPRING PINS 21051 21051 Figure 8 10 Pinning Locations 8 16 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 16 4 23 2014 7 27 46 PM Prover Maintenance d When checking alignment loosen bolt on end of guide bar and use a wrench to check that the guide bar is tight to the flange Figure 8 11 WRENCH FLATS TIGHTEN HEX BOLT TO LOCK GUIDEBAR IN PLACE TURN CLOCKWISE TO TIGHTEN GUIDE BAR AGAINST FLANGE Figure 8 11 Tighten Guidebar Part No 44200002 Revision 2 Small Volume Prover Installation 8 17 Honeywell Enraf Operation amp Service Manual 44200002 indd 17 4 23 2014 7 27 47 PM Check the ground spring to ensure it is in contact with the ground bar In the case of larger provers check that the ground cable is connected to
33. drive end plate 5 3 Figure 5 4 Static Leak Detection set up overview 5 3 Figure 5 5 Recommendation for seal 5 4 Figure 5 6 Water Draw FREU AERA ae ete ene eee 5 5 Figure 5 7 Water Draw Plumbing Diagram 5 10 Figure 7 1 Wiring Diagram 1 7 1 Figure 7 2 Wiring Diagram xm RR DR RT RR 7 2 Figure 7 3 Wiring Diagram 3 7 3 Figure 8 1 Downstream Side Exploded View 8 3 Figure 8 2 Downstream Seal Retainer Assembly 8 4 Figure 8 3 Guide Block Assembly 8 5 Figure 8 4 Piston Removal 2 2 ttc ir a ala 8 6 Figure 8 5 Piston Assembly Exploded View 8 7 Figure 8 6 Piston Insertion into Flow Tube Pulling 8 9 Figure 8 7 Upstream flange and seal retainer 8 11 Figure 8 8 Guide Block Exploded 8 14 Figure 8 9 Gearbox Lubrication Diagram 8 15 Figure 8 10 Pinning 5 8 16 Figure 8 11 Tighten
34. flat washer and a nut on to the threaded rod and pull the piston into the flow tube while wiggling the downstream shaft to be certain of correct alignment with the seals and the flow tube bore Figure 8 6 Piston Insertion into Flow Tube Pulling Method Notes Refer to Table 16 for bolt torque values for assembling flow prover Upstream flange to flow tube seal does not usually need replacement during normal maintenance nor is it necessary to remove upstream flange Figure 8 7 52201 15 Put a new o ring seal Figure 8 1 53002 onto downstream end flange Figure 8 1 53001 carefully re install flange into flow tube Re install hex socket bolts Figure 8 1 53003 securing the downstream end flange Figure 8 1 53001 to the flow tube Snug bolts evenly using a cross pattern so as to not damage the seal or distort the flange Refer to Table 16 for bolt torque specifications and carefully tighten bolts evenly using a cross pattern and moving in increments to the full torque value 16 With downstream seal retainer assembled to the downstream stop refer to Section 8 4 steps 11 amp 12 finish re assembly of the downstream side of the prover using the reverse of the procedure from 1 through 4 making sure that critical bolts are tightend as per torque specification see Table 16 Part No 44200002 Revision 2 Small Volume Prover Installation 8 9 Honeywell Enraf Operation amp Service Manual 44200002 indd 9 4 23 20
35. is open SV1 Valves V5 and V6 must be closed while recording this pressure which is the pressure at the start and the end of volume switching 15 Record temperature Td at T2 which is the detector temperature by opening the drive cover and placing the thermometer midway between volume switches which is the location of the switch bar temperature transmitter thermowell 16 Record fluid temperature Tp at T1 17 When the flag reaches the second optical volume switch the draw valve SV1 is turned OFF and the bypass valve SV2 is turned ON Carefully record scale reading SR and test measure temperature Ttm at T3 18 After all data is collected drain the test measure 19 Repeat steps 12 through 18 as necessary to obtain the required number of well repeating runs including one run at 2596 flow rate variance Please note that a log will be saved with start time and sweep time after each calibration run 20 Once you have completed the calibration select the Exit Calibration menu which will turn the bypass valve SV2 OFF 5 8 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 8 4 23 2014 7 27 24 PM Calibration 21 Calculate prover volume per Section 5 5 22 Enter the average calibration volume calculated in the previous step by selecting the Enter Average Volume menu This screen can be accessed while still in the Cal
36. longer suitably protected against ingress of water Maintenance and troubleshooting In the unlikely event of malfunction only a qualified service engineer trained by Honeywell Enraf and with knowledge of safety regulations for working in potentially explosive atmospheres is allowed to repair the instrument Part No 44200002 Revision 2 Small Volume Prover Installation xi Honeywell Enraf Operation amp Service Manual 44200002 indd 11 4 23 2014 7 27 03 PM The Honeywell Enraf Prover Series Additional information If you require additional information contact Honeywell Enraf or its representative Approvals Refer to the EC declaration of conformity and ATEX certificate s shipped with the instrument as it may vary per configuration CE Directives and approvals CE Directive Certificate number 94 9 EC ATEX electrical LCIE 05 ATEX 6068X 94 9 EC ATEX mechanical Honeywell Enraf declared 2006 42 EC Machinery Directive Honeywell Enraf declared 97 23 EC Pressure Equipment Directive 60330 2009 CE HOU DNV Environmental conditions Ambient pressure atmospheric Relative humidity 5 95 Ambient temperature ATEX Approval 20 C to 40 C 4 F to 104 F and CSA Approval 20 C to 50 C 4 F to 122 F Additional information specific to the SVP Controller Approvals ATEX Il 2 Ex d ia IIB T6 Gb IECEx Ex d ia IIB T6 Gb Certificates Approval
37. record version 3 3 9 2 Calibration Logs The details of any transaction can be viewed by going to that transaction and pressing OK After every prover run cycle in prover calibration mode the following parameters will be logged after completing the prover run The calibration log contains the following information m Date and time m Sweep time in seconds m Average volume m Repeatability There are no units displayed for the average volume as they will be known by the user and to avoid complications if the units specified in the Configuration Device Units menu are changed 3 3 9 3 Alarm Logs The Alarm log forms a permanent record of the same information that can be viewed while an alarm is active from the Diagnostics Active Alarms screen This information consists of the date and time stamp and descriptive text Part No 44200002 Revision 2 Small Volume Prover Installation 3 17 Honeywell Enraf Operation amp Service Manual 44200002 indd 17 4 23 2014 7 27 19 PM Controller Information 3 3 10 Diagnostics d This menu provides the following features m High level view of all device I O functions showing their state as High Low m Each output function can be tested by selecting and activating it m Internal memory usage overview m System health overview m Active alarms overview m Clear alarms m Activate the Run Prover Test mode 259 eH Configuration Figure 3 17
38. the flow computer signals the return drive motor to pull the piston to the up stream position The piston then mechanically disconnects from the chain drive return mechanism When the piston is released the flow thru poppet valve closes by spring tension as seen in Figure 1 2 The piston is now free to follow the fluid flow with the least possible effect on the flow stream The piston velocity is now synchronized with the fluid velocity Figure 1 2 Prover During Prove Run Mid Run After the piston has been released and synchronized with the fluid flow the precision optical start of volume switch is actuated which sends a signal to the flow computer to start the timing sequence The piston continues downstream with the flow Upon reaching the end of volume switch a signal is sent to the flow computer to stop the timing sequence After passing the end of volume switch the piston shaft is stopped mechanically The fluid pressure in the prover pushes the perimeter of the piston further downstream opening the flow thru poppet valve allowing the flow to continue with little to no pulsation or surge in line pressure The return drive motor is started electronically to pull the piston back upstream if the flow computer requires more passes and the above sequence is repeated Part No 44200002 Revision 2 Small Volume Prover Installation 1 11 Honeywell Enraf Operation amp Service Manual 44200002 indd 11 4 23 2014 7 27 07 PM Intro
39. the serial number and sales order number available to help expedite any assistance needed 5 The Honeywell Enraf small volume prover has been designed to be used as either a portable or stationary mounted flow prover The Honeywell Enraf small volume prover may be installed upstream or downstream of the meter under test as the displaced volumes are equal Part No 44200002 Revision 2 Small Volume Prover Installation XV Honeywell Enraf Operation amp Service Manual 44200002 indd 15 4 23 2014 7 27 03 PM Installation Procedure 6 The Honeywell Enraf small volume prover should be installed on a flat surface and secured using 4 bolts through the pre determined anchor points on the prover frame Refer to Figure 2 4 It is recommended to bolt the prover to the slab trailer at these four locations only It is not recommended to use any other method or type of securing the prover against the movement during operation Honeywell Enraf will not be responsible for possible damages to the prover or system parts if these recommendations are not followed 7 Itis mandatory to provide enough space around the prover to accommodate any removal of components during maintenance see Figure 2 3 8 When installing the Honeywell Enraf small volume prover follow all recommended procedures regarding positioning of prover in relation to the flow meter To assure that all flow is passed through the flow prover double block amp bleed diverter v
40. 0 GPM at 25 100 psig steady non fluctuating pressure 5 A volume catch container ideally large enough for the volume of fluid dispensed by the prover Container must be designed to be placed on the precision balance or scales 6 Certified high resolution pressure gauge 0 690 kPag 0 100 psig 7 Three traceable thermometers with 0 1 C 0 2 F graduations for thermometer reference positions see Figure 5 7 8 Water draw data sheet Table 14 9 Water overboard container volume to be at least as large as test measure Note Honeywell Enraf Water Draw P amp T kit or equivalent assembly eases installation of water draw prover instrumentation The Honeywell Enraf Water Draw P amp T kit consists of four traceable temperature thermometers one spare thermometer included and one pressure gauge All thermometers come with the calibration certifications if ordered from Honeywell Enraf Procedure Water draw notes Perform steps 14 21 at least twice prior to taking data to purge the system of air assure the temperature is stable and to get familiar with the procedure Repeat water draw procedure until at least consecutive draws repeat within 0 02 or other repeatability criteria that the certifying parties agree upon The flow rate on at least one run must vary by 25 to assure integrity of prover seals and absence of leakage Failure to achieve the necessary repeatability may be caused by leaking valves air in the s
41. 0 Ib Mr 7 82 Nm 5740 lb eft S O P120 Inlet Outlet Nozzle Nominal Diameter 16 inch FX 3737 840 Ib Mx 5125 Nm 3780 Ib eft Top Nozzle Fy 9916N 1330 lb Each Nozzle My 3796 Nm 2800 Ib eft Fz 46 1N 1050 lb Mz 2562 Nm 1890 lb eft FX 5916 N 1330 Ib Side Nozzle Fy 4671N 1050 lb Resultant Fr 11521 2590 Ib Fz 7162N 1610 lb Mr 10535 Nm 7770 lb eft Table 10 Maximum allowable inlet and outlet flange loads 1 8 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 8 4 23 2014 7 27 04 PM Introduction Prover critical dimensions See prover s critical dimensions provided below lat E LEFT SIDE RIGHT SIDE Honeywell Enraf I JE D M A CUN S 05 15 25 35 50 85 120 A 2438 96 4060 160 4060 160 4060 160 4500 177 5230 206 5590 220 B 610 24 914 36 914 36 914 36 1070 42 1270 50 1370 64 C 686 27 828 32 6 848 33 4 925 36 4 1170 45 9 1230 48 5 1380 64 5 D 427 16 8 523 20 6 523 20 6 541 21 3 673 26 5 762 30 833 32 8 E 777 30 6 1370 53 9 1370 53 9 1310 51 4 1470 58 1930 76 2040 80 5 F 930
42. 10 Rotate the adjustment screw 3 Figure 5 4 clockwise to push the plunger out to apply force to the piston shaft and create a differential pressure between the inlet and the outlet of the prover Rotate the adjustment screw until a differential pressure of 6 psid has been created Pressurize the unit slowly and watch the pressure gauge In some cases it might happen that applied pressure of 6 psid will be significantly lost in the first couple of minutes The reason is that the poppet valve will need short period of time to fully close and stabilize Therefore it is our recommendation to allow at least 5 minutes between the applied pressure and actual data recording 11 Look the prover over for any obvious external leaks 12 Start observing the differential pressure gauge for a period of 20 minutes If the pressure has not dropped by more than 25 of the starting differential pressure it may be assumed that there are no 5 2 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 2 4 23 2014 7 27 21 PM Calibration piston seal leaks If the pressure has dropped to lower levels it should be assumed that there is a seal leak and the prover piston seals should be replaced Refer to Figure 5 5 eser OF iig or P e a Figure 5 2 Gauge with HI amp LOW markings Figure 5 3 Differential pressure creator inserted in drive end plate DIFFERENTI
43. 14 7 27 41 PM 8 6 Upstream Shaft Seals Replacement 1 Make sure that the steps from 2 thru 4 mentioned in the Section 8 4 and the steps from 5 thru 7 mentioned in the Section 8 5 are fully completed 2 Remove the retaining rings seals and washers from the upstream seal retainer Figure 8 7 52101 Clean and inspect seal retainer Check seal surfaces for scratches and a surface finish of 12rms If necessary polish the seal surfaces 5 Carefully install new seals and washers in proper orientation see Figure 8 7 for correct installation Note the direction of the seal lips for correct installation of the new seals In a case of cracked or broken washers they need to be replaced when new seals are installed 6 Install the upstream seal retainer Figure 8 7 52101 in the upstream flange Figure 8 7 52201 Re install hex socket bolts Figure 8 7 52107 in order to secure the upstream seal retainer to the upstream end flange Snug bolts evenly using a cross pattern so as to not damage the seal or distort the flange Refer to Table 16 for bolt torque specifications and carefully tighten bolts evenly using a cross pattern and moving in increments to the full torque value 8 Re install the shock absorbers Figure 8 7 52108 Make sure to adjust the setting on all four shock absorbers at the same setting number see instructions in Section 8 8 10 9 Install the mechanical stop
44. 17 4 23 2014 7 27 25 PM Calibration Gravimetric Water Draw Data Sheet Date Prover Serial Number Prover Model Number Report Number Location Standard Temperature Tb Standard Pressure Pb Elevation h Field Test Weight Density Reference Test Weight Density Compressibility Factor water CPL Flow Tube Area Thermal Expansion Coefficient Ga Detector Linear Thermal Expansion Coefficient Gl Modulus of Elasticity of flow tube E Flow Tube Inside Diameter inches ID Flow Tube Wall Thickness inches WT Fill 1 Fill 2 Fill 3 Fill 4 Fill 5 Fill Time minutes Temperature Air Ta Temperature Prover Tp Temperature Detector Td Prover Pressure Pp Water Electrical Conductivity Total Mass of Water Ww Density of Air pA Calculated Density of Water pw Correction of Air Buoyancy of Weighing CBW Corrected Mass of Water Mw Volume of Water Vw Effect of Pressure on Water CPL Temperature Correction on Prover CTS Pressure Correction on Prover CPS Corrected Water Volume WD Table 14 Gravimetric Water Draw Data Sheet 5 18 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 18 4 23 2014 7 27 25 PM Calibrat
45. 2 4 Service due The prover is due for service as determined by the entry at Main Menu Configuration Alarms Service Due Reminder 6 3 Diagnostics There are several screens inside the Main Menu Diagnostics menu to aid in troubleshooting 6 3 1 Dashboard The dashboard screen allows you to verify the status of the inputs and outputs of the SVP Controller Each output function can be tested by selecting it and activating it Dashboard Down Sensor High Alarm Output Inactive Middle Sensor High Alarm Clear High Up Sensor High Motor Stop Switch High Motor Run Inactive Optical Pulse Inactive Run Permissive High Handheld OK Bypass Valve Inactive Draw Valve Inactive Press OK to change values Stop A properly functioning optical switch will normally indicate High at the dashboard screen Inserting an opaque flag into the optical switch will cause the state to change to Low 6 2 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 2 4 23 2014 7 27 25 PM Troubleshooting To check if the motor stop switch is working properly you should select Motor stop switch and trigger the motor stop The state should change from High to Low To check if the motor is working you should scroll down to the Motor run command and press OK The state of the motor will be changed from Inactive to Active You will need to press
