VD 7-100 e 07.2009 CONTOIL MDO and HFO applications
Table of contents 1 Introduction 3 1.1 Liability Disclaimer 3 1.2 Safety precautions 3 1.3 Conventions 4 1.4 Supplementary Instructions 4 2 Technical Information 5 2.1 CONTOIL Flow Meter Types 5 2.2 CONTOIL Flow Meter Materials 5 2.3 CONTOIL Flow Meter Application Specifications 6 2.4 CONTOIL Flow Meter Specifications 7 2.5 CONTOIL Flow Meter Dimensions (for flange version only) 7 2.6 CONTOIL Flow Meter Transducer Dimensions 7 3 Design Guidelines 8 3.1 Samples of measuring concepts 8 3.2 Accuracy comparison of different measurement concepts 10 3.3 Temperature Compensation 11 3.4 Density Compensation 11 3.5 Offset in differential measurement 11 3.6 Layout and Installation 12 3.7 Strainers / Filters 13 3.8 Pulsation Dampers 13 3.9 Pressure Loss 13 3.10 Installation 14 4 Commissioning / start up 15 5 Maintenance 15 6 Troubleshooting 16 7 Warranty Disclaimer 17 Appendix I. 18 Pressure Drop Curves 2
1. Introduction Thank you for your decision to work with Aquametro Fuel Performance Products. This manual describes the installation, commissioning and use of Aquametro s CONTOIL Fuel Meters. For additional information please contact your local sales agent to be found at: http://www.aquametro.com/english/distributoren_e.html. 1.1 Liability Disclaimer The manufacturer cannot monitor the compliance to this manual as well as the conditions and methods during the installation, operation, usage and maintenance of the system regulator. Improper installation can cause damages and endanger people. Therefore, we assume no responsibility and liability for losses, damages or costs that result due to incorrect installation, improper operation, usage and maintenance or in any manner associated therewith. Similarly, we assume no responsibility for patent right or other right infringements of third parties caused by usage of this system regulator. The manufacturer reserves the right, without prior notification, to make modifications concerning the product, technical data or installation and operating manual. 1.2 Safety precautions CONTOIL flow meters must only be used for their intended purpose and comply with local and international safety regulations. All documentation is to be followed exactly. None of the information stated here or elsewhere releases planners, installers and operators from their own careful and comprehensive assessment of the respective plant configuration in terms of functional capability and operational safety. Local applicable working regulations must be complied with, during all work on the plant and/or ship. All safety-, installation- and operation instruction as described in this manual must be followed. Sensors are sensitive measuring instruments and should be treated carefully. When removing or reinstalling sensors or components from the system, safety instructions in the respective operating manual must be followed. Extra caution is required, when using inflammable cleaning substances, work space must be ventilated well. The clearance distance of the piping must be adhered to when mounting the meter. If using flanged connections, the correct number of connector elements must be fitted and they must be tightened with the correct torque in accordance with the screw manufacturer s instructions. Always comply with the permissible operating data as specified and mentioned on the type plate. The meter must at all times be completely filled with liquid during operation. Check the meter periodically for tightness of the connections and for proper functioning. Make sure that no hazardous fumes can build up in the piping and in the meter during commissioning, decommissioning and dismantling. Prior to disassembly, the measuring instruments must be free from dangerous or noxious residues. Clean and rinse thoroughly! The unit must be installed to 6...30 VDC and must not be installed to 110 VAC or 230 VDC. Electrical wiring and installations are subject to statutory regulations, which must