Installation and Maintenance Manual

Steam Flowmeter
SteaMon

Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com

 Table of Contents

1. System Installation & Startup 01

2. Features 12
3. 14
Operation of signal convertor with optional configurator
4. Description of programme menu functions 24
5. Technical Data 27
6. SteaMon sizing sheet 29
7. Dimensions & Weight 30
8. Function checks 31
9. Trouble Shooting 33
10. Do's & Don'ts 34

The following symbols have been used to help you navigate this document

Warning! / Caution!
These warning signs must be observed without fail. Even only partial
disregarding such warnings can result in serious health damage, damage to
the flowmeter itself or to parts of the operator's plant.

Danger!
This symbol designates safety advice on handling electric current.

Information!
This symbol designates important information for the
handling of the flowmeter.

Handling
This symbol designates all instructions for actions to be
carried out by the operator in the specified sequence

Steam Flowmeter
1. System installation & Startup

1.1 Intended use

The steam flowmeters manufactured by Forbes Marshall Pvt. Ltd. are used to
measure the flow of saturated steam.

These flowmeters are particularly suitable for measuring steam.

The meters are available in sizes :
DN 25
DN 40
DN 50
DN 80
DN 100

Warning :
The operator shall bear sole responsibility for the use of the flowmeters in
respect of suitability, intended use and corrosion resistance of the materials
used to the process product.

The manufacturer shall not be liable for any damage resulting from improper
use or deployment contrary to the prescribed purpose.

Notes
The sensors are fabricated from stainless steel CF8.
In your project planning, please take account of the data given in the
corrosion tables.

The pressure-loaded components have been designed and rated for

stationary operation taking account of maximum pressure and temperature.

External forces and moments, caused e.g. by pipe stresses, have not been
taken into account.

Primarily, volumetric flow and temperature are measured, From these

parameters the flowmeter calculates the mass flow or volumetric flow using

1.2 Safety instructions from the manufacturer

The flowmeter has been built and tested in accordance with the current state-
of-the art design. It complies with the relevant safety standards.

However, risks can occur if used improperly or contrary to the intended

application. Therefore please consistently observe all safety instructions
given in this document.

SteaMon 1
1.2.1 Information concerning the document
In addition to the safety advice given in this document, national and regional
safety regulations and occupational health and safety provisions must also be
observed.

1.2.2 Safety instructions for the operator

Caution!
Meters from Forbes Marshall Pvt. Ltd. may only be installed, commissioned,
operated and maintained by properly trained and authorized personnel.
This document must be read and understood in its entirety by all users prior to
installation, commissioning, operation and maintenance of the flowmeter.

1.3 Scope of supply

Important information!
Please check the contents of the consignment for completeness and
intactness.

Installation and Maintenance Manual

Steam Flowmeter
SteaMon

Figure 1: Scope of supply

1 Meter
2 Certificates
3 Manual

2 Steam Flowmeter
1.4 Instrument versions

The SteaMon comes only in sandwich design with converter

Converter

Nozzle

Primary head with ensor assembly

Figure 2
1.5 Nameplate

Important information!
Before installing the flowmeter, make sure that the information given on the
nameplate complies with the ordering date.

PUNE
INDIA
SteaMon
CF8 MD : 05/11
ISN : I01112345 TAG No.: FI-12345
SIZE : DN 50/2" ANSI 300 ibs
K FACTOR : 1234567.8 p/m3
RANGE : 0-50 kg/hr
Top : 1800C Power Supply : 15-36 Vdc
Output : 4-20 mA, 2 Wire
99-000-1045770
www.forbesmarshall.com

Figure 3
1 Type of meter
2 Manufacturer
3 Configuration
4 Electrical connection data

SteaMon 3
1.6 General Installation Information
Caution!
Installation, assembly, start-up and maintenance may only be performed by
appropriately trained personnel. The regional occupational health and safety
directives and safety regulations must be observed without exception.

The following procedures have to be carried out before installing the

flowmeter!
x Check the packing and the flowmeter itself for any damage.
x Check the contents of the consignment for completeness.
x Compare your order specification with the scope of delivery.
1.7 Storage
x Store the flowmeter in a dry and dust-free location.
x Avoid direct exposure to the sun.
x Store the flowmeter in its original packing.
x The admissible storage temperatures are -40°C to +80 °C.