46. 3 9 Logs This is the user interface to various logs maintained in non volatile memory including m Transaction logs complete information for each transaction m Calibration log shows the sequence of SVP calibrations over time m Alarm Log chronological list on when alarms occurred and what type of alarms they were Main Menu Figure 3 15 Logs The log memory will be a rolling memory file with the oldest data being overwritten first when the memory is full Note that the log will be simply overwritten without issuing a warning message Transaction Transaction Info Logs Calibration Main Menu SVP HMI Screens Figure 3 16 Logs Menu Tree 3 3 9 1 Transaction Logs The transaction log will contain the following data for each Prover run m Date and time m Sweep time in seconds m Number of prover cycles 3 16 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 16 4 23 2014 7 27 19 PM Controller Information 3 3 9 1 1 Transaction information The details of any transaction can be viewed by going to that transaction and pressing OK After every prover run cycle in calibration of meter mode the following parameters will be logged after completing the prover run m Transaction ID m Stop Transaction date and time m Cycle count m Sweep time m Alarm information m Sensor Pair m Device Serial Number m Transaction
47. 8 13 Table 18 Frequently Asked 5 8 33 viii Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 8 4 23 2014 7 27 02 PM THE HONEYWELL ENRAF PROVER SERIES Safety instructions for installation commissioning operation and maintenance Preface The Honeywell Enraf HE SVP Small Volume Prover is a high precision instrument for verification of calibration of flow metering equipment The SVP Controller and the Fusion4 Local Access Device LAD form the control aspects of the SVP The LAD is a hand held controller used to interface to the SVP Controller allowing tasks such as the adjustment of parameters resetting of alarms and calibration The LAD facilitates two way data communications between the SVP Controller and the LAD allowing the rapid transfer of transaction data configuration files and calibration records and even upgrading of firmware in the field The following warnings apply to all components of the SVP A Warning Only use the instrument for its intended purpose EC declaration of conformity Refer to the EC declaration of conformity and ATEX certificate s shipped with the instrument Installation The mechanical and electrical installation shall only be carried out by trained personnel with knowledge of the requirements for installation of explosion proof equipment in potentially explos
48. 8 Drive System 8 14 8 8 1 Before working on the Drive System 8 15 8 8 2 Checking Alignment of Drive System general checking 8 15 8 8 3 Checking Alignment of Guide 8 19 8 8 4 Check the Alignment of the 8 21 8 8 5 Shimming the 8 23 8 8 6 Check the Alignment of the Shafts and Puller 8 27 8 8 7 UHMW Chain Rail 8 33 8 8 8 Check the Chain Tension 8 34 Part No 44200002 Revision 2 Small Volume Prover Installation V Honeywell Enraf Operation amp Service Manual 44200002 indd 5 4 23 2014 7 27 02 PM Table of Contents 8 8 9 Securing the Drive 8 35 8 8 10 Check Shocks o oa raura 8 35 8 9 Volume Switch 8 36 8 10 Thread Locker Fluid Location 5 8 38 8 11 After Sales Support ada aca Rcx RR UR eR RUBER QU RUN AUN 8 40 8 12 Frequently asked 5 5 8 41 LIST OF FIGURES Figure 1 1 Prover in Stand By 1 11 Figure 1 2 Prover During Prove Run amp
49. AC 4 OPTION Alarm Clear DI DC 2 Module manager Active Alarms Active Alarms Re enable device Free Space transaction Total Space transaction Total transaction records Storage Info Total calibration records Total alarm records Clear task Clear all alarms Prover Service Test Run Prover Test Exit Prover Test Figure 3 18 Diagnostics Menu Tree Part No 44200002 Revision 2 Small Volume Prover Installation 3 19 Honeywell Enraf Operation amp Service Manual 44200002 indd 19 4 23 2014 7 27 20 PM Controller Information 3 3 11 Transfer A Note Only when the LAD is connected Via this user s interface the following type of records can be transferred between the SVP Controller and the LAD Transaction records Configurations Events logs alarms Calibration records Main Menu Figure 3 19 Transfer The diagram below shows all of the information available to you Retrieve Single Transaction Record Transaction records Retrieve All Transaction Records Retrieve Range of Transaction Records Apply Configuration SVP HMI Screens Main Menu Transfer Configurations Retrieve Configuration Events Logs Retrieve Alarm Logs Retrieve Calibration Records Calibration records Retrieve Single Calibration Record Figure 3 20 Transfer Menu Tree 3 20 Small Volume Prover Installation
50. AL PRESSURE GUAGE 1 HIGH PRESSURE DIFFERENTIAL PRESSURE CREATOR 2 LOW PRESSURE Honeywell Enraf Small Volume Prover Honeywell Enraf Figure 5 4 Static Leak Detection set up overview Part No 44200002 Revision 2 Small Volume Prover Installation 5 8 Honeywell Enraf Operation amp Service Manual 44200002 indd 3 4 23 2014 7 27 23 PM Calibration Seals good Schedule seals for replacement Change seals Differential Pressure Drop psid o 0 5 10 15 20 Figure 5 5 Recommendation for seal change 5 3 Volume Water Draw Equipment 1 Water draw kit Contact Honeywell Enraf representative or factory directly to obtain a water draw kit See Figure 5 6 2 Source of clean potable water Pump or water supply must have steady flow of approximately 38 Lom 10 GPM at 172 690 kPa 25 100 psi Water supply must maintain non pulsating pressure 3 Certified volume test measures conforming to API chapter 4 section 7 traceable to the U S NIST or other National standards The test measure should be of the same volume as the displaced volume of the prover If however the test measure is smaller than the prover volume there must be at least two test measures as the flow during water draws should be continuous for the greatest precision Example For a 20 gallon prover uses a single 76 L 20 gal test measure 4 Certified high resolutio
51. Diagnostics Within this screen the user can view the diagnostics about the following subjects m Overview of all I O Dashboard m Overview of system health m Overview of all active alarms m Overview of device tasks such as clearing tasks clearing alarms and running prover test task m Overview of available memory storage space for data logs and total number of available logs The diagram below shows all of the information available to you Note that the parameters marked with an are not relevant for the first release of the SVP Controller They are reserved for future use or for internal testing 3 18 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 18 4 23 2014 7 27 20 PM Controller Information Down Sensor Mid Sensor Up Sensor Motor Stop Switch Motor Run Cmnd Optical Pulse Dashboard Run permissive Handheld Bypass Valve Draw Valve Alarm Output Alarm Clear Device manager Alarm manager Trans manager HMI Module manager Display manager COMMS Down sensor Mid sensor Up sensor Motor Stop Switch SVP Motor Run Optical Pulse SVP Controller Main Menu Diagnostics SVP HMI Screens System health Run permissive Pulse input COMMS Alarm Output DI AC 1 DI AC 2 DI AC 3 DI
52. Fy 747N 168 Each Nozzle My 503 Nm 371 Ib eft Fz 623 N 140 Mz 332 Nm 245 Ib eft FX 747 168 Side Nozzle Fy 623 N 140 Resultant Fre 1993 N 448 lb Fz 934 N 210 Mr 1329 Nm 980 Ib eft S O P15 S O P25 Inlet Outlet Nozzle Nominal Diameter 6 inch 1090 245 1613 1190 Ib eft Top Nozzle Fy 1744 392 Each Nozzle My 1234 Nm 910 Ib eft Fz 1482 322 Mz 826 Nm 609 Ib eft FX 1744 392 Side Nozzle Fy 1482 322 Resultant hrs 4671N 1050 Ib Rz 2180N 490 Mr 3322 Nm 2450 lb eft S O P35 S O P50 Inlet Outlet Nozzle Nominal Diameter 8 inch FX 1650 371 Mx 2468 Nm 1820 Ib eft Top Nozzle Fy 2647 N 595 Each Nozzle My 2577 Nm 1901 Ib eft Fz 2180N 490 Mz 1234 Nm 910 lb eft FX 2647 N 595 Side Nozzle Fy 2180N 490 Resultant Fr 7162 N 1610 Ib Fz 3425 N 770 Mr 4935 Nm 3640 Ib eft Continued on next page Part No 44200002 Revision 2 Honeywell Enraf 44200002 indd 7 Small Volume Prover Installation Operation amp Service Manual 1 7 4 23 2014 7 27 04 PM Introduction Continued from previous page S O P85 Inlet Outlet Nozzle Nominal Diameter 12 inch FX 2865 N 644 lb Mx 4271 Nm 3150 Top Nozzle Fy 4671N 1050 Ib Each Nozzle My 3227 Nm 2380 lb eft FZ 3737 840 Ib Mz 2088 Nm 1540 Ib eft FX 4671N 1050 Ib Side Nozzle Fy 3737 840 lb Resultant Fr 9030 N 2030 Ib Fz 5605 126
53. GES RETURN J 31 SVP PRESS XMITTER LOOP FOR 3 PHASE DRIVE 120 400 460 480 VAC MOTOR 2 FUSES CAN BE SUBSTITUTED WITH MOTOR PROTECTOR 3 WHEN THE INSTRUMENT POWER SOURCE IS AN AC SUPPLY USE AN AC DC CONVERTER TO CONVERT TO DC ACONVERTER IS NOT NEEDED ON DC SOURCES 4 ONLY NECESSARY IF A WATER DRAW KIT IS PURCHASED LEGEND TERMINAL BLOCK GROUND BAR TEMP XMITTER SHIELD 32 LEAK DETECTOR 1 33 LEAK DETECTOR 1 LOOP 84 LEAK DETECTOR 1 LOOP GROUND LEAK DETECTOR 1 SHIELD 35 LEAK DETECTOR 2 36 LEAK DETECTOR 2 LOOP 37 LEAK DETECTOR 2 LOOP GROUND LEAK DETECTOR 2 SHIELD 38 DENSITY METER 24VDC 39 DENSITY METER GROUND 40 DENSITY METER PULSE INPUT GROUND DENSITY METER SHIELD Figure 7 3 Wiring Diagram 3 Phase Part No 44200002 Revision 2 Small Volume Prover Installation 7 3 Honeywell Enraf Operation amp Service Manual 44200002 indd 3 4 23 2014 7 27 34 PM Electrical Schematics amp Drawings 7 2 Connections to Flow Computers Shown below are diagrams showing how to connect the SVP Controller via the Customer Connection Box to various models of flow computers Note that the first diagram shows a simplified representation of the Run Permissive Input and the Volume Pulse Output circuits in the SVP Controller The 1500 ohm current limiting resistor shown in the diagrams is required with operating voltages from 12 to 24 volts DC For operating
54. HAPTER 4 Operations RR sae 4 1 4 1 Operating Instructions eedem 4 1 4 2 Meter 4 1 LED Prover alae an diag ENERE nn ERE beet ciel arated gee dud 4 2 4 4 Prover Calibration ss rh hr 4 3 CHAPTER 5 Calibrations ceed tate eee nade 5 1 51 General 34 33 RR O DR YRR RY khe RR 5 1 5 2 Static Leak Detection 5 1 5 3 Volume Water Draw 225402050 uhr 5 4 5 4 Gravimetric Water 5 12 5 5 Calculations sees eee unen ecc eee 5 19 iv Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 4 4 23 2014 7 27 02 PM Table of Contents CHAPTER 6 6 1 6 1 Run Prover T6St os iuo nn RR LD RR RR RH O DD RD SENE 6 1 6 2 Error MeSSaU68S oce ci Rane Seana Dy AF aUa PEREA LD 6 1 6 2 1 Sensor out of Sequence 6 1 6 2 2 Motortime RR RR UR 6 1 6 2 3 Sensor stuck
55. Honeywell Enraf FOR MODEL 05 15 25 Honeywell Enraf Small Volume Prover Installation Operation amp Service Manual 44200002 indd 1 4 23 2014 7 27 02 PM HONEYWELL ENRAF SMALL VOLUME PROVER INSTALLATION OPERATION amp SERVICE MANUAL FOR MODEL 05 15 25 2 Edition Released April 2014 44200002 indd 2 4 23 2014 7 27 02 PM Table of Contents The Honeywell Enraf Prover 5 ix Installation Procedure 22233020224 RI Rma CHAPTER T lritroductiori file neri eee gt 1 1 1 1 OVerV eW RR RR EG RR RR RR 1 1 1 2 General Features 1 2 1 3 Honeywell Enraf small volume prover design specifications 1 2 1 4 Tests and Certifications 1 10 1 5 Principle of Operation as RR as a cae 1 11 CHAPTER 2 Insiallation 2 ae au lali qtu 2 1 2 1 Receipt of 2 1 2 2 Return Shipment s us ue aora MMR AU BYN YRU 2 1 2 3 Mechanical 2 1 2 4 Electrical Connection ee ea emn ewe xe de mc RR UR 2 5 2 4 1 Field wiring m 2 6 2 4 2 eiut ree mese nk RE NEUES RR ara E
56. Manual 44200002 indd 29 4 23 2014 7 27 50 PM Prover Maintenance 8 9 Volume Switch Replacement If optical volume switch replacement is necessary as determined by trouble shooting procedures found in Section 6 follow steps 1 through 5 1 Remove 3 as shown in Figure 8 3 to access electrical connector 2 Lift electrical connector very gently from the hole and disconnect the cable from the switch wires 3 With a stiff wire with a hook bent in the end or small needle nosed pliers gently disconnect the switch retaining springs from the switch bar and remove the old switch Prior to dropping the switch out of position note orientation of the switch in the switch bar L bracket 4 Install the one end of the switch retaining springs in the holes of the new optical switch 5 Position the new switch in the same position noted in step 3 and reverse steps 3 through 1 for re installation of the new volume switch Note The Honeywell Enraf volume switch assembly has been precision adjusted at the factory Water draw after switch replacement is not required Older models may be using optical switches with aluminum base plates While these switches are still valid for use the new standard is a stainless steel base plate Under no circumstance should one aluminum and one stainless steel switch be used together optical switch base plate material must be identical for both switches NOTICE to Honeywell Enraf small volume prover us
57. NOTCHED RYTON WASHER Figure 8 7 Upstream flange and seal retainer assembly Please Note On the provers models 505 005 515 015 525 025 and 535 035 all three shaft seals are the same Part No 44200002 Revision 2 Honeywell Enraf 44200002 indd 11 Small Volume Prover Installation Operation amp Service Manual 4 23 2014 7 27 43 PM 8 7 Bolt Torque Specifications mbe 52206 52107 53003 53107 531 10 54018 54020 See woe 7 Numbe 52206 52107 53003 53107 53110 54018 54020 See Note 1 Table 16 Bolt Torque Specifications Note 1 Hexagonal standard nut Figure 8 3 position1 holding guide block Figure 8 3 position 2 to upstream shaft 8 12 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 12 4 23 2014 7 27 45 PM Prover Maintenance Torque ratings for guide block components Items Items Items Items Items Model 24006 24012 24018 24002 24019 Model Screw Screw Screw Cam follower Cam follower 5 47 5 Nm 35 Ibfeft 5 15 Us 25 129 Nm 25 13 Nm 95 Ibfeft 35 9 6 Ibfeft 26 8 Nm 31 7 Nm 35 50 19 8 lbfeft 43 0 lbfeft 340 Nm 881 Nm 50 85 250 Ibfeft 650 Ibfeft 85 120 1700 Nm 120 1250 Ibfeft Table 17 Guide Block Bolt Torque Specifications Note See Figure 8 8 for items referenc
58. Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 20 4 23 2014 7 27 20 PM Controller Information 3 3 12 LAD Settings Note Only when the LAD is connected This is the user interface to the LAD specific functionality m Firmware download to the SVP Controller and the LAD m Management of the LAD s stored records m Format SD card Main Menu Figure 3 21 LAD Settings The diagram below shows all of the information available to you Fusion4 device LAD Firmware update Serial number SD card memory NVRAM memory LAD Functions Voltage SVE HMI Screens Mali Many LAD information Temperature Hardware version Application version Bootloader version Format SD card Format Confirmation Window Figure 3 22 LAD Settings Menu Tree Part No 44200002 Revision 2 Small Volume Prover Installation 3 21 Honeywell Enraf Operation amp Service Manual 44200002 indd 21 4 23 2014 7 27 20 PM Controller Information Intentionally left blank 3 22 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 22 4 23 2014 7 27 20 PM CHAPTER 4 OPERATIONS 4 1 Operating Instructions 1 Firstly carry out the removal and replacement of transit seals with the operation seals as supplied prior to introducing liquid into the Honeywell Enraf small volume prover 2 Open fluid inlet valve sl
59. Prover Installation 5 15 Honeywell Enraf Operation amp Service Manual 44200002 indd 15 4 23 2014 7 27 25 PM Calibration 22 After all data is collected drain the catch container and tare scales 23 Repeat steps 14 through 22 as necessary to obtain the required number of well repeating runs including one run at 25 flow rate variance Please note that a log will be saved with start time and sweep time after each calibration run 24 Once you have completed the calibration select the Exit Calibration menu which will turn the bypass valve SV2 OFF 25 Calculate prover volume per Section 5 5 26 Please Note A copy of Table 14 for gravimetric calibration can be used to enter water draw data An Excel readable file is available from Honeywell Enraf which will calculate the corrected prover volume using the gravimetric method After selecting Enter Average Volume following screen appears Enter Average Volume 5 37000 Backspace Confirm Enter value Stop 27 Enter the average calibration volume calculated in the previous step by selecting the Enter Average Volume menu This screen can be accessed while still in the Calibration mode or at a later time by entering the Calibration menu and then accessing this screen directly 28 After the Average Volume has been entered and confirmed the following screen is displayed to enter the Repeatability in percent The entered average volume and