be taken into account when planning the system. CONTOIL flow meters are not for installation in zones subject to explosion hazards. Make sure that no hazardous fumes can build up in the piping and in the meter during commissioning, decommissioning and dismantling. If work is to be done on the installation, before each intervention: a) Release the pressure in the installation b) If hazardous fluids are used, wear protective clothing and safety goggles. Prior to disassembly, the measuring instruments must be free from dangerous or noxious residues. Clean and rinse thoroughly! c) Place collecting vessel underneath the installation. 3
1.3 Conventions A/E Auxiliary Engine CFM-S CONTOIL Fuel Monitor - Ship CFM-T CONTOIL Fuel Monitor - Tug-boat DN Diameter Nominal ECR Engineering Control Room ER Engineering Room ETO Electro Technical Officer FM x Fuel Meter 1...5 FPA Fuel Performance Analyser FPM Fuel Performance Management FPR Fuel Performance Recorder PLC Programmable Logic Controller GPS Global Positioning System HFO Heavy Fuel Oil MDO Marine Diesel Oil MGO Marine Gas Oil M/E Main Engine MT Main Tank Pt100 Standard Resistance thermometer (R0 = 100 Ohm) Tx Temperature Sensor 1...7 (Pt100) W/H Wheel House (= bridge) 1.4 Supplementary Instructions Bedienungsanleitung / Operating instructions / Mode d emploi CONTOIL control: VZF / VZFA Art. No. 20313 4
2. Technical Information CONTOIL flow meters work on the volumetric principle of rotary piston meters (positive displacement meters). The main features of this measuring principle are large measuring ranges, high accuracy, suitability for high viscosities and independence from power supply; flow disturbances do not influence proper operation. 5.65028.4 Rotary piston, guide roller and drive are the only moving parts in contact with the liquid. Their movement is transmitted by a magnetic coupling through a sealing plate. The hydraulic part is completely separated from the totalising module. 2.1 CONTOIL Flow Meter Types Type Display Displayed Units Accuracy Accuracy values displayed Standard Paired calibration VZF Digital Display - Total volume - m3 1 % of reading Not available - Resettable vol. - Litre 0.2 % repeatability - Current Flow - US Gallons - Total hrs used - Max. Flow VZFA Digital Display - Total volume - m3 0.5 % of reading 0.1 % supply meter - Resettable vol. - Litre 0.1 % repeatability 0.3 % return meter - Current Flow - US Gallons - Total hrs used - Max. Flow VZO Roller Counter - Total volume - Litre 1 % of reading Not available - US Gallons 0.2 % repeatability VZOA Roller Counter - Total volume - Litre 0.5 % of reading 0.1 % supply meter - US Gallons 0.1 % repeatability 0.3 % return meter 2.2 CONTOIL Flow Meter Materials Part Material Remark Housing with flanges Spheroid graphite iron (GGG) Not in contact with measured fluid Measuring chamber PN 16 & 25 Cast brass in contact with measured fluid Measuring chamber PN 40 Stainless Steel in contact with measured fluid Seals FPM fluor-elastomer in contact with measured fluid Rotary Piston Anodized aluminium in contact with measured fluid Ancillaries Plastic Not in contact with measured fluid Cover of meter Plastic Not in contact with measured fluid Colour of housing Enamelled red RAL 3013 5
2.3 CONTOIL Flow Meter Application Specifications General specifications, which are same for all type of CONTOIL Flow Meters: Minimum ambient temperature: -25 C Maximum ambient temperature: +70 C Maximum viscosity to keep pressure loss 1 bar is 300 cst To keep the maximum Viscosity below 300 cst a minimum temperature for different oil types has to be kept: Recommended Min. Temp. for 300 cst IFO 1000 Fuel oil: 90 C Recommended Min. Temp. for 300 cst IFO 700 Fuel oil: 80 C Recommended Min. Temp. for 300 cst IFO 500 Fuel oil: 70 C Recommended Min. Temp. for 300 cst IFO 380 Fuel oil: 60 C General specifications, which are same for all type of CONTOIL Flow Meters: Maximum fuel temperature for below listed CONTOIL Flow Meters: 180 C Maximum pipe pressure