Honeywell Enraf Calibron Small Volume Prover 05 Operation & Installation Manual

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Small Volume Prover

Calibron

Operation & Installation Manual

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Page 1 Small Volume Prover Calibron ® Operation & Installation Manual...
Page 2 CALIBRON ® SmALL VOLume PROVeR OPeRAtION & INStALLAtION mANuAL MoDEl 05, 15, 25, 35, 50, 85, 120 U.S. PatEnt #5,052,211 Edition Released June 2012...
Page 3: Table Of Contents
table of Contents the Calibron Prover series ........vii ®...
Page 4 table of Contents 6.4 replacement of Upstream Shaft Seals ......6-12 6.5 replacement of Downstream Shaft Seals ......6-12 6.6 Drive System Maintenance .
Page 5 table of Contents FiGUrE 28 Downstream Seal retainer assembly ......6-4 FiGUrE 29 Guide block assembly ......... .6-5 FiGUrE 30 Upstream Flange and Seal retainer assembly .
Page 6 table of Contents intentionally left blank. Calibron Small Volume Prover Part no.: 44103445 - revision 0 ® operation & installation Manual...
Page 7: The Calibron Prover Series
Refer to the EC declaration of conformity and ATEX certificate(s), shipped with the instrument. installation Refer to Honeywell Enraf installation manual 44103445M for additional information. 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) explosive atmospheres.
Page 8: Operation
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 Calibron SVP can be used for its intended purpose.
Page 9: Maintenance And Troubleshooting
® 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. additional information If you require additional information, contact Honeywell Enraf or its representative.
Page 10 the Calibron Prover series ® intentionally left blank. Calibron Small Volume Prover Part no.: 44103445 - revision 0 ® operation & installation Manual...
Page 11: Installation Procedure
Please read this section carefully before installing, using, or maintaining your CALIBRON 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 CALIBRON small volume prover is fitted with transit seals in both the ®...
Page 12 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.
Page 13 21. Do not alter or modify the CALIBRON 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. 22. Ensure that the unit is fully depressurized and drained prior to disassembly or service.
Page 14 installation Procedure 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.
Page 15: Chapter 1 Introduction
This manual provides the necessary information and procedures for the proper operation of the CALIBRON small volume prover manufactured by ® Honeywell Enraf Americas, Inc. The CALIBRON small volume prover uses a wear and corrosion resistant ® precisely honed flow tube. Contained within the flow tube is the piston/ bypass valve arrangement.
Page 16: General Features
introduction 1.2 General Features Field replaceable precision optical volume measurement switches  without recalibration. Flow-through poppet valve piston to minimize flow disturbances.  Patented electromechanical chain drive piston return mechanism.  Operates from a conventional electrical circuit (options include single or ...
Page 17: Table 2 Prover Flow Range
introduction 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.) FloW ratE (Position 2, 3, 4) Prover Maximum...
Page 18: Table 4 Pressure Condition Ranges
introduction Continued from previous page Class 150 RJ connection flanges (05 Not Available). Class 300 RJ connection flanges (05 Not Available). Class 600 RJ connection flanges (15 & 120 Not Available). Class 1500 RF connection flanges (15 & 120 Not Available). operating Pressure rating (Position 7) ...
Page 19: Table 7 Electrical Hazardous Classification
8: Flow tube Finish transmitter Manufacturer: The Calibron 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.)
Page 20 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 4. S/o/P05 –...
Page 21: Table 10 Maximum Allowable Inlet And Outlet Flange Loads
introduction Continued from previous page S/o/P120 – inlet / outlet nozzle nominal Diameter: 16 inch FX = 3737 N 840 lb Mx = 5125 Nm 3780 lb •ft top nozzle Fy = 5916 N 1330 lb Each Nozzle My = 3796 Nm 2800 lb •ft...
Page 22: Tests And Certifications
III. 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 Calibron Small Volume Prover Part no.: 44103445 - revision 0...