60. R RE YE 2 6 2 4 8 EnclosureS 26 0500 s s hh m m Rm RR RD RR RR mh RR RD RR 2 6 2 4 3 1 Customer Connection 2 7 2 4 8 2 Power BOX 2 7 2 4 3 3 SVP Controller BOX eco ED her 2 8 CHAPTER Controller Information 2 200000080000 hr hr an 3 1 3 1 Initial Power RR CR RR IR d 3 1 3 2 Navigating the SVP Controller Menus Using the LAD 3 1 3 2 1 Text ConventioriS nr mtt e 3 1 3 2 2 General 5 ooi nao xag GR RR RR RR 3 2 3 2 9 COMMISSIONING acc sinus cm tan onc n arde FREUD A 3 2 3 3 Menus and Navigation 3 3 3 3 1 General Mm 3 3 3 3 1 1 Key benefits RR RR O 3 3 3 3 2 Main Menu de 3 3 3 3 3 Screen Input FieldS gt mr a 3 4 3 3 3 1 Text Input 3 4 3 3 3 2 Numeric Input 3 4 3 3 3 3 Enumeration Input 3 5 Part No 44200002 Revision 2 Small Volume Prover Installation iii Honeywell Enraf Operation amp Service Manual 44200002 indd 3 4 23 2014 7 27 02 PM Table of Contents 3 3 9 4 Status Bar x nn Re HER 3 5 3 3
61. Roswell GA 30076 4908 USA Honeywell Enraf Tel 770 475 1900 Fax 770 475 1717 44200002 April 2014 www honeywellprocess com 2014 Honeywell International Inc 44200002 indd 34 4 23 2014 7 27 50 PM
62. Servicing the prover should be done in a de engergized state but may require reactivating power for the motor or flow through the prover to position the piston Use extreme caution and keep clear of all moving components including the downstream shaft All covers should remain in place while the prover is energized if at all possible Metal tools should not be used inside the flow tube so as not to damage the surface finish 8 1 Portable Prover m Lock out AC or DC power to motor with padlock m Install Condat System and computer m Install fake flow meter signal generator if checking optical switches m urn on the 24VDC to the Condat 8 2 Stationary prover m Lock out AC power to prover with padlock 8 3 General Prover Maintenance Information Preventative Maintenance Honeywell Enraf small volume provers are designed to require minimal maintenance however several key components require periodic inspection and or replacement to prevent undue wear damage or possibly failure The following recommended maintenance intervals are based on an average usage rate of 100 passes per day proving refined petroleum products at average temperatures of 77 F 25 C The fluid is typified as clean of foreign objects or debris and possessing moderate lubricity If the fluid being introduced into the prover is high in entrained solids i e sand in crude oil or low in lubricity i e LPG s and certain chemicals then it is recommended to reduce the time b
63. T NEEDED ON DC SOURCES LEGEND Cid 4 _ ONLY NECESSARY IF WATER Li DRAW KIT IS PURCHASED TERMINAL BLOCK RETURN DRIVE MOTOR Figure 7 2 Wiring Diagram DC CUSTOMER CONNECTION BOX 1 WATER DRAW SV1 11 FLOWMETER 2 COMMON 12 FEED FLOW COMPUTER 13 RUN PERMISSIVE 14 RUN PERMISSIVE 15 COMMON FLOW COMPUTER 16 VOLUME PULSE 17 VOLUME PULSE 18 EMR CONTACT A 19 EMR CONTACT B 20 ALARM CLEAR 21 ALARM CLEAR 41 TXIRX 42 TXRX GROUND COMM SHIELD 23 BAR TEMP XMITTER 24 BAR TEMP XMITTER LOOP 25 BAR TEMP XMITTER LOOP GROUND BAR TEMP XMITTER SHIELD 26 SVP TEMP XMITTER 27 SVP TEMP XMITTER 28 SVP TEMP XMITTER LOOP GROUND SVP TEMP XMITTER SHIELD 29 SVP PRESS XMITTER 30 SVP PRESS XMITTER LOOP 31 SVP PRESS XMITTER LOOP GROUND BAR TEMP XMITTER SHIELD 32 LEAK DETECTOR 1 33 LEAK DETECTOR 1 LOOP 34 LEAK DETECTOR 1 LOOP GROUND LEAK DETECTOR 1 SHIELD 35 LEAK DETECTOR 2 36 LEAK DETECTOR 2 LOOP 37 LEAK DETECTOR 2 LOOP GROUND LEAK DETECTOR 2 SHIELD 38 DENSITY METER 24VDC 39 DENSITY METER GROUND 40 DENSITY METER PULSE INPUT GROUND DENSITY METER SHIELD 7 2 44200002 indd 2 Small Volume Prover Installation Operation amp Service Manual Part No 44200002
64. alves are recommended 9 Ensure not to overload prover inlet amp outlet nozzles Maximum allowable loads on prover nozzles are provided in the Table 10 It is the customer s responsibility to design piping systems and maintain nozzle loads within the provers maximum allowable loads It is also important to provide adequate support of inlet and outlet piping 10 Prover vent and drain lines must be plumbed to drain collection sumps Do not vent directly from the bleed valves as personal injury may occur A Warning For proper operation of the SVPs it is mandatory to properly vent the prover and to make sure that fluid vapor is removed from the SVP SVPs can fully function when proving fluids are in the liquid form only 11 Install a correctly sized strainer filter upstream of the prover in order to ensure the flow entering the prover is free from debris and foreign material Honeywell Enraf s recommendation would be to use strainers with minimum 40 mesh screen 12 To avoid over pressuring of the prover and prover components a correctly sized pressure relief as per API 520 API 521 and API 526 should be installed on the downstream side of the prover The option for the installation of the relief valve would be to use one of the spare openings in the downstream end flange or to install the relief valve in the downstream section between the prover outlet flange and the closest discharge valve 13 Lifting instruction Ref Figure 2
65. at all Honeywell Enraf small volume prover users implement a method of preventing an over pressurization of the flow prover This task is most readily achieved through the use of a pressure or safety relief valve The use of a pressure or safety relief valve will reduce if not eliminate possible failures due to over pressurization of the prover Due to the fact that each installation will require a different pressure relief valve based upon system pressure fluid properties flow rate etc the equations provided in API 520 API 521 and API 526 should be used to size the appropriate relief valve The pressure rating of the relief valve should be calculated by taking the maximum operating pressure and adding 10 for a momentary over pressurization or line surge of the system IMPORTANT WATCH DISCHARGE FROM RELIEVING DEVICES Additionally take extra care when pressuring the flow prover at cold temperatures All Honeywell Enraf small volume prover tubes are manufactured from stainless steel which experiences a reduction in ductility at reduced and elevated temperatures below 29 C 20 F or above 37 8 C 100 F Therefore pressurization of flow provers in these temperature regions should be done slowly by water trapped in piston and shaft seal areas for long periods of time result of water draws Chrome pitting can also be caused from welding to or near structural components of the prover such as the skid frame or piping i
66. ature F Calculation for the Correction for Air Buoyancy on Weighing CBW CBW2 1 0 0012 pTWr J 1 0 0012 pTW 1 pA pTWf 1 pA pFtp Where CBW is the correction for air buoyancy on weighing pT Wr is the density of reference test weights gm cc pT Wf is the density of the field test weights gm cc as per certificate of traceability pFtp is the density of fluid at test temperature and test pressure gm cc pA is the density of dry air gm cc 5 20 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 20 4 23 2014 7 27 25 PM Calibration Calculation for the Density of the Calibration Water pwtF Density of water at temperature t F kg cm From API 12 2 4 or calculate by algorithm taken from API 4 9 4 Using the algorithm taken from API 4 9 4 pwtF 1 ptF B ptF 2 C ptF S D ptF 4 E ptF 5 1000 Where pwtF is density at temperature t F kg cm pO is density at temperature tO 999 97358 kg m3 tis temperature F AtF is t 32 1 8 10 tO is 3 9818E 00 C A is 7 0134E 08 C 1 B is 7 926504E 06 C 2 C is 7 575677E 08 C 3 D is 7 314894E 10 C 4 E is 3 596458E 12 C 5 Note Above provided equation provide density correlations for density of distilled water If the water to be used in the Gravimetric Method does not meet the criteria of distilled or deionized wa
67. both the ground strap and frame Figure 8 12 RIGID GROUND STRAP 24011 SHAPE VARIES BY MODEL GROUND TERMINAL 21060 FLEXIBLE BRAIDED GROUND STRAP 21059 DETAIL GROUND TERMINAL DETAILA 21060 NOTE SOME COMPONENTS REMOVED FOR CLARITY Figure 8 12 Grounding the Prover Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 18 4 23 2014 7 27 47 PM Prover Maintenance 8 8 3 Checking Alignment of Guide Block a With the piston close to the downstream position remove the piston shaft nut Being careful not to break the optic switch slide the guide block off the stud b Check side play of guide block clearance should be 076 to 0 127mm 003 to 005 If play is excessive remove and shim Ryton bushing see Figure 8 13 003 005 CLEARANCE BEARING 24003 DETAILA SHIMS DETAIL B 24004 DEPENDING ON MODEL Figure 8 13 Guide Block Shims c Check that the Dimple Stud is straight and square in all direction to the end of the piston Part No 44200002 Revision 2 Small Volume Prover Installation 8 19 Honeywell Enraf Operation amp Service Manual 44200002 indd 19 4 23 2014 7 27 47 PM Prover Maintenance Care should be taken to ensure that the hole in the guide block aligns with the Dimple stud in the piston shaft If the hole does not align with the stud adjust shims accordingly Slide th
68. cal Switch Installation Bottom View 1 8 31 Figure 8 28 Improper Optical Switch Installation Bottom View 2 8 31 LIST OF TABLES Table 1 Environmental Configuration 1 3 Table 2 Prover Flow Range 1 3 Table 3 Wetted Parts ea RE 1 4 Table 4 Pressure Condition Ranges 1 4 Table 5 Inlet and Outlet Configuration 1 5 Table 6 Motor Voltage 5 1 5 Table 7 Electrical hazardous 5 1 6 Table 8 Flow Tube Finish hr hh RR RD 1 6 Table 9 Transmitler See teuer ben cue ie 1 6 Table 10 Maximum allowable inlet and outlet flange loads 1 8 Table 11 Prover DimerisioriS suu rt RR Rr RR ee 1 9 Table 12 Maximum pressure drop per prover 5 27 1 10 Table 13 Volumetric Water Draw Data Sheet 5 11 Table 14 Gravimetric Water Draw Data Sheet 5 18 Table 15 Honeywell Enraf Troubleshooting 6 3 Table 16 Bolt Torque Specifications 8 12 Table 17 Guide Block Bolt Torque Specifications
69. ce The thermometer T4 is supposed to be used to monitor ambient temperature see Figure 5 7 for reference Have available Table 14 to record data from prover calibration using gravimetric water draw technique 4 Calibrate the scale as specified in API 4 9 4 Connect water supply to prover refer to Figure 5 7 Make sure that the water draw kit is wired to the customer connection enclosure as specified in the Figure 5 6 7 Turn water supply on and open valves V1 V2 After all air is bled off close V2 and V3 Open V5 valve and allow water to circulate until the temperature has stabilized and is not changing 8 Valve V2 may be opened slightly to allow just a very small stream of water to flow this will bleed off air which may be in the water supply 9 Calibrate scales with test weights totaling 10 of draw weight per API 4 9 4 10 With volume catch container on the scales and under water draw valve tare scales Part No 44200002 Revision 2 Small Volume Prover Installation 5 13 Honeywell Enraf Operation amp Service Manual 44200002 indd 13 4 23 2014 7 27 25 PM Calibration 11 Ensure power is applied to the prover Navigate to Calibration screen from the Main Menu as shown below Prover Calibration Enter Calibration Mode Run Calibration Exit Calibration Mode Enter Average Volume Abort Calibration Press OK to choose Stop 12 Enter the prover calibration mode using Enter Ca
70. code requirements on connections made to the Honeywell Enraf small volume prover Covers must be in place on all explosion proof electrical enclosures at all times when prover is energized If it is necessary to troubleshoot electrical components it must be done in a safe area following site procedure drive covers must be in place during operation or anytime electrical power is applied to the prover to avoid personal injury Shaft cover located on the downstream side of the flow tube must be in place during prover operation to avoid personal injury Do not alter or modify the Honeywell Enraf small volume prover without prior written consent from the factory Honeywell Enraf will not be responsible for possible damages loss or injury as a result of unauthorized use or modification Ensure that the unit is fully depressurized and drained prior to disassembly or service Prover frame must be correctly earth grounded prior to electrical service Grounding connector is located on the prover frame Part No 44200002 Revision 2 Honeywell Enraf 44200002 indd 17 Small Volume Prover Installation Operation amp Service Manual xvii 4 23 2014 7 27 03 PM Installation Procedure 24 Follow all hazardous warning stickers Pinch and crush points are present on this equipment in addition to electrical shock hazards Important Notice to ALL Honeywell Enraf small volume prover users It is mandatory th
71. curing the flange plate to the frame If these pins are not in place install one on each side next to the mounting bolts of the flange plate see Figure 8 10 c Drill two holes through the mount bracket and the end plate next to the mounting bolts Drill two holes through the mount plate and the frame next to the mounting bolts d All holes must be tight fit with the pins which will need to be installed into the drilled holes 8 8 9 Check Shocks a Push down on the shock very fast and it should stop then continue moving some more 8 28 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 28 4 23 2014 7 27 49 PM Prover Maintenance b If you push down on the shock and it bottoms out check the adjustment Almost all of the shocks are adjustable All shocks must be on the same setting c If after adjusting and retesting the shock it still does not perform correctly the shock needs replacement d The shocks depth must also be adjusted on the prover itself see Figure 8 23 This insertion depth must be correct and the same on all four shocks UPSTREAM FLANGE UPSTREAM SEAL RETAINER 4X SHOCK ABSORBERS GUIDE BLOCK LEAVE A 125in 3 18mm GAP PROVERS WITH MECHANICAL STOPS Figure 8 23 Shock Installation Depth Part No 44200002 Revision 2 Small Volume Prover Installation 8 29 Honeywell Enraf Operation amp Service
72. d and removing the 54020 hex head cap screws The poppet assembly may now be removed from the piston body Remove seal retainer flange 54023 not shown from 54008 and remove poppet seal 54014 from 54003 Remove the main piston seals 54013 and riders 54008 very carefully so as not to damage the seal surfaces on the piston Note Use caution on larger units 585 and S120 as it takes three people to remove the piston support two to stand on the support and the other one to remove the bolts If the support should be stuck in the piston body the two people standing on the support should remain until the third person can tap it loose using a dead blow hammer 10 Clean and inspect all parts 11 Check seal groove width for proper seal fit use gauge if available If the groove is too small check with factory to get the proper dimensions to have the piston body machined 12 Reassemble the piston by reversing the disassembly procedure and use new seals in all locations refer to Figure 8 5 Note the direction of the seal lips for correct installation of the new seals see Figure 8 5 To assist in installing the riders and main piston seals put them in hot water 60 65 C 140 1509F to make the seals and riders more flexible and to reduce the chance for damage All piston bolts should have a thread lock compound applied to them Loctite 242 is recommended Note If piston appears tight when installing new seal kits into the tube a gro
73. duction Intentionally left blank 1 12 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 12 4 23 2014 7 27 08 PM CHAPTER 2 INSTALLATION 2 1 Receipt of Equipment The Honeywell Enraf small volume prover is pressure and function tested and water draw calibrated at the factory prior to shipment When the equipment is received inspect the outside of the packing case or cases to see if the case has been damaged If there has been any damage to the case the carrier should be notified immediately concerning their liability for damage to the equipment If anything is missing or incorrect from your shipment please contact your local Honeywell Enraf sales representative or sales office Have the serial number and sales order number of your order available to help expedite any needed assistance 2 2 Return Shipment Before any attempt is made to return the shipment in part or whole contact a Honeywell representative The Honeywell Global Technical Support group HFS TAC should be contacted for all requests or inquiries relating to service operation repair and or replacement By telephone 1 800 423 9883 By email HFS TAC Support Honeywell com 2 3 Mechanical Installation The Honeywell Enraf small volume prover has been designed to be used as a portable or as a stationary mounted flow prover The Honeywell Enraf small volume prover may be instal