for below listed CONTOIL Flow Meters: 25 bar Maximum filter mesh size is given in the table below. In general it is recommended to install the flow meters after the automatic filter, before the engine, which anyway requires a much lower mesh size. Type (preferred choise) for Art. No. Required min. Recommended Max. filter mesh size different specs please refer flow rate max. flow rate* (before flow meter) to our website l/h l/h mm VZF 20 FL 180/25 DIN 93710 30 1 000 0.080 VZF 25 FL 180/25 DIN 93727 75 2 000 0.100 VZF 40 FL 180/25 DIN 93732 225 6 000 0.100 VZF 50 FL 180/25 DIN 93736 750 20 000 0.100 VZF 20 FL 180/JIS 20K 94116 30 1 000 0.080 VZF 25 FL 180/JIS 20K 94118 75 2 000 0.100 VZF 40 FL 180/JIS 20K 94120 225 6 000 0.100 VZF 50 FL 180/JIS 20K 94122 750 20 000 0.100 VZFA 20 FL 180/25 DIN 93760 30 1 000 0.080 VZFA 25 FL 180/25 DIN 93765 75 2 000 0.100 VZFA 40 FL 180/25 DIN 93770 225 6 000 0.100 VZFA 50 FL 180/25 DIN 93774 750 20 000 0.100 VZFA 20 FL 180/JIS 20K 94124 30 1 000 0.080 VZFA 25 FL 180/JIS 20K 94126 75 2 000 0.100 VZFA 40 FL 180/JIS 20K 94128 225 6 000 0.100 VZFA 50 FL 180/JIS 20K 94130 750 20 000 0.100 VZO 20 FL 180/25 DIN 92258 30 1 000 0.080 VZO 25 FL 180/25 DIN 92264 75 2 000 0.100 VZO 40 FL 180/25 DIN 92274 225 6 000 0.100 VZO 50 FL 180/25 DIN 92280 750 20 000 0.100 VZO 20 FL 180/JIS 20K 94099 30 1 000 0.080 VZO 25 FL 180/JIS 20K 94101 75 2 000 0.100 VZO 40 FL 180/JIS 20K 94103 225 6 000 0.100 VZO 50 FL 180/JIS 20K 94105 750 20 000 0.100 VZOA 20 FL 180/25 DIN 92319 30 1 000 0.080 VZOA 25 FL 180/25 DIN 92322 75 2 000 0.100 VZOA 40 FL 180/25 DIN 92325 225 6 000 0.100 VZOA 50 FL 180/25 DIN 92328 750 20 000 0.100 VZOA 20 FL 180/JIS 20K 94107 30 1 000 0.080 VZOA 25 FL 180/JIS 20K 94109 75 2 000 0.100 VZOA 40 FL 180/JIS 20K 94111 225 6 000 0.100 VZOA 50 FL 180/JIS 20K 94113 750 20 000 0.100 * depending on the individual conditions on board, like pumping, piping system, vibration, viscosity, fuel condition, etc. this value can vary. 6
2.4 CONTOIL Flow Meter Specifications Type (preferred choice) Approx. volume of Approx. weight measuring chamber cm3 kg VZF, VZFA, VZO, VZOA 20 FL 180/25 DIN/JIS 36 4.5 VZF, VZFA, VZO, VZOA 25 FL 180/25 DIN/JIS 100 7.5 VZF, VZFA, VZO, VZOA 40 FL 180/25 DIN/JIS 330 20.3 VZF, VZFA, VZO, VZOA 50 FL 180/25 DIN/JIS 1200 41.0 2.5 CONTOIL Flow Meter Dimensions (for flange version only) ØF b h1 h2 H B L Type (preferred choice) L B F b h1 mm mm mm mm mm VZF, VZFA, VZO, VZOA 20 FL 180/25 DIN/JIS 165 105 105 54 54 VZF, VZFA, VZO, VZOA 25 FL 180/25 DIN/JIS 190 130 115 77 77 VZF, VZFA, VZO, VZOA 40 FL 180/25 DIN/JIS 300 210 150 116 116 VZF, VZFA, VZO, VZOA 50 FL 180/25 DIN/JIS 350 280 165 166 166 2.6 CONTOIL Flow Meter Transducer Dimensions Transducer dimension for VZF(A): DN 15 - DN 50 Transducer dimension for VZO(A): DN 15 - DN 50 90 VZF(A) VZO(A) 7
3. Design Guidelines Flow sensors are accurate measurement devices, which need some considerations in design and care during installation. Any measuring sensor can only perform in the optimum range, when it is used within it s specific requirements. Please check chapter CONTOIL Flow Meter Application Specifications for application specific limit values. Further we want to give some consideration for the whole fuel pipe installation: Tank CONTOIL Filter Pulsation dampers Engine Pressure release valve Pump Pulsation dampers Auto Filter CONTOIL Pulsation dampers Pressure release valve 3.1 Samples of measuring concepts Measuring concept 1 (MC1) Service Tank FM0 MT M/E In the first measuring concept, there is only one fuel meter after the service tank. Hence all consumption displayed is the oil consumption coming from the service tank, regardless to which engine it will flow. M/E consumption = FM0 Disadvantage: Depending on the tank level changes of MT the consumption of M/E is not instantly displayed it has to be averaged over time as FM0 actually measures the consumption of MT and not directly the consumption of M/E. Advantage: No pulsation issues from the