Page 23: Principle Of Operation
introduction dual-valve assembly in conjunction with an electronic scale. Base volume on the certificate of calibration is corrected to 0 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.
Page 24 introduction 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.
Page 25: Chapter 2 Installation
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.
Page 26: Figure 4 Process Connections And General Arrangement
installation 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. 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.
Page 27: Figure 5 Prover Lifting Diagram
installation 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 CALIBRON small volume prover is equipped with integral lifting points. ®...
Page 28: Figure 6 Prover Service Clearance Diagram
installation Please remember to place permanent structures of any type outside the required Service Clearance area detailed in Figure 6. MoDEl 610 (2) 610 (2) 610 (2) 1220 (4) 1520 (5) 1520 (5) 610 (2) 610 (2) 610 (2) 2140 (7) 1520 (5) 1830 (6) 610 (2)
Page 29: Electrical Connection
Honeywell Enraf will not be responsible for possible damages to the prover or system parts if these recommendations are not followed. Figures 7: Designated anchor points (plates) located on the bottom side of the prover frame.
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Page 31: Chapter 3 Calibration
ChAPteR 3 CALIBRAtION 3.1 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.
Page 32: Equipment
Calibration 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. 3.2.1 Equipment 1. Static leak differential pressure creator assembly, included with prover. 2.
Page 33: Figure 8 Static Leak Detection Set-Up
Calibration minutes. If the pressure has not dropped by more than 25% of the starting differential pressure, it may be assumed that there are no 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.
Page 34: Figure 12 Recommendation For Seal Change
(see Figure 14) 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&T kit or equivalent assembly eases installation of water draw prover instrumentation. Calibron Small Volume Prover Part no.: 44103445 - revision 0...
Page 35: Figure 13 Water Draw Kit
Calibration Figure 13: Water Draw Kit Figure 14: Water Draw P&t Kit Part no.: 44103445 - revision 0 Calibron Small Volume Prover ® operation & installation Manual...
Page 36 Figure 15, and install ® Honeywell Enraf available water draw kit, see Figure 13 and Figure 14. Install certified thermometers and certified pressure gauge, even if the prover is equipped with P&T transmitters. If using Honeywell Enraf Water Draw P&T kit, remove the plug in the wafer spacer and connect...
Page 37: Figure 15 Water Draw Plumbing Diagram
18. Calculate prover volume per Section 3.5. A copy of Table 12 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.
Page 38: Volumetric Water Draw
Calibration Figure 16: 401D interface for Water Draw Controller Connection 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):...
Page 39: Gravimetric Water Draw
8. Water draw data sheet, Table 12. 9. Water overboard container, volume to be at least as large as test measure. note: Honeywell Enraf Water Draw P&T kit or equivalent assembly eases installation of water draw prover instrumentation. Procedure Water draw notes:...
Page 40 Refer to CALIBRON water draw configuration, Figure 15, and install ® Honeywell Enraf available water draw kit, (Figure 13 and Figure 14). Install certified thermometers, and certified pressure gauge, even if the prover is equipped with P&T transmitters. If using Honeywell Enraf Water Draw P&T kit, remove the plug in the wafer spacer and connect...
Page 41 21. Calculate results per Section 3.5. A copy of Table 4 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. Gravimetric Water Draw Data Sheet...
Page 42: Calculations
Calibration Continued from previous page Calculated Density of Water ( ρw) = 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 13: Gravimetric Water Draw Data Sheet...
Page 43 Calibration CCTs = Correction for prover/test measure steel temperature difference = (CTStm) / (CTSp) = Adjusted Base Volume of Draw = BMVa*CTDW*CCTs CPSp = Correction for the effect of pressure on prover = 1 + [(Pp*ID) / (E*WT)] CPLp = Correction for effect of pressure on liquid (water) = 1 / [1-(0.0000032*Pp)] = Average of all WD’s = [@sum (WDz Fill 1..WDz Fill5)]/n...
