Clamp-on Ultrasonic Flowmeter

Installation
Module FU060BBEB
Training Handbook
Internal Training


Editor
The following training handbook is produced by Endress+Hauser Flowtec AG. Changes and extracts are subject to the
permission of the editor. To contact the editor please use address below.

Copyright
This document is protected by copyright. The use outside of E+H or the right to copy the document is only permitted with
written permission of Endress+Hauser Flowtec.
For further information and permissions please contact:
Endress+Hauser Flowtec AG
Training Manager
Kgenstrasse 7
4153 Reinach BL
Switzerland


E-Mail: training@flowtec.endress.com

Prerequisite of the trainee
Before attempting this learning module it is expected that the trainee has successfully finished the training module FU010B to
FU050B. If necessary this knowledge has to be built up first.

Objective of this learning module
The participant understands
the relevant parameters to install an ultrasonic flowmeter
the parameters which have the greatest influence on a successful installation
how to verify a successful installation
where to install the meter to have the greatest chance of success






Additional documents

Power Point Presentation FU060BPEB
Assessment document FU060BAEB
Installation Video CD 044D/06/en/11.07 (also available via internet)
Installation_93P_small_sensor.WMV


Changes REV B
Completely up-dated, fully replaces REV A


Training Handbook FU060BBEB Page 2 of 14 J. Metcalfe/MTU

Internal Training


Content
1. Selecting an Installation Location ......................................................................................................................4
1.1. General Requirements .........................................................................................................................................4
1.2. Inlet and Outlet requirements for Clamp-on Ultrasonic Meter..............................................................................4
1.3. Insufficient Inlet and Outlet run Information .......................................................................................................4
1.4. Sensor Radial Location.........................................................................................................................................5
1.5. Electronics Installation Location ..........................................................................................................................5
2. Transmitter Programming .................................................................................................................................6
2.1. Outer Diameter (circumference) ..........................................................................................................................6
2.2. Liquid Sound Velocity .........................................................................................................................................6
2.3. Number of Traverses ...........................................................................................................................................6
2.4. Sensor Type ........................................................................................................................................................7
2.5. Pipe Wall Thickness ............................................................................................................................................7
2.6. Pipe Wall Thickness ............................................................................................................................................7
2.7. Pipe Sound Velocity.............................................................................................................................................7
2.8. Pipe Liner and Thickness.....................................................................................................................................7
2.9. Temperature .......................................................................................................................................................7
3. Transmitter Programming Steps ........................................................................................................................8
4. Installation of Mounting Post...........................................................................................................................10
4.1. 1 Traverse Installation of Mounting Post............................................................................................................10
4.2. 2 Traverse Installation of Mounting Post............................................................................................................11
5. Installation Sensor Holders..............................................................................................................................12
6. Installation of P sensor 6 MHz (small) .............................................................................................................13
7. Installation Verification...................................................................................................................................14

Training Handbook FU060BBEB Page 3 of 14 J. Metcalfe/MTU

Internal Training


1. Selecting an Installation Location
1.1. General Requirements
The specification of ANY flowmeter is based on an ideal installation. Installation guidelines for any technology
exist. They should be looked at as a MINIMUM requirement.

Particular installation requirements of a Ultrasonic clamp-on meter:
The meter must be installed with sufficient straight pipe up- and down-stream
The pipe must remain completely full of liquid during measurement
The programming
1.2. Inlet and Outlet requirements for Clamp-on Ultrasonic Meter
Clamp-on ultrasonic meter,
installation location is critical for a
successful installation. It is critical
that the meter be installed in a
location where the flow will have
a flow profile that is fully
developed. To insure the flow is
fully developed it is required that
the meter have a straight
metering section before and after
the meter. The length of this
straight section will depend on
what flow disturbances that is
before the metering section. If
several flow disturbances are
before the meter, the disturbances requiring the greatest straight run is the determining distance.