engine. Measuring concept 2 (MC2) Service Tank FM1 MT A/E M/E Measuring concept 2 shows 2 different consumption values. One for the auxiliary engine (A/E) and one for the main engine (M/E). M/E consumption = FM0 and A/E consumption = FM1 Disadvantage: same as MC1. Advantage: same as MC1. MT FM0 Measuring concept 3 (MC3) Service Tank 8 MT FM1 FM0 M/E Measuring concept 3 offers a more precise measurement result of the main engine (M/E) consumption, as it is a differential measuring concept and our meters (VZFA) are calibrated in pair to ensure highest accuracy. The consumption is measured in the M/E fuel circulation and calculated as M/E consumption = FM0 - FM1 Disadvantage: Pulsation issues, if there is no pulsation damper. Advantage: The consumption values are instant values as there is no tank before the engine. Flow meters can be calibrated in pair and have a better accuracy.
Measuring concept 4 (MC4) Service Tank FM0 MT This concept is not recommended FM3 FM2 A/E M/E Measuring concept 4 offers a more precise measurement result of the auxiliary engine (A/E) consumption, as it is a differential measuring concept and our meters are calibrated in pair to ensure highest accuracy. It shows very precise the consumption of A/E. The consumption is measured in the A/E fuel circulation and calculated as A/E consumption = FM1 - FM2 and M/E consumption = FM0 - A/E consumption = FM0 - (FM1 - FM2). Disadvantage: The M/E consumption has to be averaged over some time as the MT is buffering between the real consumption of the engines and the consumption of the Service Tank. Also the dimensioning of the A/E flow meters is not optimal, as it must be as big as the maximum consumption of M/E or A/E (which ever is bigger). Pulsation issues for the A/E are possible, if no pulsation dampers are used. Advantage: The A/E consumption values are instant values, as there is no tank before the engine. Measuring concept 5 (MC5) Service Tank MT FM3 FM2 FM1 FM0 A/E M/E Measuring concept 5 offers the most precise measurement result for both the main engine (M/E) and the auxiliary engine (A/E) consumption, as it is a differential measuring concept in both circulation lines and our meters are calibrated in pair to ensure highest accuracy. A/E consumption = FM2 - FM3 and M/E consumption = FM0 - FM1. Disadvantage: Pulsation issues, if there is no pulsation damper. Advantage: The A/E and M/E consumption values are instant values, as there is no tank before the engines. Flow meters can be dimensioned according to engine consumption. Flow meters can be calibrated in pair and have a better accuracy. Measuring concept 6 (MC6) Service Tank FM0 MT FM2 FM1 A/E M/E Measuring concept 6 is better then measuring concept 4, as usually the M/E are the bigger engines. If a more precise measurement of both engines is required measurement concept 5 is preferred. MC6 shows very precise the consumption of M/E. The consumption is measured in the M/E fuel circulation and calculated as M/E consumption = FM1 - FM2 and A/E consumption = FM0 - M/E consumption = FM0 - (FM1 - FM2). Disadvantage: The A/E consumption has to be averaged over some time as the MT is buffering between the real consumption of the engines and the consumption of the Service Tank. Pulsation issues for the A/E are possible, if no pulsation dampers are used. Advantage: The M/E consumption values are instant values, as there is no tank before the main engine. 9