1.8 Installation Requirements

Important information!
For accurate volumetric flow measurement the flowmeter has to have a
completely filled pipe and a fully developed flow profile.
Please comply with the instructions regarding inlet and outlet pipe runs and
installation position.
In the case of vibrations on the piping choose the installation site in such a
way that the vibrations are at their lowest in transverse direction to the
f l o w m e t e r .

Caution
When installing the flowmeter in the piping please observe the following
points:
x Nominal diameter of connection pipe flange = nominal
diameter of the meter!
x Use flanges with smooth holes, e.g. welding neck flanges.
x Carefully align the ID of the connecting flange with the meter.
x Check the compatibility of the gasket with the process

4 Steam Flowmeter
 x The flanges have to be concentric.
x There must not be any pipe bends, valves, flaps or other
internals in the immediate inlet run.
x Do not lay signal cable directly next to cable for power supply.
x Asufficient distance around the flowmeter in all directions must be kept
free to allow servicing.
x Protect the flowmeter from direct exposure to the sun.

Figure 4: General installation instructions

1.8.1 Important installation instructions, vapor measurement

Figure 5: Fundamental installation advice

1 Prohibited: Installing the flowmeter in the lower pipe bend, risk of
condensate formation
2 Recommended: Installing the flowmeter in the top pipe bend

Caution!
Condensate can lead to cavitation and inaccurate measurement.

SteaMon 5
1.8.2 Important installation instructions, piping with control valves
Important information!
To ensure trouble-free and accurate measurement, Forbes Marshall Pvt. Ltd.
recommends not installing the flowmeter after a control valve. There is a risk
of turbulence occurring that falsifies the measuring result.

Figure 6: Fundamental installation advice

1 Not recommended: Installing the flowmeter directly after control valves
2 Recommended: Installing the flowmeter upstream of the control valve,
distance 5 DN

1.8.3 Preferred Installation Location

Figure 7: Preferred installation locations

1 Above a horizontal pipe
2 Below a horizontal pipe
3 Configuration
4 On a vertical pipe

6 Steam Flowmeter
1.8.4 Insulation
Caution!
The area above the converter support must not be thermally insulated.
The thermal insulation (2) may only extend to the maximum height (1)
shown below up to the connecting screws of the sensor.

Figure 8: Thermal insulation on connection piece

1.8.5 Inlet and Outlet Runs

Figure 9: Thermal insulation on connection piece

1 General inlet run without flow disturbances

³ 20DN
2 After a control valve ³ 50 DN*
3 After a pipe diameter reduction ³ 20DN
4 After a single 90° bend ³ 20DN
5 After a double bend 2x90° ³ 30DN
6 After a double three-dimensional 2x90° bend
³ 40 DN
(DN is meter diameter)

SteaMon 7
1.8.6 Installation of Flow Straightener
If, due to the type of installation, the required inlet runs are not available,
Forbes Marshall recommends using flow straighteners. Flow straighteners are
installed between two flanges in front of the flowmeter and shorten the
required inlet run

Fig. 10: with Flow Straightener

1 Straight inlet run upstream of flow straighteners ³ 2DN
2 Flow straightener
3 Straight pipe section between flow straigtener and flowmeter ³ 8DN
4 Minimum straight outlet run 5DN

1.8.7 Minimum outlet runs

Fig. 11: Minimum outlet runs

1 General outlet run in front of pipe widening, pipe bends, control valves etc.
³ 5 DN
2 In front of metering points ³ 5 DN

Important information!
The interior of the pipe at the metering points must be free of burrs and other
flow impediments. The flowmeter has an internal temperature sensor. It must

8 Steam Flowmeter
1.8.8 Procedure for Installation
Caution!
Installation, assembly, start-up & maintenance may only be performed by
appropriately trained personnel. The regional occupational health and safety
directives and safety regulations must be observed without exception.

The following procedures have to be carried out before installing the

flowmeter in the piping:
Remove all transport locks and protective coverings from the flowmeter.
Make sure that the gaskets have the same diameter as the piping.
Make sure that the flowmeter is in the correct flow direction. This is indicated
by an arrow on the sensor housing.