74. e 19mm 84 of play in the motor chain Any adjustments can be made using the adjustment bolts in the adjustment blocks b Check everything twice to avoid any missed items DO NOT OVER TIGHTEN c Loctite the adjustment bolts with 242 Blue Loctite see Figure 8 20 If the adjustment blocks are missing install new ones as needed Part No 44200002 Revision 2 Small Volume Prover Installation 8 27 Honeywell Enraf Operation amp Service Manual 44200002 indd 27 4 23 2014 7 27 49 PM Prover Maintenance 2 Checking the tension on two drive chains chains with puller in between a Check the drive chain alignment and tension Any adjustments can be made using the downstream adjustment bolts in the adjustment blocks b There must be 19mm 34 of play in the chain DO NOT OVER TIGHTEN see Figure 8 22 TAI T _ H Sis 31 SI ETO SIS SIS SIS SIS SIS SIE SIE SIS SIS ETO a SIS SIE SIE IS SDO SDO TO 4 4 LJ P s j 3 4 DEADE ADJUST THES EMG Figure 8 22 Recommended Chain Sag c Loctite the adjustment bolts with 242 Blue Loctite If the adjustment blocks are missing install new ones as needed 8 8 8 Securing the Drive End a After all mentioned adjustments have been completed prover must be pinned to maintain drive end alignment see Figure 8 10 Check everything twice to avoid any missed items b Check to see if there are pins se
75. e guide block upstream and check the side play If side play is too tight upstream you will have to readjust shims remembering that the guide block MUST always align with the Dimple stud in the downstream position see Figure 8 14 HOLE IN THE GUIDE BLOCK SAG Mg 0 8 mm TO 1 58 mm FROM TOP OF THE HOLE TO TOP OF THE THREADS DIMPLE STUD CORRECT VIEW INCORRECT VIEWS Figure 8 14 Stud Alignment d Reinstall the guide block to the piston shaft e Pull the piston upstream being careful not to break the optic switches 8 20 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 20 4 23 2014 7 27 47 PM Prover Maintenance f Use a wrench on the hub of the large drive sprocket and move the piston to the position that you want Remove nut slide guide block off the Dimple stud and check alignment with the guide block g The hole in the guide block should be aligned side to side with the Dimple stud and the shaft should have 8 to 1 6mm 1 82 to 1 16 sag when upstream see Figure 8 14 h If the Dimple stud is not aligned properly adjust the upstream plate by loosening the respective bolts and removing the M6 1 4 spring pins used to maintain alignment Once you remove the alignment pins you must drill and tap new holes after all adjustments have been made see Section 8 8 9 Adjust the upstream drive end plate so that th
76. e pressure has been recorded Water Draw Calibration Test Water Draw calibration using NIST traceable test equipment on an NMI certified test stand The water draw is performed by the gravimetric method using the Honeywell Enraf dual valve assembly in conjunction with an electronic scale Base volume on the certificate of calibration is corrected to psig and 60 F or to meet alternate standard conditions specified by customer If requested the water draw calibration can be completed using volumetric method for at least 20 minutes Piston Seal Leak Test During the execution of the piston seal leak test the differential pressure will be maintained across the piston assembly Function Test As a final stage of the testing procedure the Honeywell Enraf small volume provers are functionally tested on water test loop Each prover is operated at all flow rates including minimum and maximum flow rates 44200002 indd 10 Small Volume Prover Installation Operation amp Service Manual Part No 44200002 Revision 2 Honeywell Enraf 4 23 2014 7 27 07 PM Introduction 1 5 Principle of Operation Figure 1 1 Prover in Stand By Mode In the stand by mode the piston is down stream and stationary see Figure 1 1 The piston s inner flow thru poppet valve is open allowing free flow of the fluid through the measurement cylinder with minimal pressure drop When the operator initiates a proving run sequence
77. e side of the plate is perpendicular to the frame Tighten all the bolts and check the alignment again i To avoid a twist on the drive system squareness between the two plates in the drive end must be maintained 8 8 4 Check the Alignment of the Flag a Inspect the upstream and downstream optical switches to verify they are correctly seated see Figure 8 15 If not reposition and replace springs and seals as needed Figure 8 15 Correctly Seated Optical Switch Bottom and Side View Part No 44200002 Revision 2 Small Volume Prover Installation 8 21 Honeywell Enraf Operation amp Service Manual 44200002 indd 21 4 23 2014 7 27 48 PM Prover Maintenance b Position the flag with the guide block in the opening of the downstream optical switch and check the alignment The flag should be centered as showed in the Figure 8 16 This can be observed through the hole in the upstream drive end plate or using a mirror positioned close to the optical switch 1 4 20 BOLT THREADED ROD SWITCH BAR SHIM PLATE PROPERLY CENTERED FLAG Figure 8 16 Switchbar Position c If necessary gently shift the flag until it is centered d Repeat first two steps at the upstream optical switch 8 22 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 22 4 23 2014 7 27 48 PM Prover Maintenance e If adjusting the flag does not pr
78. ed in Table 17 ES 9 24012 24011 Nw iA 24013 24003 J 24006 pm 24007 24005 O e 24008 24004 _ f 24002 24018 24010 24009 24001 24002 24019 Part No 44200002 Revision 2 Small Volume Prover Installation 8 13 Honeywell Enraf Operation amp Service Manual 44200002 indd 13 4 23 2014 7 27 46 PM DESCRIPTION 24001 GUIDE BLOCK 24002 CAM FOLLOWER 24003 BEARING GUIDE BAR 24004 BEARING GUIDE BAR SHIM 24005 FLAG 24008 MOTOR STOP RAMP 24009 SOCKET HEAD CAP SCREW 24010 LOCK WASHER 24011 GROUND STRAP 24012 SOCKET HEAD CAP SCREW 24018 SOCKET HEAD CAP SCREW 24019 CAM FOLLOWER Figure 8 8 Guide Block Exploded View 8 8 Drive System Maintenance The Honeywell Enraf small volume prover mechanical piston return mechanism is rugged and trouble free requiring little maintenance All bearings are sealed and chains are stainless steel Maintenance on the drive system normally would be done at the same time as normal prover maintenance such as seal change and water draw If at any time the piston return chains need adjustment adjust only the bearings at the end closest to the flow tube Adjust chains for even tension A Chains should be lubricated with a dry chain lube or lubricant that has a carrier fluid which evaporates and does not cause dirt and dust to collect Recommended is a PTFE filled c
79. ed metric or NPT threaded stopping Stopper plugs Take care to select whichever is appropriate and contact Honeywell Enraf in case of doubt Improper installation of cable glands conduit or stopping plugs will invalidate the Ex approval A Warning Risk of Explosion Intrinsically safe connections to the SVP are factory wired No unauthorized changes are allowed as these would invalidate the approval The LAD and the SVP Controller are intrinsically safe devices and as such may only be connected to devices with compatible intrinsically safe parameters Intrinsically safe cabling may only be connected to the outside 5 pin socket of the SVP Controller Connection of non intrinsically safe signals will invalidate the approval The electrical data of the intrinsically safe circuits is to be taken from the ATEX IECEx certificates numbers see below which are shipped with the instruments Warning Risk of Explosion In order to withstand the explosion pressure the bolts of the SVP Controller are fastened at the factory with a moment of 13 5 to 17 6 Nm 10 to 13 Lbf Ft Warning Risk of Explosion For ensuring intrinsic safety ground connection of one of the internal boards to the enclsoure and the box to the local grounding system is crucial The former is done at the factory but the local grounding is required to ensure compliant installation x Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp
80. emperature Detector Td Prover Pressure Pp Scale Reading on Volume Measure SR Volume of Water adjusted for SR BMVa Test Measure Temperature Correction for Temp Differential Ctdw Effect of Temp on Test Measure CTStm Effect of Temperature on Prover CTSp Combined effect of CTSM amp CTSP CCTs Volume Waterdraw WD Effect of Pressure on Flow Tube CPSp Compressibility of water in prover CPLp Corrected Water Drawn Volume WDzb Table 13 Volumetric Water Draw Data Sheet Part No 44200002 Revision 2 Honeywell Enraf 44200002 indd 11 Small Volume Prover Installation Operation amp Service Manual 4 23 2014 7 27 24 PM Calibration 5 4 Gravimetric Water Draw Equipment 1 Water draw kit Contact Honeywell Enraf representative or factory directly to obtain a water draw kit Figure 5 6 2 Precision electronic weigh scales of the correct size and resolution for example for an S25 prover balance must have a capacity of at least 100kg and 4 gram 200 Ib and 0 01 Ib resolution 1 part out of 20 000 or better resolution For proper scale verification prior to the gravimetric water draw refer to API 4 9 4 3 Certified test weight set ANSI ASTM Class equivalent or better 4 Source of air free or deaerated deionized or distilled water with approximately 38 Lpm at 172 690 kPag 1
81. equipped with integral lifting points Figure 5 shows the location of these points along with an approximate weight distribution of the prover Please use these lifting points for all movement of the prover to avoid damage to the unit INTEGRAL FRAME LIFTING POINTS 4X gt a a n a n a n a n a n HN CAIN ERE Honeywell Enraf x 7 APPROX 70 7596 APPROX 25 3096 WEIGHT FLOW gt WEIGHT Figure 2 2 Prover Lifting Diagram As with all pressure containing equipment it is essential to protect your Honeywell Enraf small volume prover from any possible route of suffering the impact of a foreign body This especially applies to provers located in high vehicular traffic areas and portable units Permanent vehicle barricades or pylons are highly recommended around the perimeter of the unit and again at the inlet outlet connections Part No 44200002 Revision 2 Small Volume Prover Installation Honeywell Enraf 2 3 Operation amp Service Manual 44200002 indd 3 4 23 2014 7 27 10 PM Installation Extra inspection should be given to portable units after transport operations to ensure that no foreign body impacts have been encountered that would sacrifice pressure containing components Please remember to place permanent structures of any type outside the required Service Clearance area detailed in Figu
82. ers The following figures detail new optical switch shape As seen below the optical switch plate has one straight side and one rounded side Figures 8 24 and 8 25 below illustrate a correct optical switch installation Figure 8 24 Correct Optical Switch Installation Bottom View 8 30 44200002 indd 30 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 4 23 2014 7 27 50 PM Prover Maintenance Figure 8 25 Correct Optical Switch Installation Side View Figure 8 26 Figure 8 27 and Figure 8 28 below show an improper installation To maintain correct installation the optical switch must be pushed tightly to the inner corner of the L bracket and must be seated entirely in the machined pocket of the switch bar Finally before installing any optical switches be sure that the machined pockets of the switch bar and inner faces of the L brackets are free of any debris Figure 8 26 Improper Optical Figure 8 27 Improper Optical Figure 8 28 Improper Optical Switch Installation Side View Switch Installation Bottom View 1 Switch Installation Bottom View 2 Part No 44200002 Revision 2 Small Volume Prover Installation 8 31 Honeywell Enraf Operation amp Service Manual 44200002 indd 31 4 23 2014 7 27 50 PM Prover Maintenance 8 10 Thread Locker Fluid Location List Back out t
83. etween preventative maintenance intervals by 5096 This also applies for applications involving high duty load cycles i e 3rd party service portables Extra time spent on careful preventative maintenance can often prevent otherwise avoidable costly repairs and calibration downtime Always remember to depressurize drain and block amp blind your prover in addition to meeting your site required electric power lockout tag out procedures before performing maintenance procedures A Prior to Each Proving Session 1 Visually inspect pressure retaining components i e flow tube flanges bleed manifolds and valves drain valves shaft seal assemblies transmitter ports for signs of leakage damage or failure Repair or replace any suspect items Part No 44200002 Revision 2 Small Volume Prover Installation 8 1 Honeywell Enraf Operation amp Service Manual 44200002 indd 1 4 23 2014 7 27 37 PM Prover Maintenance 2 Verify Return Drive Assembly protective cover set and Downstream Shaft Cover are intact with no signs of tampering or unauthorized entry 3 Verify all required safety devices are functioning and any exposed pressure relief blow down is directed away from personnel 4 Verify Purge Gas is present for units using Purge Cover Assemblies B Monthly 1 All items in A 2 Remove Return Drive Assembly Side Panels Visually examine return drive assembly i e conveyor shaft assemblies with bearings and puller
84. fastened with 290 Green Loctite after all adjustments have been made see Figure 8 20 If the sprockets are loosened or are loose from the shaft they must be Part No 44200002 Revision 2 Small Volume Prover Installation 8 25 Honeywell Enraf Operation amp Service Manual 44200002 indd 25 4 23 2014 7 27 49 PM Prover Maintenance Figure 8 20 Shaft Loctite Locations 8 26 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 26 4 23 2014 7 27 49 PM Prover Maintenance e On models where the sprocket shafts are not set at a fixed distance 805 515 S25 the chain must have 19mm 84 play checked at the bottom Any adjustments made for this purpose should be done with the downstream pillow blocks as this will not affect the adjustment of the puller see the next section UHMW Chain Rail Adjustment for more details 8 8 6 UHMW Chain Rail Adjustment a Adjust plastic rail so it holds chain flat and even with the top of the sprockets and is centered in the chain see Figure 8 21 UHMW CHAIN SUPPORT HORIZONTAL ADJUSTMENT VERTICAL ADJUSTMENT Figure 8 21 Chain Support Adjustment b Verify by observing a flat smooth transition from the sprockets to the chain support while moving the chain back and forth 8 8 7 Adjust the Chain Tensioners 1 Checking the motor chain tension a There must b
85. g seals checking alignment of drive end and changing optical switches and a differential pressure test to check for seal leakage Recommended annually m Water draw is Recommended every 2 years m Small Volume Prover Inspection and Refurbishment m Project consultation Honeywell GTS Email HFS TAC Support Honeywell com Call 1 800 423 9883 8 32 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 32 4 23 2014 7 27 50 PM 8 12 Frequently asked questions What type of prover is the Honeywell Enraf The Honeywell Enraf prover is classified as a Small Volume Unidirectional Piston Displacement Prover Why is the Honeywell Enraf prover considered to be small volume when it can hold up to 350 gallons of fluid The small volume classification is based on the volume displaced in relationship to the number of flow meter pulses collected A large volume prover requires greater than 10 000 meter pulses be collected to generate a meter factor typically a pipe prover A small volume prover in conjunction with Double chronometry can generate a meter factor in less than 10 000 meter pulses How can the Honeywell Enraf flow prover be used on Corriolis and UltraSonic meters By slowing the prover down to allow for longer run up time the flow disturbance caused by the internal valve closure will have had