3.2 Accuracy comparison of different measurement concepts Calculation example for low consumption Flow meter type and accuracy choice M/E Supply line assumption (l/h) 9000 VZO/VZF VZOA/VZFA VZOA/VZFA M/E Return line assumption (l/h) 7000 1.0 % 0.5 % 0.1 % 0.3 % A/E Supply line assumption (l/h) 500 A/E Return line assumption (l/h) 300 Measuring Concept Accuracy Standard Standard Pair calibration calibration calibration MC1 & MC2 M/E 8.0 % 4.0 % n.a. measure actually MT consumption A/E 4.0 % 2.0 % n.a. MC3 M/E 8.0 % 4.0 % 1.5 % same results, if used for A/E A/E 4.0 % 2.0 % 0.7 % MC4 M/E 1.5 % 0.8 % 0.6 % with limitation of max flow over A/E A/E 4.0 % 2.0 % 0.7 % MC5 M/E 8.0 % 4.0 % 1.5 % A/E 4.0 % 2.0 % 0.7 % MC6 M/E 8.0 % 4.0 % 1.5 % A/E 15.0 % 7.5 % 20.5 % For Fuel Performance Management systems like FPR, CFM-S or CFM-T our CONTOIL VZFA meters with pair calibration, used in differential measurement are always strongly recommended (MC3 or MC5). Explanation & Sample calculation of measuring concept 4 versus 5 Sample calculation measurement concept 4 / ASSUMPTIONS: All Flow meter 1 % accuracy M/E consumption 4 000 l/hr A/E consumption 200 l/hr Booster pump 10 000 l/hr Service Tank FM3 FM2 A/E M/E Accuracy M/E with A/E running MT A/E circulation approx 1 000 l/hr (assumption) FM2: 1 % of 1 000 l/hr 10 l/hr FM0 FM3: 1 % of 800 l/hr 8 l/hr 10 + 8 l/hr = 18 l/hr of 200 l/hr A/E consumption 9 % error (max) FM0: 1 % of 4 000 + 200 l/hr 42 l/hr Total accuracy of M/E = 42 + 18 = 60 l/hr of 4000 l/hr M/E consumption 1,5 % error (max) Booster 1,5 % of 96 tons/day = 1.44 tons/day difference! (max) 1.44 tons/day x 330 days x US$ 300 = US$ 142.560 / year Sample calculation measurement concept 5 / ASSUMPTIONS: All Flow meter calibrated in pair (0.1 % / 0.3 accuracy) M/E consumption 4 000 l/hr A/E consumption 200 l/hr Booster pump 10 000 l/hr Service Tank FM3 FM2 A/E M/E Accuracy M/E with A/E running A/E circulation approx 1 000 l/hr (assumption) FM2: 0.1% of 1 000 l/hr 1.0 l/hr FM3: 0.3% of 800 l/hr 2.4 l/hr 1.0+2.4 l/hr = 3.4 l/hr of 200 l/hr A/E consumption 1.7 % error (max) FM0: 0.1% of 10 000 l/hr à 10.0 l/hr (assume supply = 2.5 x consumption M/E) FM1: 0.3% of 6 000 l/hr à 18.0 l/hr Total accuracy of M/E=10+18=28.0l/hr of 4000 l/hr M/E consumption 0.7 % error (max) MT Booster pump FM1 FM0 10
3.3 Temperature Compensation The installation of temperature sensors at the flow meter positions are absolutely essential for, without temperature compensation of the flow data, the errors in the measurements can become extremely large, depending on the process conditions. As a rule of thumb you can assume almost 1 % volume difference for each 10 C Temperature difference. (Usually there is a temperature difference between the oil temperature in the supply line and in the return line.) With Aquametro Fuel Performance Management Systems like: Fuel Performance Recorder (FPR) CONTOIL Fuel Monitor-S (CFM-S) CONTOIL Fuel Monitor-T (CFM-T) These compensation calculations are done automatically, according to DIN 51757. 3.4 Density Compensation If you need to compare fuel oil consumption in mass instead of volume, it is important to know that the mass is changing with the density, which itself is changing with the temperature. To obtain most precise measurement results, it is recommended to measure the density online on board. If there is no sensor available you have to use the density, which is given in each bunkering report and calculate volume values at different temperatures back to the corresponding mass values. However there is difference in HFO qualities over the world and you should consider that the density mentioned on the bunkering report refers to the required specification. The real density of bunkered fuel is usually not the same. A density difference of 10cSt results approximately in a 1 % different mass value. With Aquametro Fuel Performance Management Systems like: Fuel Performance Recorder (FPR) CONTOIL Fuel Monitor-S (CFM-S) CONTOIL Fuel Monitor-T (CFM-T) These compensation calculations are done automatically, according to DIN 51757. 3.5 Offset in differential measurement Sample calculation for differential measurement ASSUMPTION: Standard calibration 1 % accuracy (CONTOIL VZF): Supply (FM#0) 10 000 l/h ±1 % = ±100 l/h Return (FM#1) 10 000 l/h ±1 % = ±100 l/h Max. difference (theoretically) 2 % = 200 l/h Service Tank MT FM1 FM0 M/E ASSUMPTION: pair calibration 0.1 % & 0.3 % accuracy (CONTOIL VZFA): Supply (FM#0) 10 000 l/h ± 0.1 % = ±10 l/h Return (FM#1) 10 000 l/h ± 0.3 % = ±30 l/h Max. difference (theoretically) 0.4 % = 40 l/h As seen there remains an offset, even with the better pair calibration, of theoretically 40 litres different values read on supply meter (FM#0) versus return meter (FM#1). With Aquametro Fuel Performance Management Systems like: Fuel Performance Recorder (FPR) CONTOIL Fuel Monitor-S (CFM-S) CONTOIL Fuel Monitor-T (CFM-T) we are able to set an offset value, to avoid this kind of confusion. 11