1.3. Insufficient Inlet and Outlet run Information
The WRC in England
conducted an independent
study of 3 manufactures of
ultrasonic clamp on meters.
They determined the single
most determining factor of
accuracy of a clamp-on
ultrasonic flow meter was flow
profile and the straight run
length before the meter. In the
table the effects can be seen as
a range on the accuracy. A
range is used since the radial
position around the pipe will
also have an effect. It is important to note that all the add uncertainty is negative. This means in practice if the
up stream requirements can not be met, then the highest flow value at constant conditions when the sensor are
radial moved around the pipe is most likely the best value to the true value, however most likely still under
registering the flow.
-4 to -5 -3 to -6 -5 to -7 Double bend
0 to -2 -2 to -4 -3 to -5 Expander (1:2)
0 0 to -2 -1 to -3 Reducer (2:1)
0 to -1 -2 to -3 -2 to -3 Gate valve
(2/3 open)
-1 to -4 -2 to -6 -3 to -8 Single bend
20 D 10 D 5 D
Influence (% reading) at separation
distances of
Source of
disturbance
-4 to -5 -3 to -6 -5 to -7 Double bend
0 to -2 -2 to -4 -3 to -5 Expander (1:2)
0 0 to -2 -1 to -3 Reducer (2:1)
0 to -1 -2 to -3 -2 to -3 Gate valve
(2/3 open)
-1 to -4 -2 to -6 -3 to -8 Single bend
20 D 10 D 5 D
Influence (% reading) at separation
distances of
Source of
disturbance
Training Handbook FU060BBEB Page 4 of 14 J. Metcalfe/MTU

Internal Training


1.4. Sensor Radial Location
A vertical installation is the preferred method of installation. This is the best installation to avoid partially filled
pipes and it avoids placing the sensors where
solid particles or entrained gas can accumulate
and disturb the flow measurement.

If the sensors must be installed in a horizontal
pipe avoid the top and bottom of the pipe. Try
to place the sensors directly on the sides or at
least 15 from the top or bottom of the pipe.
This is done to avoid accumulating gas at the
top and solid build up at the bottom of the pipe,
both of which can disturb the flow
measurement.
1.5. Electronics Installation Location
With the Ultrasonic Clamp-on meters, the electronics are always a remote version. Thus the location for
mounting the electronics must be within the cable length ordered. Each electronics can either be wall or pipe
mo

unted. The appropriate ambient condition within specification must be adhered followed.

Training Handbook FU060BBEB Page 5 of 14 J. Metcalfe/MTU

Internal Training


2. Transmitter Programming
In order to install the ultrasonic sensors, the relative information concerning the application must be programmed into
the transmitter. After this information is programmed into the transmitter via the display or FieldTool/FieldCare, the
transmitter will then output the proper sensor distance. Applicator can also be used as an alternative. It is very
important this information be as accurate as possible as the accuracy of the system is strongly dependent on these
variables.
2.1. Outer Diameter (circumference)
The diameter of the pipe can be determined by measurement (preferred) , reading the diameter printed on the
pipe, or using a pipe dimensions reference book.

Alternatively, the circumference could also be entered. The value can be determined just as the diameter.

If the diameter is inputted the circumference is automatically calculated and vice versa. The last entered value is
the value used for sensor distance.
2.2. Liquid Sound Velocity
The Prosonic Flow transmitter already contains an extensive list of liquids which the sound velocity is already
preprogrammed. If liquid be measured is not listed then the sound velocity will need to be entered manually.
This can be done by selecting the option others and then entering sound velocity.

The sound velocity of other liquids can be determined by references (books, internet, etc), using the liquid
sound velocity sensors (DDU 18), or a trial and error method (this is taught in Advance Hands-on Training).
2.3. Number of Traverses
The number of traverses will determine if the sensors are mounted on opposite sides of the pipe, in a 1 traverse
installation or on the same side of the pipe in a 2 traverse installation.

The main factor for deciding the number of traverses is the size of the pipe and the easy of installation. Generally
a 2 traverse installation is always the easiest form of installation. If signal strength is low, changing to a 1
traverse installation can improve the signal strength.

The following table can be used as a guideline.