86. hain lubricant A Warning Do not lubricate chains with normal oils which collect dirt and cause wear B Gearbox oil level should be checked periodically Oil level should be approximately 13mm 1 2 below vent port for horizontally mounted provers see Figure 8 9 Gearbox was filled at the factory with Mobil SHC 626 gear oil ISO viscosity 68 If the oil level is low drain the remaining oil and refill the reducer to the correct level do not mix types of oil Note Mobil SHC 626 is satisfactory for temperatures from 40 C to 66 C 40 F to 150 F 44200002 indd 14 Small Volume Prover Installation Operation amp Service Manual Part No 44200002 Revision 2 Honeywell Enraf 4 23 2014 7 27 46 PM OIL LEVEL Figure 8 9 Gearbox Lubrication Diagram 8 8 1 Before working on the Drive System a Ensure that the power to the motor is removed and locked and tagged b Check that the piston is in the downstream position the distance between the mechanical stop and the upstream seal retainer should be approximately 51 76mm 2 inches Close and lock the block and bleed valves at inlet and outlet to prover d Bleed and drain prover e Remove the motor main drive chain the chain between the output sprocket on the gear reducer and the main drive sprocket 8 8 2 Checking Alignment of Drive System general checking a Check the drive system to see if there are
87. hanging the configuration parameters will not affect the performance of Part No 44200002 Revision 2 Small Volume Prover Installation 3 7 Honeywell Enraf Operation amp Service Manual 44200002 indd 7 4 23 2014 7 27 18 PM Controller Information the prover although caution must be used if changing the Motor parameters or the Sensor Pair Changing of the Sensor Pair is only applicable if you have the optional third optical switch installed Changing of the Motor parameters should only be done after consultation with Honeywell Enraf experts as damage to the drive end could occur the Motor parameters are set at the factory for the specific model of your prover When the device is locked the following configuration parameters cannot be changed via the LAD menu until the user unlocks the controller again gt gt Device 1 Identification Site Name Device Name 2 Units Units of volume 3 Display Display brightness Display Contrast Session time out value 4 Time Date display format Time display format Date Time 5 Motor Motor switch timeout Motor off delay 6 Sensor Pair 7 Volume Total volume Upstream volume Downstream volume gt gt I O Setting 1 Output Alarm Relay output gt gt Alarm 1 Service due reminder Alarm action 2 Machine Fault Alarm action 3 Cycle count Threshold Cycle count 3 8 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual
88. he LAD at Run Prover Test causes a prover run cycle to be executed and the SVP Controller display will appear as shown below With the piston at the extreme downstream position the Parked Position the motor will pull the piston upstream and the piston position will be shown on the Prover Status screen as the associated optical sensor flag passes through the Downstream sensor and the Upstream sensor until the motor stop switch is activated Run Prover Test can be executed 4 2 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 2 4 23 2014 7 27 20 PM Operations repeatedly while the liquid flows through the prover pushing the piston towards the downstream side This test will only run in the absence of a Flow Computer run permissive signal it will not be executed if the run permissive has been asserted by a Flow Computer See Chapter 6 Troubleshooting if an error status is indicated To exit this operating mode use the LAD to navigate to Main Menu Diagnostics Prover Service Test Exit Prover Test Prover Status Prover Test Piston Parked Position Motor Idle Error Status No Error 787 Stop Time 10 31 12 11 39 32 AM Sweep Time 00 00 01 020 Press OK to enter menu Stop 4 4 Prover Calibration The third operating mode of the controller is Prover Calibration and will be described in more detail in the next chapter Part No 44200002
89. he bolt and apply Loctite to threads After application of the Loctite readjust bolt back to a tight position This procedure must be completed at all the following locations a All bolts on the inside of the prover use 242 Blue Loctite b Dimple stud assembled in to the piston shaft uses 272 Red Loctite 2H nut for the Dimple stud uses 242 Blue Loctite d Tension bolts used to hold the adjustment of the pillow blocks and gear box use 242 Blue Loctite Sprockets to shafts use 290 Green Loctite f Pillow blocks to shaft use 290 Green Loctite 8 11 After Sales Support Honeywell GTS Global Technical Services support the Honeywell Enraf provers globally All after sales support enquiries should be channeled to GTS in the first instance Honeywell Enraf have strategically positioned global service partners in USA Europe amp Asia to support Honeywell Enraf provers worldwide In order to analyze the problem the following information is required m Serial number of prover Model number Point of contact Contact details Location of prover Process conditions when problems occurred flow rate viscosity product temperature number of prover runs m Historic information about prover date installed repair history m Pictures of damage Honeywell Enraf can offer m Commissioning amp start up including replacement of the transit seals m periodic maintenance service which normally consists of changin
90. hown of the following device components m Device serial number m Production date m Serial number of each FlexConn board m Hardware version of each FlexConn board m Application firmware version of each FlexConn board m Build information of the firmware of each FlexConn board m Boot firmware information of the firmware of each FlexConn board m FlexConn stack firmware version of each FlexConn board m Build information of the FlexConn stack firmware of each FlexConn board 3 14 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 14 4 23 2014 7 27 19 PM Controller Information The menu tree below shows how the information menus are accessed Device Device serial number Production date Board serial HW version App firmware HMI App build Boot firmware FlexConn version FlexConn build Board serial ff HW version App firmware App build Board SVP PP PIC firmware SVP HMI Screens Main Menu System Info Boot firmware FlexConn version FlexConn build Board serial HW version App firmware OPTION App build Boot firmware FlexConn version FlexConn build HMI FC HMI ARM Versions SVP OPTION Figure 3 14 System Information Menu Tree Part No 44200002 Revision 2 Small Volume Prover Installation 3 15 Honeywell Enraf Operation amp Service Manual 44200002 indd 15 4 23 2014 7 27 19 PM Controller Information 3
91. ibration mode or at a later time by entering the Calibration menu and then accessing this screen directly After selecting Enter Average Volume following screen appears 5 37000 me Backspace 415 6 1 2 3 Reu IE Enter value Stop 23 After the Average Volume has been entered and confirmed the following screen is displayed to enter the Repeatability in percent 96 The entered average volume and the repeatability values will be stored in the log with a timestamp of the entry After selecting Enter Average Volume following screen appears Enter Repeatability 0 00200 Backspace Confirm Enter value Stop Selecting Abort Calibration will stop the calibration process This action will stop the motor if in running state bypass value SV2 will be turned ON and draw valve SV1 will be turned OFF If the Prover is in sweep mode with the piston moving downstream no action will be taken for upstream and downstream sensor inputs Calibration log entry will not be made Part No 44200002 Revision 2 Small Volume Prover Installation 5 9 Honeywell Enraf Operation amp Service Manual 44200002 indd 9 4 23 2014 7 27 24 PM Calibration In calibration mode alarms will be generated as per the configuration and the run permissive signal from the flow computer or the run prover test signal will be ignored The operating mode of the prover will be saved in NVM so that the mode wi
92. ing the commissioning procedure and prior to the process fluid being introduced into the unit An additional set of seals are supplied with every Honeywell Enraf small volume prover for this purpose 1 Before performing any operations with the Honeywell Enraf small volume prover read this operation manual completely Also read API MPMS 4 8 Operation of Prover Systems Current Edition If there are any uncertainties please consult your Honeywell Enraf representative or the factory directly 2 Honeywell Enraf small volume prover has been designed to meet certain operational conditions Using the prover outside of these boundaries may cause permanent damage and will void warranty ref Section 1 3 provers are designed as per pressure standard ANSI B16 5 For process temperatures above 37 8 C 100 F pressure must be de rated following the above mentioned standard 4 Each Honeywell Enraf small volume prover is functionally tested at different flow rates starting from the lowest to the maximum flow rates pressure tested hydrostatic pressure test and water draw calibrated at the factory prior to shipment When the equipment is received inspect the outside of the packing case s for damage Any visible damage should be reported to the carrier immediately for the purpose of liability If anything is missing or incorrect from your shipment please contact your local Honeywell Enraf sales representative or sales office Have
93. ion 5 5 Calculations Volumetric Water Draw Calculations Water draw volume corrections taken from API Manual of Petroleum Measurement Standards API chapters 4 2 4 9 and 12 2 4 and Appendix B 4 F2 a 11 2 3 5 Symbols and Calculations from API 12 2 4 Given RHOtm Density of liquid water in test measure API 12 2 4 RHOp Density of liquid water in prover API 12 2 4 CPL Correction for the compressibility of liquid For water 3 2E 6 Base calibration temperature 60 deg in US G Area coefficient of expansion for flow tube API 12 2 1 11 2 1 G Linear coefficient of expansion for detector 12 2 1 11 2 1 G Coefficient of expansion for the test measure from calibration certificate E Modulus of elasticity for flow tube material from API 12 2 Appendix A WT Thickness of flow tube wall inches ID Diameter of flow tube inches Calculate BMVa Base Measured Volume adjusted for scale reading BMV SR CTDW Correction for prover test measure liquid temperature difference RHOtm RHOp CTStm Correction for effect of temperature on test measure 1 Ttm 60 x Gc CTSp Correction for effect of temperature on prover 1 Tp Tb Gal 1 Td Tb Gl CCTs Correction for prover test measure steel temperature difference CTStmy CTSp WD Adjusted Base Volume of Draw BMVa CTDW CCTs CPSp Correction for the effect of pressure on prover 1 Pp
94. ion 8 3 Honeywell Enraf Operation amp Service Manual 44200002 indd 3 4 23 2014 7 27 38 PM Prover Maintenance 11 Carefully install new seals and washers in proper orientation as showed in the Figure 8 2 Note the direction of the seal lips for correct installation of the new seals In a case of cracked or broken washers they need to be replaced when new seals are installed 12 Assemble the downstream seal retainer Figure 8 1 53109 to the downstream stop Figure 8 1 53101 using hex socket bolts Figure 8 2 53110 Make sure that the O ring seal Figure 8 2 53111 is in place before the seal retainer is assembled to the downstream stop 13 Snug bolts evenly using a cross pattern so as to not damage the seal or distort the flange Refer to Table 16 for bolt torque specifications and carefully tighten bolts evenly using a cross pattern and moving in increments to the full torque value ED p CHIH 531 MN DETAIL A DETAIL B AND DETAIL C ITEM NO DESCRIPTION 53102 SHAFT SEAL 53103 IGUS BUSHING 53104 SHAFT SEAL 53105 NOTCHED RYTON WASHER 53109 DOWNSTREAM SEAL RETAINER 53110 SOCKET HEAD CAP SCREW 53111 O RING SEAL 53112 RYTON WASHER 53106 RETAINING RING Figure 8 2 Downstream Seal Retainer Assembly Please Note On the provers models 505 005 515 015 S25 025 and 535 035 all three shaft seals are the same 8 4 Small Volume Prover Installation Pa
95. ion amp Service Manual 44200002 indd 1 4 23 2014 7 27 20 PM Operations Prover Status Meter Calibration Piston Unknown Position Motor Idle Error Status No Error Cycle 779 Stop Time 10 31 12 11 32 32 Sweep Time 00 00 01 102 Press to enter menu Stop On the first power up and after any machine fault alarm the piston position will be unknown and one proving run needs to be successfully completed in order to initialize the piston position status Upon sending the signal from the PROVEit software or the other flow computers the prover motor will retract the piston assembly and the proving run will start At the end of the proving run the flow rate will be displayed on the screen and the next proving run can be initiated During the return and proving mode different piston positions and the motor status will be displayed on the SVP controller screen At the end of the proving run the sweep time cycle count and the stop time will be updated If any errors occur during the proving run the error will be reported on the screen and will need to be cleared via the LAD Main menu Diagnostics Dashboard Alarm Clear see Chapter 6 Troubleshooting 4 3 Prover Test The Prover Test mode can be useful to become familiar with your prover and to verify proper operation This mode is accessed by navigating with the LAD through the following menus Main Menu Diagnostics Prover Service Test Run Prover Test Pressing OK on t
96. ive atmospheres The entire installation procedure shall be carried out in accordance with national local and company regulations The entire electrical installation shall be carried out in accordance with the International Standard EN 60079 14 for electrical equipment to be installed in potentially explosive atmospheres The mechanical and electrical installation of the SVP Controller shall only be carried out at the Honeywell factory no other electrical adjustments or modifications are allowed No specific installation requirements apply to the LAD the device is factory ready for connection to Fusion4 parent devices for example the SVP Controller Part No 44200002 Revision 2 Small Volume Prover Installation ix Honeywell Enraf Operation amp Service Manual 44200002 indd 9 4 23 2014 7 27 02 PM The Honeywell Enraf Prover Series E Warning Risk of Explosion Do not open any of the electronics enclosures when an explosive atmosphere may be present gt Warning Risk of Explosion Explosion proof Ex d compound cable glands or conduit sealed directly at all cable entries must be used Which type depends on local amp national requirements and legislation For the SVP Controller these glands and seals are installed at the factory In the rare event that there is a need to replace these this shall be done at the factory A Warning Risk of Explosion Unused cable entries must be sealed with an approv
97. just pillow blocks to get the correct clearance of the cam followers see Figure 8 19 PULLER THERE SHOULD BE NO GAP SIDES SHOULD BE EQUAL FEELER GUAGE TEST LOCATION SIDE SLICE VIEW Figure 8 18 Puller Alignment 8 24 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 24 4 23 2014 7 27 49 PM ADJUST PILLOW BLOCKS THIS END c Ki ADJUST PILLOW BLOCKS THIS END TO ADJUST PULLER TO ADJUST FOR CHAIN SLACK TOP VIEW il H o 5 IT EX um IIT LEL TI mTWM rr c 1 o co A KXXAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA VA a E LOCTITE 242 S za LI or I IL 6 PLACES PIF LI VW RRP PPP PP 9999999090 09 9 14 uo RSE L bg Olan al ADJUST GEAR BOX D FOR MOTOR CHAIN SLACK Figure 8 19 Adjustment Blocks d When you are making the above adjustments you need to check the chain to be sure that it does not climb on the side of the sprocket as the puller approaches the sprockets If this occurs adjust the sprockets to eliminate the problem Sprocket adjustment must be checked both downstream and upstream
98. led upstream or downstream of the meter under test as the displaced volumes are equal When installing the Honeywell Enraf small volume prover follow all recommended procedures regarding placement of the prover in relation to the flow meter To assure that all the flow goes through the prover use double block and bleed type diverter valves Refer to the system overview in the Figure 2 1 Process Connections and General Arrangement for connecting the Honeywell Enraf small volume prover to the process line Before connecting the prover be certain that all piping and connections are clean and unobstructed Also ensure that no debris i e weld slag will be introduced into the system Check all drain and vent valves on the prover to make certain that they are closed Part No 44200002 Revision 2 Small Volume Prover Installation 2 1 Honeywell Enraf Operation amp Service Manual 44200002 indd 1 4 23 2014 7 27 08 PM Installation Please Note It is an advantage to provide sufficient back pressure on the down stream side of the flow prover in order to achieve satisfactory repeatability results CONTROL amp VOLUME SIGNAL POWER SUPPLY Honeywell Enraf 3 i Small Volume PROVING COMPUTER DRIVE END OPEN INLET OPEN OUTLET VALVE pcd VALVE PRESSURE RELIEF VALVE CLOSED DOUBLE BLOCK