3.6 Layout and Installation Rotary piston meters (such as our CONTOIL ) do not require flow conditioners or inlet runs after bends, T-pieces or fittings. CONTOIL flow meters might be installed in a horizontal, vertical or inclined position. The only requirement is, that the transducer is not pointing downwards. Stop valves / non-return valves must be installed after the flow meter in order to prevent backflow and draining. Backflow and draining can cause measuring errors and can damage the meter. This concept is recommended Formation of gas is to be avoided. Hence the layout of the piping must ensure, that the meter is at all time filled with liquid and that no inclusions of air or gas may occur do not install the meter at the highest point of the installation. This concept is recommended Flow meters must be installed in such a way, that all flow to the consumer and in differential measurement also away from the consumer is counted. Flow via bypass has to be limited to exceptions. Most classifications require a bypass with pressure relieve or manual valve in the fuel supply system, to ensure that the engine can still be operated at full power, even if the filter is heavily contaminated or if the flow meter is blocked due to any reason. The pressure release valve opens as soon as the pressure drops below a defined level and the engine can be temporarily operated without measuring the consumption. This value must be set carefully, to prevent undesirable flow over the bypass - the correct setting must be ensured over the whole range of flow rates and for all possible viscosities (the higher the viscosity the higher the pressure loss). When switching over to the bypass, attention may be drawn to necessary maintenance via an alarm output. 12
Tank CONTOIL Filter Pulsation dampers Engine Pressure release valve Pump Pulsation dampers Auto Filter CONTOIL Pulsation dampers Pressure release valve 3.7 Filters / Strainers Filters are any way required in the system to protect engines and pumps to keep their performance and live time. For flow meters this is not different - that s why we recommend installing the flow meters (in flow direction) always directly after the filter. Some particles in the fuel are also from engine s wear and tear, that s why we also recommend a filter in the fuel return line. Usually basket type filters are best choice for the return line and automatic filters in the supply line. Major engine producers recommend a mesh size of 5-10 μm (automatic filters), especially to filter out very abrasive cut fines - it would be best for the flow meter to install it between this automatic filter and the engine. 3.8 Pulsation Dampers Engines and pumps can cause pressure peaks, which are transmitted throughout the whole fuel piping system and can cause damage to all parts in the system like filters, the viscosity control system, pumps themselves as well as the flow meters. It is recommended to install pressure pulsation dampers directly after the device, which is generating such pressure peaks (usually after the pump and after the engine). Sample pictures 3.9 Pressure Loss For the dimensioning of oil meters not only the flow rate, but also the pressure loss is important. All components in the fuel piping system and the piping layout itself cause a pressure loss. In general a higher flow and a higher viscosity cause a higher pressure loss over the flow meter. Piping bends, valves, reduction of pipes, as well as strainers and flow meters do also have a pressure loss, which must be taken into account when dimensioning the fuel