Training Handbook FU060BBEB Page 6 of 14 J. Metcalfe/MTU

Internal Training


2.4. Sensor Type
The sensor type is printed on the name plate. The corrected sensor should have been selected in the selection
process (see training module Selection and Sizing)
2.5. Pipe Wall Thickness
The pipe wall thickness can be determined by measurement (preferred with DDU19) , reading the diameter
printed on the pipe, or using a pipe dimensions reference book.
2.6. Pipe Wall Thickness
The pipe wall thickness can be determined by measurement (preferred with DDU19) , reading the diameter
printed on the pipe, or using a pipe dimensions reference book.
2.7. Pipe Sound Velocity
The pipe sound velocity is in almost every circumstance preprogrammed into the Prosonic Flow transmitter
through the selection of the pipe material. In the rare case it can be measured using the DDU 19 sensor.
2.8. Pipe Liner and Thickness
If the pipe is lined, the liner material and thickness need to be determined. Often this is only possible by
referring to reference material or consulting the pipe manufacturer.
2.9. Temperature
The normal process temperature is required. The temperature influences the speed of sound of the measured
liquid and the pipe, thus it influences the sensor position.
After a suitable sensor location is found the transmitter is programmed to determine the sensor spacing













Training Handbook FU060BBEB Page 7 of 14 J. Metcalfe/MTU

Internal Training


3. Transmitter Programming Steps
It is highly recommended to refer to the Installation Video (CD 044D/06/en/11.07) available on the internet to
understand the installation sequence. If access to video is not available, the following can be used as an outline for
installation.

Begin the programming of the Prosonic Flow meter by pushing the "E"-button. This button is used to initiate the
programming sequence, and later for confirming selections.

The plus and minus buttons are used to access the various selection options.

After entering into programming, select "quick set-up" or "sensor set-up". Text displayed will depend on the Prosonic
Flow device employed.

After entering the set-up routine, confirm again, that you wish
to enter the sensor set-up.

The first programming change requires an access code. Enter
the model number (The model number of the device serves as
the default access code).

Then enter the liquid being measured. Various options are
available: if your particular liquid is not listed, simply choose t
option "others".
he

The temperature for normal operations is then to be entered. If
temperature varies during operations, enter an average
temperature value.

The sound velocity of the liquid is then displayed for the normal
operating temperature. If you have chosen others earlier, you
will need to enter the liquid sound velocity.

The material of the pipe in which the liquid is being conveyed
should then be entered. Select the appropriate material.

The sound velocity of the pipe is then displayed.

You now have the choice of entering either the outer pipe
circumference or outer pipe diameter. After entering one of the
values, the other value is automatically calculated.

The outer pipe diameter can often be found printed on the pipe,
along with the pipe wall thicknes

If the pipe diameter cannot be found, we suggest measuring the
circumference of the pipe and entering that value.

Now enter the pipe wall thickness. If this is unknown, it is
possible to estimate the value.

Training Handbook FU060BBEB Page 8 of 14 J. Metcalfe/MTU

Internal Training


If a lined pipe is being used, the material of the liner will need to be entered along with the thickness of the liner. If the
pipe is not lined, simply choose none.

The sensor type is required; this can be found printed on the sensor itself.

The transmitter will prompt the number of traverses. The number of traverses determines if the sensors are to be
mounted on opposite sides of the pipe, in a one-traverse installation, or on the same side of the pipe in a 2-traverse
installation.

For pipes smaller than 80mm, one traverse is suggested. For pipes in the size range of 80 mm to 600mm, 2 traverse-
installation is suggested. And for pipes larger than 600 mm, one traverse is suggested.

The length of the sensor cable will now need to be entered.

Now, all the parameters for installation have been programmed into the transmitter, and the mechanical installation
can begin.
Training Handbook FU060BBEB Page 9 of 14 J. Metcalfe/MTU

Internal Training


4. Installation of Mounting Post
Depending on the selected number of traverse in the transmitter programming one of the two possible procedures will
be required:
4.1. 1 Traverse Installation of Mounting Post
It is highly recommended to refer to the Installation Video (CD 044D/06/en/11.07) available on the internet to
understand the mechanical installation of the 1 traverse mounting post. If access to video is not available, the
following can be used as an outline.

For a one-traverse installation, the transmitter will display a sensor distance and wire length.

The instrument is delivered with
two wires with a flat cable shoe
on one end, and a variable-length
cable shoe on the other end.