Page 44 Calibration ρTWr is the density of reference test weights (gm/cc), ρTWf is the density of the field test weights (gm/cc) as per certificate of traceability, ρFtp is the density of fluid at test temperature and test pressure (gm/cc), ρA is the density of dry air (gm/cc) Calculation for the Density of the Calibration Water ρwtF = Density of water at temperature t°F (kg/cm) (From API 12.2.4 or...
Page 45: Chapter 4 Operations And Troubleshooting
ChAPteR 4 OPeRAtIONS AND tROuBLeShOOtING 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 CALIBRON small volume prover. ® 2. Open fluid inlet valve slowly. After the inlet valve is completely open, open fluid outlet valve, connecting the prover to the process line, Figure 4.
Page 46: Trouble Shooting Chart
operations and troubleshooting the piston being released by the puller and starting a proving run. Steps e. and f. simulate the piston completing its proving run and returning to the downstream stand by position. If you do not receive pulses when you trip the upstream optical switch check the 401D board and see if the light is on and flashing, if so replace the upstream optical switch and run test again.
Page 47: Chapter 5 Electrical Schematics & Drawings
CALIBRON small volume prover. If there are electrical questions ® not addressed by these figures contact your nearest Honeywell Enraf representative or the factory directly. 5.1 Customer electrical Connections Figure 17 details the customer electrical connections for a prover with one electrical box (assuming that the power to the motor will be supplied to the motor directly.
Page 48: Figure 18 Customer Electrical Connections Two Box Models
Electrical Schematics & Drawings Figure 18: Customer Electrical Connections two box Models Figure 19: Customer Electrical Connections three box Models Calibron Small Volume Prover Part no.: 44103445 - revision 0 ® operation & installation Manual...
Page 49: Calibron ® Wiring Diagrams
Electrical Schematics & Drawings note 1: See appropriate wiring diagram and information for connection to your proving computer in Section 5.2. note 2: See Figure 18 for single phase AC power, Figure 19 for 3 phase AC Power, and Figure 20 for DC power. 5.2 CALIBRON Wiring Diagrams ®...
Page 50: Figure 21 Wiring Diagram For 3 Phase Models
Electrical Schematics & Drawings Figure 21: Wiring Diagram for 3 Phase Models Please note: Exercise extreme caution when wiring 401D module. The 401D module is a very sensitive electronic device and if wired incorrectly will be rendered useless. Calibron Small Volume Prover Part no.: 44103445 - revision 0 ®...
Page 51: Figure 22 Wiring Diagram For 24 Vdc Models
Electrical Schematics & Drawings Figure 22: Wiring Diagram for 24 VDC Models Please note: Exercise extreme caution when wiring 401D module. the 401D module is a very sensitive electronic device and if wired incorrectly will be rendered useless. Part no.: 44103445 - revision 0 Calibron Small Volume Prover ®...
Page 52: 401D Wiring Diagrams
Electrical Schematics & Drawings 5.3 401D Wiring Diagrams 401D to oMni Flow Computer wiring and setup 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.
Page 53: Figure 24 401D To Condat Wiring
Electrical Schematics & Drawings Figure 24: 401D to ConDat Wiring Figure 25: 401D to Daniel 2500 Flow Computer Wiring Part no.: 44103445 - revision 0 Calibron Small Volume Prover ® operation & installation Manual...
Page 54: Figure 26 401D To Dynamic Flow Computer Wiring
Electrical Schematics & Drawings 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. 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.
Page 55: Chapter 6 Prover Maintenance
ChAPteR 6 PROVeR mAINteNANCe 6.1 General Prover maintenance Information Preventative Maintenance CALIBRON 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 77ºF [25ºC].
Page 56 Section 4 while wiring diagrams and schematics common to all CALIBRON small volume models are found in Section 5. ® Please contact the Honeywell Enraf factory for information on problems or repairs not covered by CALIBRON small volume Operation Manual. ®...