supply system. Please check the pressure drop at each flow meter with the help of following pressure drop curves (Appendix I.) For a pressure drop of more than 1 bar, it is recommended to use the next larger flow meter size. Ideally the flow meters are installed on the pressure side of the pump. If the flow meters are on the suction side of the pump there is under pressure, which can cause out-gassing of the oil (1 % gas in the oil causes 1 % measurement failure). Depending on the viscosity of the oil you have to check the pressure loss and decide if there is still enough pressure after the flow meter. Pressure drop curves can be found for all meters from DN 15 to DN 50 in Appendix I. 13
3.10 Installation Mechanical Flow meters are sensible sensors, to maintain its high accuracy they have to be treated with care and installed in the correct way. Flow meters with pair calibration are marked / labelled with supply or return and must be installed respectively. supply meter must be installed in the supply line (fuel flow from tank to engine) return meter must be installed in the return line (fuel flow from engine back to tank) Mount flow meters according to the flow direction (see arrow on meter body) Electromagnetically effects are to be avoided (e.g., magnetic valve of the burner). As a basic rule a safety distance of about 40 cm of any potential electromagnetic source is recommended. Insulation of pipe and flow meter must not cover the transducers, as the maximum operating temperature is 70 C. This example is not recommended This example is recommended This example is not recommended This example is recommended 14
4. Commissioning / start up Before first use of the whole fuel oil system the pipes are usually flushed to remove all dirt and particles in the system. Flushing must not be done via the flow meters, as they would immediately block the safety filters, or in worst case block the ring piston. If water would be used for flushing, there would be no lubrication, which would also damage the flow meter. Please close all valves before and after the flow meters and open the respective bypasses. Pressure shocks must be avoided in order not to damage the meter. Please open valves slowly and fill pipeline network gradually to avoid pressure surges. Avoid inclusions of air or gas, as both will cause measuring errors and in operation air or gas may damage the meter. If you expect the formation of gas a degasser is strongly recommended. 5. Maintenance CONTOIL Flow Meters are basically maintenance free. Please make sure that no unfiltered fuel flows via the flow meter (close valve before and after flow meter and open bypass). Filters prior to the flow meters must be cleaned periodically, initially at short intervals. Please do not open the flow meter, as long as it is in the guarantee period, as an opened flow meter will loose its guarantee. Warrantee seal measuring chamber DN 25 Warrantee seal measuring chamber DN 40-50 Warrantee seal transducer group Warrantee seal DFM Meters 15
6. Troubleshooting Please check according to this fault finding list before placing a complaint. Fault symptoms Possible causes Solution Pointers on roller counter rotate This is normal at some flow rates and No action required. irregularly has no effect on accuracy of measurement. Counter runs backwards Meter mounted in wrong direction Install meter with arrow pointing in flow direction Counter not running Flow rate outside allowed range Check flow rate. On meters VZF/VZFA: (below Qmin or above Qmax of meter). If too high, reduce flow or install larger sized No flow rate indication. meter. Indicated quantity or flow rate too small. If too low, increase flow or install smaller sized meter. Moving parts heavily worn out due to Install larger sized meter. continuous overload. Dirt trap / filter heavily soiled. Clean dirt trap, replace filter. Safety filter in meter intake clogged. Replace safety filter. Install dirt trap / filter with correct mesh size. Moving parts