99. libration Mode submenu Notification to user after selecting Enter Calibration Mode will show up on the SVP Controller screen see below Please note that permissive signal from the flow computer will be ignored while in prover calibration mode Entering Calibration Mode Pressing OK will enter the controller into Calibration Mode The bypass valve will open immediately To perform calibration run select Calibration from next menu Press OK to proceed Stop 13 Bypass valve SV2 will be turned ON immediately after entering the prover calibration mode and the water from the prover will be drained into the wastewater catch container 14 Select Run Calibration which will cause the prover piston to be returned to the upstream position and start the draw sequence See resulting Prover Status screen as shown below 5 14 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 14 4 23 2014 7 27 25 PM Calibration After selecting Run Calibration following screen appears Prover Status Prover Calibration Piston Retract To Down Sensor Motor Waiting Motor Switch Error Status No Error Cycle 774 Stop Time 00 00 00 00 00 00 AM Sweep Time 00 00 01 101 Press OK to enter menu Run 15 Water should now be draining into the wastewater container until the flag reaches the first optical volume switch Note To decrease the time neces
100. ll Enraf Operation amp Service Manual 44200002 indd 1 4 23 2014 7 27 21 Calibration to have a differential pressure gauge with a sufficient pressure rating to withstand line pressure if the prover is not removed from the process line Temperatures both ambient and fluid should be stable during the procedure 5 2 1 Equipment 1 Static leak differential pressure creator assembly included with prover 2 Differential pressure gauge 0 69 kPa 10 psi or greater with sufficient static pressure specifications to be equal or greater than the current prover pressure 8 Plumbing and valve arrangement similar to that shown in Figure 5 1 5 2 2 Static Leak Detection Procedure Block all inlet and outlet ports on the prover including drains Refer to Figure 5 1 5 2 amp 5 4 below and install the differential pressure gauge 1 between the inlet and outlet ends of the prover Fill the prover with liquid and vent off all air from the system Determine there are not leaks from the prover ports If necessary blind the inlet outlet and drain lines with blind flanges Power up the proving computer and the Honeywell Enraf prover a o From the proving computer initiate a proving run to pull the piston upstream Remove the plug from the drive cover end panel Install the differential pressure creator 2 in the threaded hole provided in the drive system end plate and hand tighten refer to Figure 5 3
101. ll Enraf will not be responsible for possible damages to the prover or system parts if these recommendations are not followed ANCHOR POINTS Figure 2 4 Designated anchor points plates located on the bottom side of the prover frame The Honeywell Enraf small volume prover is fitted with transit seals in both the up amp downstream shaft seal retainers upon its shipment from the factory It is important to replace these seals during the commissioning procedure and prior to the process fluid being introduced into the unit An additional set of seals are supplied with every prover for this purpose 2 4 Electrical Connection The Honeywell Enraf small volume prover is certified by one of the following agencies CSA US certified for Class 1 Group D T2C CSA US certified for Class 1 Group ATEX certified for Il 2 G Ex d ia ia IIB T4 Gb and ll 2 Gc IIB 4 Be certain to conform to all applicable national and local electrical codes when making electrical connections to the Honeywell Enraf small volume prover to maintain electrical safety ratings Part No 44200002 Revision 2 Small Volume Prover Installation 2 5 Honeywell Enraf Operation amp Service Manual 44200002 indd 5 4 23 2014 7 27 13 PM Installation Refer to Section 7 of this manual for connection to several brands of flow computers The proving computer used for the operation of the provers must be equipped with the double chronometry function For brands not
102. ll be restored if power is turned off while in Prover Calibration mode To exit calibration mode navigate to the Exit Calibration Mode menu and press OK A copy of Table 13 can be used to enter water draw data An Excel readable file is available from Honeywell Enraf which will calculate the corrected prover volume using the volumetric method VENT VENT X Pe GG Ke OO SVP CONTROLLER WATER SUPPLY Fim WASTEWATER CATCH CONTAINER TEST MEASURE Figure 5 7 Water Draw Plumbing Diagram 5 10 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 10 4 23 2014 7 27 24 PM Calibration Volumetric Water Draw Data Sheet Date Prover Serial Number Prover Model Number Report Number Location Base Temperature Tb Base Measure Volume from calibration cert BMV Volume Measure Thermal Coefficient Gc Compressibility Factor water CPL Flow Tube Area Thermal Expansion Coefficient Ga Detector Linear Thermal Expansion Coefficient Gl Modulus of Elasticity of flow tube E Flow Tube Inside Diameter inches ID Flow Tube Wall Thickness inches WT Fill 1 Fill 2 Fill 3 Fill 4 Fill 5 Fill Time minutes Flow Rate Nominal Volume Fill Time Temperature Prover Tp T
103. ls Actual terminal locations for the Daniel flow computer is dependent upon the application software being used in the Daniel flow computer See the appropriate Daniel manual and software information for more information Part No 44200002 Revision 2 Small Volume Prover Installation 7 5 Honeywell Enraf Operation amp Service Manual 44200002 indd 5 4 23 2014 7 27 35 PM Electrical Schematics amp Drawings A Warning Due to scan speed the 2500 has limitations in flow rate when used with small volume flow provers due to short time period between volume detectors Customer Connection Box To Daniel 2500 Flow Computer Description Terminal Number Feed Flow Computer 12 DC 24VDC Run permissive 13 Run permissive 14 Control Output Common Flow Computer 15 Volume pulse 16 Detector Input Volume pulse 17 DC 7 2 4 Dynamic 24VDC Power Supply External by Customer Dynamic Flow Computer DET1 Customer Connection Box Description Terminal Number Feed Flow Computer 12 DET2 SW3 Run permissive 13 SWA SW5 Run permissive 14 ST2 ST3 Common Flow Computer 15 ST4 DET RET Volume pulse 16 SW3 5 RET ST2 4 RET Volume pulse 17 moo TX Resistors not labeled are LO RET 7 6 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 6 4 23 2014 7 27 37 PM CHAPTER 8 PROVER MAINTENANCE
104. ls or faulty calibration technique 1 Becertain that all maintenance that needs to be done to the prover has been accomplished before starting the volumetric calibration It is advisable to perform a static leak test prior to performing a water draw see Section 5 2 Replace the seals on the prover if there is any doubt as to their integrity 2 Block prover inlet and outlet by using a blind flanges or double block and bleed valves 3 Refer to Honeywell Enraf water draw configuration Figure 5 7 and install Honeywell Enraf available water draw kit see Figure 5 6 Install certified thermometers and certified pressure gauge even if the prover is equipped with P amp T transmitters If using Honeywell Enraf Water Draw P amp T kit remove the plug in the wafer spacer and connect the pressure gauge P1 to the opening see Figure 5 7 for reference The thermometer used to monitor prover fluid temperature T1 is supposed to be installed into the spare thermowell located on the downstream side of the flow tube see Figure 5 7 for reference The thermometer used to monitor switch bar temperature T2 is supposed to be installed on top of the switch bar close to the center line between two optical switches see Figure 5 7 for reference The thermometer used to monitor test measure temperature T3 is supposed to be installed on the test measure see Figure 5 7 for reference Have available Table 13 to record data from prover calibration using
105. ly This setup will launch the prover when the I O point goes high voltage applied When it is low no voltage the prover motor will be idle A jumper must be connected between the Volume Pulse terminal 17 of the Customer Connection Box and the Common terminal 15 of the Customer Connection Box Please read the Omni s Operator s manual prior to connection and or operation of the Honeywell Enraf small volume prover 7 4 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 4 4 23 2014 7 27 34 PM Electrical Schematics amp Drawings SVP Customer Omni Back Controller Connection Panel Box Feed Flow Computer 12 DC 24VDC Vec Isolation DIGITAL OUTPUT m RUN COMMAND FROM OMNI Run Run Permissive Permissive Input Run Permissive 1 5 Ko Common Flow Computer Isolation 16 DOUBLE CHRONOMETRY DETECTOR SWITCH IN OMNI TERM 7 E COMBO MODULE Volume Pulse 47Q Volume Pulse Output 17 SIGNAL RETURN OMNI TERM 10 E COMBO MODULE Volume Pulse 7 2 2 Condat CIU Customer Connection Box Condat CIU Cable Description Terminal Number Wire color Feed Flow Computer 12 Red Pin 1 1 5KO Run permissive 13 Run permissive 14 Green Pin 19 Common Flow Computer 15 Volume pulse 16 White Pin 17 Volume pulse 17 Black Pin 9 7 2 3 Danie
106. mation m Via the Configuration menu you can access the device configuration parameters m The diagram below Figure 3 11 allows you to locate all of the configuration parameters m Always the current device configuration values are shown m All configuration values are edited one at a time in type specific data entry window Disable Service Due Reminder Alarm Action Display Display shutdown Alarms Disable Machine Fault Alarm Action Display Display shutdown Cycle Count Threshold Cycle Count Settings Output Alarm Relay Output Site Name Identification Device Name Units Units of volume Display Brightness Display Display Contrast Mantenu Session timeout value Date display format Time display format Device Date Time ita Motor Switch Timeout Motor Off Delay Total Sensor Pair Upstream Downstream Total Volume Volume Upstream Volume Downstream Volume Figure 3 11 Configuration Menu Tree 3 10 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 10 4 23 2014 7 27 18 PM Controller Information 3 3 6 2 Device 3 3 6 2 1 Identification Site name The name of the site at which the SVP Can be a text string of maximum is located 20 characters Device name The name of the SVP itself In order to have Can be a text string of maximum a unique identification of the device by a 20 characters text string Will be
107. mplifier with an oscilloscope Defective CONDAT interface unit or signal Input a frequency signal with a signal generator and check for conditioners if using CONDAT prover control signal at computer or output of signal conditioner with an oscilloscope If using flow computer of other manufacture Check flow computer s operation manual for possible solution to problem Table 15 Honeywell Enraf Troubleshooting Chart Part No 44200002 Revision 2 Small Volume Prover Installation 6 3 Honeywell Enraf Operation amp Service Manual 44200002 indd 3 4 23 2014 7 27 25 PM Troubleshooting Intentionally left blank 6 4 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 4 4 23 2014 7 27 25 PM CHAPTER 7 ELECTRICAL SCHEMATICS amp DRAWINGS DOWN MID UP MOTOR STREAM STREAM STREAM STOP SWITCH SWITCH SWITCH SWITCH SE CONTROLLER T BLACK WHITE RED E T Lu Sko E8 I x a This section contains various electrical schematics and drawings for the Honeywell Enraf small volume prover If there are electrical questions not addressed by these figures contact your nearest Honeywell Enraf representative or the factory directly 7 1 Schematics for prover wiring aT POWER BOX POWER 24VDC CONVERTER 24VDC 126 02 ISEENOTEA on
108. n pressure gauge 0 690 kPag 0 100 psig psig 5 Three traceable thermometers with 0 1 C 0 2 F degree graduations for thermometer reference positions see Figure 5 7 6 Water overboard container volume to be at least as large as test measure and approximately the same height Note Honeywell Enraf Water Draw P amp T kit or equivalent assembly eases installation of water draw prover instrumentation The Honeywell Enraf Water Draw P amp T kit consists of four traceable temperature thermometers one spare thermometer included and one pressure gauge All thermometers come with the calibration certifications if ordered from Honeywell Enraf 5 4 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 4 4 23 2014 7 27 23 PM Calibration CUSTOMER CONNECTION ENCLOSURE SOLENOID VALVE CONNECTION AND POWER SUPPLY EY EE lt o lt j 1 amp A OW
109. ng Calibration Mode Pressing OK will enter the controller into Calibration Mode The bypass valve will open immediately To perform calibration run select Run Calibration from next menu Press OK to proceed Stop 11 Bypass valve SV2 will be turned ON immediately after entering the prover calibration mode and the water from the prover will be drained into the wastewater catch container Part No 44200002 Revision 2 Small Volume Prover Installation 5 7 Honeywell Enraf Operation amp Service Manual 44200002 indd 7 4 23 2014 7 27 24 PM Calibration 12 Select Run Calibration which will cause the prover piston to be returned to the upstream position and start the draw sequence See resulting Prover Status screen as shown below After selecting Run Calibration following screen appears Prover Status Prover Calibration Piston Retract To Down Sensor Motor Waiting Motor Switch Error Status No Error Cycle 774 Stop Time 00 00 00 00 00 00 AM Sweep Time 00 00 01 101 Press OK to enter menu Run 13 Water should now be draining into the wastewater container until the flag reaches the first optical volume switch When the first optical switch is reached the signal will be sent to the SVP controller to switch the valves turn the SV2 valve OFF and turn the SV1 valve ON At that time the water will start flowing into the Test Measure 14 Record the prover pressure Pp at P1 while only the water draw valve
110. nmental protection if required Flow Tube finish Position 12 A Stainless Steel Brushed B Painted White Table 8 Flow Tube Finish Transmitter Manufacturer The Honeywell Enraf SVP comes with one each Honeywell Pressure transmitter and two each Honeywell Temperature Transmitter Note Only one of the temperature transmitters comes with the local display Other manufactures can be supplied as option Transmitters Position 13 H Honeywell Pressure and Temperature Transmitter R Rosemount Pressure and Temperature Transmitter Y Yokagowa Pressure and Temperature Transmitter Table 9 Transmitters Using the values from Table 1 through 9 allows information of the design of the prover EXAMPLE S25C1A4H4AH 1 6 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 6 4 23 2014 7 27 03 PM Introduction Maximum allowable flange loads It is customer s responsibility to design the piping system so that the forces loads on the inlet and outlet nozzles of the prover are lower than the maximum allowable loads specified in the Table 10 S O PO5 Inlet Outlet Nozzle Nominal Diameter 3 inch FX 467 105 Mx 664 Nm 490 Ib eft Top Nozzle
111. nstallation repair or modification work Caution Evidence has shown pitting in chromed surfaces can be caused xviii Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 18 4 23 2014 7 27 03 PM CHAPTER 1 INTRODUCTION 1 1 Overview This manual provides the necessary information and procedures for the proper operation of the Honeywell Enraf small volume prover manufactured by Honeywell Enraf Americas Inc The Honeywell Enraf small volume prover uses a wear and corrosion resistant precisely honed flow tube Contained within the flow tube is the piston bypass valve arrangement Piston bypass valve arrangement has been designed in such a way that during the proving runs disturbance to the flow is minimal The free flowing piston has an inherent fail safe feature that will not cause disruption to the flowing fluid in case that the poppet actuator shaft becomes disconnected or otherwise fails The poppet valve is coaxially mounted within the free moving piston At the time a calibration run is initiated by the operator the piston assembly is moved to the upstream end of the flow tube by a mechanical drive driven by an explosion proof electric motor When upstream position has been reached the poppet valve actuator shaft is released by the return mechanism allowing the poppet valve to close and the flowing fluid to move the piston through the measurement cylinder