Page 57: Figure 27 Downstream Side Exploded View
Prover Maintenance itEM no. DESCriPtion 53001 DOWNSTREAM FLANGE 53002 O-RING SEAL DOWN STREAM FLANGE 53003 FLANGE RETAINING BOLT 53101 DOWNSTREAM STOP 53107 DOWN STREAM STOP RETAINING BOLT 53108 O-RING SEAL DOWN STREAM STOP 53109 DOWN STREAM SEAL RETAINER 53110 DOWN STREAM SEAL RETAINER BOLT Figure 27: Downstream Side Exploded View 10.
Page 58 Prover Maintenance 13. Check seal surfaces for scratches and a surface finish of 12rms. If necessary, polish the seal surfaces. 14. Install new seals and washers in proper orientation (see Figure 28 for correct installation). Note the direction of the seal lips for correctly installing of the new seals.
Page 59 Prover Maintenance 15. Remove the securing nut and the standard nut, (1) Figure 29, from the guide block (2). Figure 29: Guide block assembly 16. Remove the upstream seal retainer assembly, Figure 30 #52101, from the upstream flange by first removing the shock absorbers, Figure 30 #52108, and then removing the hex socket cap screws, Figure 30 #52107 holding the seal retainer to the end flange.
Page 60 Prover Maintenance 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...
Page 61 Prover Maintenance 21. With sufficient personnel and/or a hoist or crane at the downstream end of the prover to lift the piston assembly, pull the piston assembly out of the flow tube. 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, see Figure 31.
Page 62 Prover Maintenance 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 #54003, 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.
Page 63 Prover Maintenance 23. Reassemble the piston by reversing the disassembly procedure and use new seals in all locations, refer to Figure 32. To assist in installing the riders and main piston seals, put them in hot water [60 - 65°C (140 - 150°F)] to make the seals and riders more flexible and to reduce the chance for damage.
Page 64: Bolt Torque Specifications
Prover Maintenance 25. Put a new o-ring seal, Figure 27 #53002, onto downstream flange, Figure 27 #53001, carefully re-install flange into flow tube. Re-install hex socket bolts, Figure 25 #53003, securing the downstream end flange, Figure 27 #53001, to the flow tube. Snug bolts evenly, using a cross pattern, so as to not damage the seal or distort the flange.
Page 65: Table 15 Bolt Torque Specifications
Prover Maintenance Continued from previous page 85X1A 295 lbf•ft 150 lbf•ft 295 lbf•ft 150 lbf•ft 75 lbf•ft 11 lbf•ft 170 lbf•ft 250 lbf•ft 85X2B 295 lbf•ft 150 lbf•ft 295 lbf•ft 150 lbf•ft 75 lbf•ft 11 lbf•ft 170 lbf•ft 250 lbf•ft 85X3C 1200 lbf•ft 150 lbf•ft...
Page 66: Replacement Of Upstream Shaft Seals
Prover Maintenance Figure 34: Guide block Exploded View itEM no. 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...
Page 67: Drive System Maintenance
Prover Maintenance 6.6 Drive System maintenance The CALIBRON 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.
Page 68: Volume Switch Replacement
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.
Page 69 Prover Maintenance Figure 37: Correct optical Switch installation Side View Figure 38, Figure 39, and Figure 40 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.
Page 70: After-Sales Support
® 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 & Asia to support CALIBRON provers worldwide. ® In order to analyze the problem the following information is required: Serial number of prover ...
Page 71: Frequently Asked Questions
If you have any questions, please consult the factory. How is the installed base of CALIBRON provers Honeywell Global Technical Support (GTS) is the focal point for ® supported? all CALIBRON related after-sales support questions and GTS ®...
Page 72 Americas, Inc. 2000 Northfield Court, Roswell, GA 30076-4908 U.S.A. Tel: +770-475-1900 Fax +770-475-1717 44103445_ENG June 2012 www.honeywellenraf.com © 2012 Honeywell International Inc.

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