Adjust the cable shoes to
correspond with the wire length
indicated from the transmitter.
The distance should be measured
from the center of each cable shoe.

Securely tighten the screw on the variable cable shoe, so that the cable shoes are firmly positioned at the proper
distance.

Tighten one of the mounting posts firmly to the side of the pipe, and leave the other post loose, so it can slide
along the pipe.

Place the flat cable shoe on each mounting post.

Then take the other end with the variable-length cable shoe and run each wire around opposite sides of the
pipe.

Place the cable shoe on the mounting post,
so that the screw is on the outside, and
thus accessible to be loosened later.

Slide the free mounting post, so the cables
are pulled tight. Then secure the post to
the pipe.

Loosen the screw on the cable shoe, and
detach from the mounting post.

The mounting posts for one-traverse installation are now in place..
Training Handbook FU060BBEB Page 10 of 14 J. Metcalfe/MTU

Internal Training


4.2. 2 Traverse Installation of Mounting Post
It is highly recommended to refer to the Installation Video (CD 044D/06/en/11.07) available on the internet to
understand the mechanical installation of the 2 traverse mounting post. If access to video is not available, the
following can be used as an outline.

To position the mounting posts for the two-traverse installation, the ruler supplied in the delivery will be
needed.

After programming the application parameters, the transmitter will indicate a "letter" and "number",
corresponding to two holes, drilled into the ruler. The mounting posts will feed through these holes for proper
positioning.

Tighten the mounting posts to the pipe, making sure the posts are at the same radial position on the pipe.

The ruler can then be removed.
Training Handbook FU060BBEB Page 11 of 14 J. Metcalfe/MTU

Internal Training


5. Installation Sensor Holders
Secure the sensor holders to the mounting post. Make sure they are
nsor holders are fastened to the pipe,
ply coupling gel to the face of the sensor.
e

upling gel provides a good acoustic coupling
tween the sensor and the pipe.

the holders.
hey only slide into the holders in a particular

pipe, compressing
e internal spring. Then turn the sensor covers, so

tective caps from sensor and sensor
ble, and firmly secure the sensor cable to the
he mechanical installation is now complete
facing in the correct direction as shown.
After the se

ap
Approximately 1 mm thickness is required for the
surface area, which will be in contact with th
pipe.
The co
be
Now the sensors can be placed into
T
orientation, where a groove in the sensor aligns
with a guide rail in the holder.
Push the sensor firmly onto the
th
that the closed arrow aligns with the arrow on the
sensor holder.
Remove the pro
ca
sensor.

T

Training Handbook FU060BBEB Page 12 of 14 J. Metcalfe/MTU

Internal Training


6. Installation of P sensor 6 MHz (small)
The 6 MHz P sensor installation can begin by installing the mounting plate.
Unlike the other sensors this can be done before knowing the sensor d
For smaller pipes DN15-32 a U-bolt is used for securing the mounting
to the pipe for pipes sizes DN40-65 a band is used.
istance.
plate

After the sensor distance is determined, the freely adjustable sensor must be
adjusted to the proper sensor distance. This must be done precisely as sensor
distance on such small pipes can have a large influence on the overall
accuracy of the system. The sensor distance is measured from the points
shown on the graphic. This needs to be done with the supplied callipers
(Vernier).

Finally coupling media can be applied to the transmitting portion of the
sensor (raised portion at the sensor spacing location) and the sensor attached
to the mounting plate.

See video Installation_93P_small_sensor.WMV for procedure.

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Training Handbook FU060BBEB Page 13 of 14 J. Metcalfe/MTU

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7. Installation Verification
To verify successful installation, check the signal strength from the transmitter under "measured values". This value
should not undercut exceed 50 decibels. If it is below this minimum, the installation should be improved if possible.

Also check the measured sound velocity of the liquid. This should be within 3% of the sound velocity of liquid, entered
into the transmitter in the initial programming sequence.

After confirming that installation is successful, the Prosonic Flow meter is ready to measure.


Liquid Sound Velocity
Measured versus
programmed
Signal Strength

Parameter Verification
+/- 3%
> 50 decibels (dB)
Training Handbook FU060BBEB Page 14 of 14 J. Metcalfe/MTU