112. on amp Service Manual 44200002 indd 1 4 23 2014 7 27 03 PM Introduction 1 2 General Features m Field replaceable precision optical volume measurement switches without recalibration m Flow through poppet valve piston to minimize flow disturbances m Patented electromechanical chain drive piston return mechanism m Operates from a conventional electrical circuit options include single or 3 phase power in most standard voltages and frequencies m 24 Volt DC models available for portable proving applications requiring no outside electrical service Please note that 24 VDC motors are available for installation on the prover sizes from the model S O PO5 through S O P35 only m Low consumables design reduces operating cost m Quick and easy seal change All seals are serviceable without removing the unit from the pipeline m Free flowing piston greatly reduces induced line disturbances m Operates with industry standard flow computers for meter proving capability and double chronometry m Local display with menus driven by Local Access Device LAD m Direct reading of sweep time proving time m Alarm on off display for flow computer m Prover cycle counter m Diagnostic dashboard m Adjustable motor off delay which reduces wait time m Scalable motor time off system failure safe protection m Firmware in situ upgradeable m Alarm log records m Calibration log records These unique features provide greater confidence and opera
113. ove could be cut on the rider surface This will consist of two 45 degree grooves cut in the rider spaced 90 or 180 degrees apart Use a sharp utility knife to create groove Depth of groove is to be 8096 of the rider thickness and 3mm 1 8 wide Cut grooves after rider is installed on piston body All riders should have chamfered inside edges to allow for proper seating in the piston Note Be extremely careful to not damage the piston seals in any way or to lay the piston on the seals and cause them to be deformed 13 Clean and inspect flow tube Check for gouges excessive wear de plating pitting etc 14 Insert the piston by carefully guiding the piston assembly into the flow tube being very careful to not damage the new seals or the precision bore flow tube It will be necessary to apply some considerable force to the piston assembly to compress the piston seals to enter the flow tube bore It may be necessary to use a length of the appropriate size threaded rod inserted through the hole in the drive end plate where the static leak detector is inserted refer to Figure 8 6 Screw the threaded rod into the piston shaft A piece of 13mm 1 2 PVC 8 8 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 8 4 23 2014 7 27 41 PM Prover Maintenance pipe over the threaded rod will prevent the threads from hanging up in the upstream flange Install a large
114. ovide centering of the flag on both switches the switch bar may not be aligned with the piston assembly a First confirm that the guide block is aligned with the piston shaft see Section 8 8 3 b Use a pipe clamp and pull the switch bar if possible in the direction needed being careful not to affect other adjustments You may have to move both ends see Figure 8 17 TOP VIEW PIPE CLAMP Figure 8 17 Pipe Clamp Position f If the pocket in the plate is bigger than the switch bar the gap will need to be shimed The shim must be installed between the 16mm 5 8 rod and the switch bar itself This shim must be bolted to the plate These adjustments will most likely need to be performed at both ends of the switch bar on opposite sides see Figure 8 16 g Recheck the flag alignment 8 8 5 Check the Alignment of the Puller a With the piston close to the downstream position rotate by hand the main drive sprocket to position puller behind guide block in pull position b Check clearance between puller and two cam followers using a feeler gage set at 0 076mm 003 Please note Tablet paper is an approximate measurement Part No 44200002 Revision 2 Small Volume Prover Installation 8 23 Honeywell Enraf Operation amp Service Manual 44200002 indd 23 4 23 2014 7 27 48 PM Prover Maintenance The drag should be the same at both cam followers see Figure 8 18 If the drag is not the same ad
115. owly After the inlet valve is completely open open fluid outlet valve connecting the prover to the process line Figure 2 1 Vent trapped air from the prover by opening the vent valves located at the top of the prover flow tube 4 Close process diverter valve Figure 2 1 slowly to divert the flow through the prover 5 The Honeywell Enraf small volume prover is now ready for meter proving Refer to the appropriate proving computer manual for procedures for performing meter proving runs 6 After meter proving runs have been completed open process diverter valve and slowly close the prover connection valves If you have the optional third optical switch installed on your prover refer to Chapter 3 section 3 3 6 2 6 for Sensor Pair configuration prior to operating your prover in any of the following three modes of operation 4 2 Meter Calibration Upon initial power up of the SVP Controller the Prover Status screen will indicate that the operating mode of the controller is Meter Calibration This is the default operating mode of the controller The other two operating modes Prover Test and Prover Calibration require entering into those modes via the LAD In order to do proving runs on a meter make sure that you are operating in the Meter Calibration mode as indicated by the Prover Status Meter Calibration screen as shown below Part No 44200002 Revision 2 Small Volume Prover Installation 4 1 Honeywell Enraf Operat
116. played showing the operating mode of the prover Meter Calibration Prover Calibration or Prover Test and the following information An example of a Prover Status screen is shown below Press OK to enter menu Stop Navigating the SVP Controller Menus Using the LAD Piston status or position Motor status Error status Number of cycles Stop time Sweep time Prover Status Meter Calibration Piston Parked Position Idle Error Status 776 Stop Time 10 31 12 11 29 32 AM Sweep Time 00 00 01 102 Pressing the OK button on the Local Access Device LAD will result in the Main Menu screen being displayed on the SVP Controller Text Conventions In the following sections of this document the entity and entity related text are shown in a distinctive format as shown below All Entity and lt entity related gt text is recognizably formatted Part No 44200002 Revision 2 Honeywell Enraf 44200002 indd 1 Small Volume Prover Installation Operation amp Service Manual 3 1 4 23 2014 7 27 14 PM Controller Information 3 2 2 General The SVP Controller can be configured through the wired Ex i interface with a Local Access Device LAD The LAD Local Access Device is a hand held controller used to interface with the Fusion4 product family allowing tasks such as parameter adjustment alarm resetting and calibration The device facilitates two way data communica
117. quence was not completed successfully In order to clear the error check if m the optical switches are functioning using the dashboard function see 6 3 1 m motor stop switch is functioning using the dashboard function see 6 3 1 m the ramp located on the guide block is adjusted properly m the flag located on the guide block is correctly positioned 6 2 2 Motor time out This error message means that the signal from the motor stop has not been sent To clear the error check if m motor stop switch is functioning using the dashboard function see 6 3 1 m the ramp located on the guide block is adjusted properly m or any part of the drive mechanism is broken such as main driving chain etc Part No 44200002 Revision 2 Small Volume Prover Installation 6 1 Honeywell Enraf Operation amp Service Manual 44200002 indd 1 4 23 2014 7 27 25 PM Troubleshooting 6 2 3 Sensor stuck This error message means that one of the sensors is triggered and is sending the signal to controller at the beginning of the proving run To clear the error check if m the optical switches are functioning using the dashboard function see 6 3 1 m ensuring that the flag is not triggering one of the optical switches if repositioning is required user can use dashboard function Motor run command to relocate the piston assembly m motor stop switch is functioning using the dashboard function see 6 3 1 6
118. rd provers have an Upstream optical sensor and a Downstream optical sensor An option is available for a third optical switch The configuration entities are as shown below 3 12 Small Volume Prover Installation Part No 44200002 Revision 2 44200002 indd 12 Operation amp Service Manual Honeywell Enraf 4 23 2014 7 27 19 PM Controller Information Total Selects the Upstream Sensor to be Upstream Sensor Downstream Sensor used as the high volume gate and the Downstream Sensor to be used as the low volume gate This is the default configuration Upstream Selects the Upstream Sensor to be Upstream Sensor Midstream Sensor used as the high volume gate and the Midstream Sensor to be used as the low volume gate Downstream Selects the Midstream Sensor to be Midstream Sensor Downstream Sensor used as the high volume gate and the Downstream Sensor to be used as the low volume gate 3 3 6 3 I O Settings 3 3 6 3 1 Alarm Relay Output The Alarm Relay Output can be configured to be Energized normally closed or De energized normally open 3 3 6 4 Alarms The following alarm entity applies to Service Due Reminder and Machine Fault Alarm action With this entity the user can configure the e lt Disabled gt The alarm is ignored alarm behavior in case this particular alarm e lt Display gt will occur Alarm shown on the display Alarm indica
119. re 2 3 meme ETT pum i i i i 1 1 I Honeywell Enraf 1 E LA F NI VON EO i i UL Ll O E de p MODEL A B D E F 05 610 2 610 2 610 2 1220 4 1520 5 1520 5 15 610 2 610 2 610 2 2140 7 1520 5 1830 6 25 610 2 610 2 610 2 2140 7 1520 5 1830 6 35 610 2 610 2 610 2 2140 7 1520 5 1830 6 50 920 3 920 3 920 3 2750 9 1830 6 2140 7 85 920 3 920 3 920 3 3050 10 2140 7 2140 7 120 1220 4 1220 4 1220 4 3360 11 2440 8 2440 8 NOTES 1 The lettered dims represent a minimum recommended service clerance around the prover 2 All dimensions are in mm ft 3 Clearance must be provided by customer Figure 2 3 Prover Service Clearance Diagram 2 4 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 4 4 23 2014 7 27 12 PM Installation The Honeywell Enraf small volume prover should be installed on a flat surface and secured using 4 bolts through the pre determined anchor points on the prover frame See Figure 2 4 It is recommended to bolt the prover to the slab trailer at these four locations only It is not recommended to use any other method or type of securing the prover against the movement during operation Honeywe
120. rt No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 4 4 23 2014 7 27 39 PM Prover Maintenance 8 5 Prover Piston Assembly Seal Replacement 1 Complete the steps from 1 thru 6 mentioned in the Section 8 4 2 Remove the bracket securing the flow tube and downstream end flange to the frame 3 Remove pressure and temperature transmitters from the downstream end flange 4 Remove the hex socket bolts Figure 8 1 53008 securing the downstream end flange Figure 8 1 53001 to the flow tube except for 1 bolt at the top Connect a hoist to the threaded hole in the top of the downstream end flange Remove the last hex socket bolt and using the hoist to support the flange remove it from the flow tube 5 Open the drive end cover and remove the securing nut locking nut the standard hexagonal nut and the washer Figure 8 3 position 1 from the guide block Figure 8 3 position 2 on the upstream side of the flow tube 3 VA V C HH DU WIW WWW WYWWYWWYWW FFF FNWRNNWYW e YY AU j AU y 1 2 4 5 Figure 8 3 Guide Block Assembly Part No 44200002 Revision 2 Small Volume Prover Installation 8 5 Honeywell Enraf Operation amp Service Manual 44200002 indd 5 4 23 2014 7 27 39 PM Prover Maintenance 6 Remove the guide block Figure 8 3 position 2 and the mechanical stop Figure 8 3 position 4 with the rubber bumper Figure 8 3 position
121. s Required for O Models Table 3 Wetted Parts Operating pressure range Honeywell Enraf small volume provers comply with ANSI 16 5 regulations depending on the prover flange rating and operating temperature Note Any operating temperature outside the 29 C to 37 8 C 20 F to 100 C temperature range requires de rating of maximum allowable pressure as per ANSI B16 5 ANSI B16 5 Flange Rating Position 6 1 Class 150 RF connection flanges 05 Not Available 2 Class 300 RF connection flanges 05 Not Available 3 Class 600 RF connection flanges 15 Not Available 4 Class 900 RF connection flanges 15 amp 120 Not Available 5 Class 900 RJ connection flanges 15 amp 120 Not Available 6 Class 150 RJ connection flanges 05 Not Available 7 Class 300 RJ connection flanges 05 Not Available 8 Class 600 RJ connection flanges 15 Not Available 9 Class 1500 RF connection flanges 15 amp 120 Not Available Operating Pressure Rating Position 7 V 275 psi Pressure rating For use with Flange Rating 1 amp 6 720 psi Pressure rating For use with Flange Rating 2 amp 7 1440 psi Pressure rating For use with Flange Rating amp 8 D 2160 psi Pressure rating For use with Flange Rating 4 amp 5 3600 psi Pressure rating For use with Flange Rating 9 Table 4 Pressure Condition Ranges 1 4 Small Volume Prover Installation
122. s chains motor and speed reducer drive end plates and anchor bolts guide bars guide block assembly including optical switch and ground assembly switch bar assembly for any loose fasteners or signs of adverse wear and or damage Repair or replace any suspect items 3 Visually inspect all electrical cabling for signs of wear or damage C Semi Annually 1 All items in B 2 Remove upstream and downstream bleed manifolds Insert boroscope with flashlight attachment into both upstream and downstream vent flanges Visually inspect both upstream and downstream piston seals for and signs of damage or wear Inspect poppet valve seal for any signs of damage or wear Inspect flow tube calibrated surface for damage to chrome plating Repair or replace any suspect items 3 Verify prover anchor bolts are tight This maintenance section covers most of the routine maintenance procedures to be performed on your prover Trouble shooting information is contained in Section 6 while wiring diagrams and schematics common to all Honeywell Enraf small volume models are found in Section 7 Please contact the Honeywell Enraf factory for information on problems or repairs not covered by Honeywell Enraf small volume Operation Manual 8 4 Downstream Shaft Seal Replacement Please Note When referring to an item in the following instructions please refer to Figure 8 1 through Figure 8 8 1 Do not remove upstream seal retainer at this time 2 Mo
123. sary to reach the first volume switch valve V5 may be opened until just before the first volume switch has been reached 16 When the first optical switch is reached the signal will be sent to the SVP controller to switch the valves turn the bypass valve SV2 OFF and turn the draw valve SV1 ON At that time the water will start flowing into the Test Measure 17 Record the prover pressure Pp at P1 while only the water draw valve is open SV1 Valves V5 and V6 must be closed while recording this pressure which is the pressure at the start and the end of volume switching Note The draw can be sped up by opening valve V6 after the valves have switched to flowing into the Test Measure located on the scale and the prover pressure Pp is recorded Again close V6 at least 13mm or 2L 1 2 or 1 2 gal prior to solenoid draw valve switching 18 Record ambient temperature Ta at T4 19 Record temperature Td at T2 which is the detector temperature by opening the drive cover and placing the thermometer midway between volume switches which is the location of the switch bar temperature transmitter thermowell 20 Record fluid temperature Tp at T1 at prover 21 Allow Test Measure located on the scale to fill until the second volume switch downstream sensor is reached resulting in the draw valve SV1 turning OFF and bypass valve SV2 turning ON Carefully record scale reading Ww Part No 44200002 Revision 2 Small Volume