jammed. Clean measuring chamber, replace defective parts. Separating plate broken by. Check and rectify operating conditions and meter Pressure hammers. position. Gas inclusions. Fill pipe system slowly. De-aerate pipes thoroughly Indicated quantity or flow rate too high Meter positioned wrongly (e.g. at highest Check and rectify operating conditions and meter point). position. Gas or air inclusion in fluid. De-aerate pipes carefully. Pressure drop at meter too high Dirt trap or filter heavily soiled Clean dirt trap, replace filter On meters VZF/VZFA: No power supply. Check wiring. No reading Transducer defective. Replace transducer. Electronic counter defective. Replace transducer. No frequency signal No flow. Check flow using Indication. No current signal Wrong parameterisation. Set correct parameters for outputs. No pulse output signal Transducer defective. Replace transducer. Pulse sensor defective. Replace sensor. Pulse module defective. Remove sensor and check if pulser disk does rotate. Pulser disk does not rotate. Remove pulser module, place counter on first. module, and check flow indication. If indication is positive, replace pulser module, otherwise see Counter not running. Reed pulser defective. Replace roller counter. Please do not open the flow meter, as long as it is in the guarantee period, as an opened flow meter will loose its guarantee. 16
7. Warranty Disclaimer Aquametro guarantees the quality of the product in the context of its General Terms of Business. The ship yard, owner or operator will be liable for the correct installation as well as the appropriate handling of the equipment upon its receipt. Please observe the application-, mounting- and operation- instructions! Use the unit exclusively for its designed purpose. Maintain the unit and service it according to prescriptions. Use accessories only if their applicability is technically safe. Warranty shall not cover in particular the following cases: Inadequate installation works (please follow installation instructions) Unsuitable or improper use Faulty or negligent treatment Excess load Unsuitable operating equipment Natural wear and tear Product has been opened Faulty assembly or start-up by the customer or third parties Improper maintenance Chemical, electronic or electrical influences Corrosive media Excessively high media and/or ambient temperatures Broken separating plates due to missing pulsation dampers Blocked flow meters due to missing strainers before the fuel meters. Force majeure 17
Appendix I.Pressure Drop Curves DN 15 DN 20 10 000 10 000 1000 1000 100 100 Pressure drop in mbar 10 F E Pressure drop in mbar 10 F E D 1 D C 1 C 0,1 B 0.1 A A 0,01 Flow rate in l/h 1 10 100 1000 565412.4 0.01 Flow rate in l/h 10 100 1000 10000 565413.4 Q min 10 l/h Q max 600 l/h Q min 30 l/h Q max 1500 l/h DN 25 DN 40 10 000 10 000 1000 1000 100 100 Pressure drop in mbar 10 F E Pressure drop in mbar F 10 E D C 1 D 1 C 0,1 0,1 A A 0,01 Flow rate in l/h 10 100 1000 10000 565414.4 0,01 Flow rate in l/h 100 1000 10000 100000 565415.4 Q min 75 l/h Q max 3 000 l/h Q min 225 l/h Q max 9 000 l/h 18
DN 50 10 000 1000 100 Pressure drop in mbar 10 F E D 1 C 0,1 A 0,01 Flow rate in l/h 100 1000 10000 100000 565416.4 Q min 750 l/h Q max 30 000 l/h Example 10 000 Mineral oil, viscosity 450 mpa.s VZO 25 mounted on pressure side of pumps ç 1000 ❶ Viscosity curves DN 25 select closest curve F = 500 mpa.s 100 ❷ Assume max. permissible pressure drop = 1 bar Pressure drop in mbar 10 F E å ❸ The intersection of curve F with the line corresponding to 1bar gives a flow rate of 2 000 l/h. 1 D C 0,1 A 0,01 Flow rate in l/h 10 100 1000 10000 é 565414.4 Q min 75 l/h Q max 3 000 l/h 19
Änderungen vorbehalten / Sous réserve de modifications Modification rights reserved / Copyright Aquametro AG DISTRIBUTOR: Contact, Adress and Stamp HEAD OFFICE: AQUAMETRO AG Ringstrasse 75 CH-4106 Therwil Phone +41 61 725 11 22 Fax +41 61 725 15 95 info@aquametro.com www.aquametro.com A0.3-07.2009 - Art. Nr. 12017