124. shown in the running screens 3 3 6 2 2 Units Units of volume With this entity the user can Liter L select the engineering units Cubic meter m3 for volume Cubic centimeter cm3 Cubic decimeter dm3 US Gallons US gal UK Gallons UK gal Barrel bbls 3 3 6 2 3 Display Display brightness With this entity the user can select the 0 low 100 high brightness of the display The brightness is controlled by the backlight of the display Display contrast With this entity the user can select the 0 low 100 high contrast of the display Session timeout value This value selects the time in seconds between last key press on LAD and the moment the display will switch back to one of the running screens User display language This entity selects the display language for the English US running screens e List may expand as additional languages are supported Part No 44200002 Revision 2 Small Volume Prover Installation 3 11 Honeywell Enraf Operation amp Service Manual 44200002 indd 11 4 23 2014 7 27 18 PM Controller Information 3 3 6 2 4 Time Date display format This entity selects the format of the date e DD MM YY MM DD YY e YY MM DD e DD MM YYYY e MM DD YYYY Note Only the first 3 selections will be completely visible on the SVP screen Time display format This entity selects the format of the time e 24 hours 12 hours
125. ter water from an approved public water potable supply may be used in this procedure However the conductivity must not exceed 50ys If the conductivity of the test water is between 50us 1 000us the density shall be determined as per API 4 9 4 section A 5 Mw Corrected Mass of Water gm Ww CBW Vw Volume of Water cc Mw pwtF CPLp E Correction for the effect of pressure on water 1 1 Pp 0 0000032 CTSp Correction for effect of temperature on prover 1 Tp Tb Gal 1 Td Tb Gl CPSp Correction for effect of pressure 1 Pb x 10 WT WD Corrected Water Volume Vw CTS CPL CPS Part No 44200002 Revision 2 Small Volume Prover Installation 5 21 Honeywell Enraf Operation amp Service Manual 44200002 indd 21 4 23 2014 7 27 25 PM Calibration Intentionally left blank 5 22 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 22 4 23 2014 7 27 25 PM CHAPTER 6 TROUBLESHOOTING 6 1 Run Prover Test Running the prover in the Prover Test operating mode is a good way to verify proper operation See Section 4 3 for more information 6 2 Error Messages If any device on the prover malfunctions the error will be shown on the controller screen The following are possible errors and how to correct them 6 2 1 Sensor out of sequence This error message means that the proving se
126. the repeatability values will be stored in the log with a timestamp of the entry 5 16 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 16 4 23 2014 7 27 25 PM Calibration After selecting Enter Average Volume following screen appears Confirm Enter value Stop Selecting Abort Calibration will stop the calibration process This action will stop the motor if in running state bypass value SV2 will be turned ON and draw valve SV1 will be turned OFF If the Prover is in sweep mode with the piston moving downstream no action will be taken for upstream and downstream sensor inputs Calibration log entry will not be made In calibration mode alarms will be generated as per the configuration and the run permissive signal from the flow computer or the run prover test signal will be ignored The operating mode of the prover will be saved in NVM so that the mode will be restored if power is turned off while in Prover Calibration mode To exit calibration mode navigate to the Exit Calibration Mode menu and press OK A copy of Table 14 can be used to enter water draw data An Excel readable file is available from Honeywell Enraf which will calculate the corrected prover volume using the gravimetric method Part No 44200002 Revision 2 Small Volume Prover Installation 5 17 Honeywell Enraf Operation amp Service Manual 44200002 indd
127. tion output set to ON Next prover cycle will be allowed e lt Shutdown gt Alarm shown on the display Alarm indication output set to ON Operation of further machine run cycles are disabled until the alarm is cleared Still able to perform diagnostics via RunProver Test or via Dashboard screen from LAD The Service Due Reminder alarm is activated when the cycle count reaches the threshold value programmed by the user at the Cycle Count Threshold menu The default setting for the Cycle Count Threshold is 1000 Part No 44200002 Revision 2 Small Volume Prover Installation 3 13 Honeywell Enraf Operation amp Service Manual 44200002 indd 13 4 23 2014 7 27 19 PM Controller Information 3 3 7 Prover Calibration LJ The menu screens for Prover Calibration are shown in the diagram below Figure 3 12 See Chapter 5 for detailed calibration procedures Enter Calibration Mode Calibration Notice Run Calibration Exit Calibration Mode SVP HMI Screens Main Menu Calibration Enter Repeatability Enter Average Volume Abort Calibration Figure 3 12 Prover Calibration 3 3 8 System Information The SVP Controller About box is showing important information about m The Device SVP Controller m The individual boards HMI SVP and Option m The firmware versions Main Menu 59 Configuration Figure 3 13 System Information Within this screen identification information is s
128. tions Transfer 9 Events Logs Calibration records a Firmware update LAD Functions LAD information Format SD Figure 3 7 Menu Structure 3 6 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 6 4 23 2014 7 27 18 PM Controller Information 3 3 5 Device Locking Menu Within this screen the user can lock and unlock the SVP Controller m A single password is used to lock the controller from further configuration via HMI m Password is alphanumeric Only capital letters A Z 0 9 No spaces e Maximum of 6 characters m Device remains unlocked until explicitly locked again The lock status is shown at the status bar in the bottom right corner padlock as seen in the following screen 5 7 NEM Configuration Figure 3 8 Device Locking Menu To lock the device the user must enter a password Configuration Lock Device ir Confirm Figure 3 9 Password Input Screen To unlock the controller the user must enter the password as entered during the locking of the controller The password will be stored in non volatile memory Note that the locking feature is not infallible as the password is visible to any user with a LAD connected to the controller It is intended to keep the uninformed user from accidentally changing configuration settings C
129. tions between the SVP Controller and the LAD allowing the rapid transfer of transaction data configuration files and calibration records and even firmware upgrading while in the field LAD Key Panel Board Keys Figure 3 1 The Local Access Device LAD and its system overview 3 2 3 Commissioning The LAD is used to commission the SVP Controller by configuring entities or parameters to the desired specific values This is done by using the LAD to navigate through the Menu functions of the SVP Controller See 3 3 4 3 2 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 2 4 23 2014 7 27 15 PM Controller Information 3 3 Menus and Navigation 3 3 1 General An intuitive and informative Human Machine Interface HMI is available to the user to operate configure and service the SVP Controller This menu based user interface is as clear and accessible as possible using easily understandable colored icons for the Main Menu and logically structured sub menus 3 3 1 1 Key benefits m Clean intuitive and informative user interface m No need to memorize parameter codes enumeration value m Diagnostic screens m Record based approach to transactions and calibrations make re use possible m Interoperable with the Local Access Device LAD m Provides a graphical user interface to the LAD 3 3 2 Main Menu Title
130. tor convenience while attaining more accurate performance tests of a fluid flow meter in an operational line 1 3 Honeywell Enraf small volume prover design specifications Environmental Configuration Honeywell Enraf small volume prover can be installed and used in different configurations as specified in the Table 1 see next page 1 2 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 2 4 23 2014 7 27 03 PM Introduction Operating process temperature range 40 C to 80 C 40 F to 176 F Standard ambient temperature range 20 C to 40 4 F to 4104F For ambient temperatures below 20 C 4 F please consult factory Local Access Device LAD Operating temperature 20 C to 65 C 4 F to 149 F Storage temperature 40 C to 85 C 40 F to 185 F Environmental Configuration Position 1 O Offshore marine coastal platform amp ship applications Wetted Parts E only p Portable Applications O or S unit trailer mounted S Standard stationary product design Table 1 Environmental Configuration Operating flow range The operating flow range depends of the meter type as stated in the Table 2 below Please Note Below mentioned maximum flow rates must be de rated when the fluids with viscosity above 100 cSt are used
131. utilized for the gravimetric method API 4 9 4 is the API standard used for the density determination of water The displaced volume has been calibrated as described in the MPMS API chapters 4 2 4 9 and 12 2 4 The Honeywell Enraf small volume prover base volume has been determined at the factory Recalibration is recommended either at 1 year intervals or as determined by the authorities and parties responsible for the measurement Recalibration is also required after any maintenance which may affect the base volume i e complete switch bar replacement Honeywell Enraf small volume prover optical switches are field replaceable and adjusted to an extremely high degree of precision Individual switch replacement does not necessitate re calibration See Section 6 7 for more information on optical switches 5 2 Static Leak Detection The Honeywell Enraf static leak detection procedure should be used prior to water draw or at any time that meter proof repeatability is difficult to attain It is not necessary to remove the prover from the process line to perform a leak test It is only necessary to block off the inlet and outlet of the prover with it full of fluid Block off the drain valves and verify there is no leak path from the prover If necessary insert blind flanges into the inlet and outlet ports to isolate the prover from the system It is also necessary Part No 44200002 Revision 2 Small Volume Prover Installation 5 1 Honeywe
132. ve the piston to the downstream position 3 Disconnect power from prover 4 Disconnect prover from line or block off from line and drain it completely 5 Remove downstream shaft cover by removing outer support carefully sliding tube cover from the shaft and unscrew the threaded rod from the downstream stop Figure 8 1 453101 8 2 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 2 4 23 2014 7 27 37 PM Prover Maintenance 6 Remove the 4 bolts Figure 8 1 53107 in order to remove the downstream stop from the downstream end flange Figure 8 1 53001 7 Disassemble the downstream seal retainer Figure 8 1 53109 from the downstream stop 8 Remove the retaining rings seals and washers from the downstream seal retainer as showed in the Figure 8 2 53002 HOLE FOR LIFTING 3X ITEM NO DESCRIPTION 53001 DOWNSTREAM FLANGE 53002 O RING SEAL DOWNSTREAM FLANGE 53003 FLANGE RETAINING BOLT 53101 DOWNSTREAM STOP 53107 DOWNSTREAM STOP RETAINING BOLT 53108 O RING SEAL DOWNSTREAM STOP 53109 DOWNSTREAM SEAL RETAINER 53110 DOWNSTREAM SEAL RETAINER BOLT Figure 8 1 Downstream Side Exploded View 9 Clean and inspect seal retainer 10 Check seal surfaces for scratches and a surface finish of 12rms If necessary polish the seal surfaces Part No 44200002 Revision 2 Small Volume Prover Installat
133. very carefully so as not to damage the seal surfaces on the piston Figure 8 4 Piston Removal 8 6 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 6 4 23 2014 7 27 39 PM 54010 4X SEE DETAIL A NOTE DETAILS SHOW COMPONENT ORIENTATION ONLY DETAIL A BELLEVILLE WASHER 54010 ORIENTATION ITEM NO DESCRIPTION 54001 PISTON BODY 54002 PISTON SUPPORT 54003 POPPET 54004 UPSTREAM SHAFT 54005 DOWNSTREAM SHAFT 54006 BELLEVILLE RETAINER WASHER 54008 PISTON SEAL RIDER 54009 PISTON SPRING 54010 PISTON BELLEVILLE SPRING 54011 IGUS BUSHING 54013 PISTON SEAL QUANTITY MAY VARY BASED ON PROVER MODEL 54014 POPPET SEAL 54017 BELLEVILLE RETAINER SEAL 54018 SOCKET HEAD CAP SCREW 54020 HEX HEAD BOLT Figure 8 5 Piston Assembly Exploded View Part No 44200002 Revision 2 Small Volume Prover Installation 8 7 Honeywell Enraf Operation amp Service Manual 44200002 indd 7 4 23 2014 7 27 41 PM Prover Maintenance 9b Referring to Figure 8 5 disassemble the piston by first removing the downstream shaft 54005 from the poppet valve 54003 Then remove the piston support 54002 from the piston body by placing the piston body 54001 face down on a clean surface and hold pressure to keep the spring 54009 compresse
134. voltages from 6 up to 12 volts the 1500 ohm resistor must be replaced with a zero ohm jumper The resistor and jumper must be connected to the terminals in the Customer Connection Box 7 2 1 Omni An Omni flow computer requires that the meter be connected to one of the two E Combo card pulse inputs The E combo card will use the double chronometry proving method Although there are other ways to make the connections we will describe the connections according to the diagram below The Volume Pulse terminal 16 of the Customer Connection Box connects to the prover detector input of the E Combo Module The prover detector input on the Omni is usually Pin 7 Connect Volume Pulse terminal 17 of the Customer Connection Box to common on the rear of the Omni This is usually Pin 10 which is tied to common on the power supply The prover Run permissive command terminal 13 of the Customer Connection Box connects to any Omni Digital I O point That point must be assigned a Boolean point that has been programmed with the value of 1927 Then the Digital point must be assigned the Boolean point Example Program the Boolean point 1025 with the statement 1927 Then program Digital I O point 12 with the number 1025 Connect the run command wire to Digital Point 12 A 1500 ohm resistor must be installed between the Run permissive terminal 14 of the Customer Connection Box and the common terminal 15 for the run command to work proper
135. ystem varying pressure leaking seals or faulty calibration technique 5 12 Small Volume Prover Installation Part No 44200002 Revision 2 Operation amp Service Manual Honeywell Enraf 44200002 indd 12 4 23 2014 7 27 24 PM Calibration 1 Becertain that all maintenance that needs to be done to the prover has been accomplished before starting the gravimetric calibration It is advisable to perform a static leak test prior to performing a water draw see Section 5 2 Replace the seals on the prover if there is any doubt as to their integrity 2 Block prover inlet and outlet by using a blind flanges or double block and bleed valves 3 Refer to Honeywell Enraf water draw configuration Figure 5 7 and install Honeywell Enraf available water draw kit see Figure 5 6 Install certified thermometers and certified pressure gauge even if the prover is equipped with P amp T transmitters If using Honeywell Enraf Water Draw P amp T kit remove the plug in the wafer spacer and connect the pressure gauge P1 to the opening see Figure 5 7 for reference The thermometer used to monitor prover fluid temperature T1 is supposed to be installed into the spare thermowell located on the downstream side of the flow tube see Figure 5 7 for reference The thermometer used to monitor switch bar temperature T2 is supposed to be installed on top of the switch bar close to the center line between two optical switches see Figure 5 7 for referen
136. ywell Enraf 4 23 2014 7 27 17 PM Controller Information 3 3 3 3 Enumeration Input Screen Config Units of volume Scrollbar wii Mi Focus rectangle Press OK to choose op ses Action message Figure 3 5 Enumeration Input Screen 3 3 3 4 Status Bar Press to choose Status Message bar Open lock Figure 3 6 Status Bar m Always visible on all screens m Contains the following information Context specific information directions to user e Status of the transactions e g Idle Running Error Device Locking Icon 3 3 4 Menu Structure For a high level overview of the entities and parameters see the following diagram Figure 3 7 For a detailed view of all menu items see the individual section Continued on next page Part No 44200002 Revision 2 Small Volume Prover Installation 3 5 Honeywell Enraf Operation amp Service Manual 44200002 indd 5 4 23 2014 7 27 18 PM Controller Information Continued from previous page Prover Status Screen B Lock O Alarms O Configuration Settings Device O Enter Calibration Mode 5 Run Calibration Calibration Exit Calibration Mode Enter Average Volume a Abort Calibration Device O Info Board O Versions Transaction SVP HMI Screens Logs Calibration Main Menu Alarm Dashboard 5 System health Active Alarms Diagnostics 3 Storage Info Prover Service Test S Transaction records Configura

Honeywell Enraf Small Volume Prover Installation, Operation

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