Caution !
On metering points with varying thermal loads the flowmeters are to be
mounted with stress bolts.
Stress bolts and/or nuts and bolts are not included in the scope of delivery.
Make absolutely certain that the mating flanges are sitting concentrically.
When preparing the metering point, keep in mind the exact installed length
of the flowmeter.
The dimensions are given in Section 7 "Technical Data".

Fig. 12: Preparing the metering point

1 Installed length of flowmeter + thickness of gaskets.

SteaMon 9
 Caution!
The inside diameters of the connection pipe, of the flowmeter and of the
gaskets must be the same! The gaskets must not project into the pipe
cross-section.

Fig. 13: Preparing the metering point

1 Inside diameter connection pipe
2 Inside diameter gasket

1.8.9 Installing Instruments in Sandwich Design

Fig. 14: Installing Instruments in sandwich design

1 Sandwich design sensor
2 Bolts with fixing nuts
3 Hole A
4 Hole B
5 Gasket

Install the flowmeter as follows:

x Push the first bolt through hole 4 of both flanges.
x Screw on the nuts with washers at both ends of the bolt but do
not tighten them.
x Screw on the nuts with washers at both ends of the bolt but do
not tighten them.
x Mount the second bolt through the holes 3.
x Place the sensor between the two flanges.

10 Steam Flowmeter
 x Check that the flanges are sitting concentrically.
x Install the remaining bolts, nuts and washers. But do not
tighten the nuts yet.
x Align the flowmeter.
x Check that the gaskets are concentric, they must not project

1.8.10 Start-up
x Check that the system has been correctly installed as described in Section
1.
x Before the initial start-up check that the following details on the name
plate agree with the data specified in the report of settings for the signal
converter. If not, reprogramming will be necessary.
x Avoid abrupt changes in pressure in the pipeline.
x As the process product is steam, condensate may form initially and cause
faulty measurements when the system is started up for the first time.
x When powered, the signal converter normally operates in the
measurement mode.

SteaMon 11
2. Features
2.1 Basic Features
x 2-wire loop powered convertor 24 V DC supply (4-20 mA)
x Temperature measurement as standard
x Online density compensation and mass flow calculations for saturated
steam
x 4-20 mA programmable current output
x All measured and calculated parameters such as volumetric
flow & mass flow, etc. are fully programmable at factory.
x Notch Filter Algorithm for predicting correct input frequency
for improved vibration and noise immunity
x Simple single level user-friendly menu - optional with
conflgurator.
x Integral version

2.2 Connection Diagram

Fig. 15: Connection Diagram

x Loop Current is galvanically isolated and can, therefore, be
simultaneously connected to a receiver instrument which is grounded or
separately connected to two receiver instruments.
x Ensure that the 24 V, 4-20 mA loop is grounded at one point
only (i.e. either at the input of the signal convertor or at the input of the
indicator, or at the output of the power supply). Do not ground the loop

12 Steam Flowmeter
2.3 Current Output
x The current output is galvanically isolated from the sensors.
x The maximum load at terminals.

UB - 15 V*
Max. load in RB, = £ 1000 CI
20 mA
Where UB=Applied Loop Power supply, Normally 24VDC

SteaMon 13
3. Operation of the Signal Convertor with configurator
3.1 General
Display indication is possible by connecting configurator only.
3.1.1 Starting up signal convertor with configurator
When the power is switched ON to the signal convertor Configurator displays
soft "VerX.Y.Z" and then goes to the measurement mode. In this initial
sequence, carries out self diagnostics to check the preamplifier section, sensor
integrity and then loads the configuration data from the non-volatile
memory.The first measured parameter displayed is the one being displayed
when the power supply was switched off the last time. It is possible to enter
the programming mode by pressing the → key.
3.1.2 Measurement Mode
In the measurement mode, the parameters that the convertor
measures/computes are shown on the display in the appropriate units. As per
the configuration, the display can be either in the non cyclic/cyclic mode. In
the non-cyclic mode of display, use key to see the next parameter or error
message on the display. In the cyclic mode, the display shows all the
parameters one after another, wherein each parameter/ error message is
displayed for about 6 seconds.
3.1.3 Error Handling
The convertor can detect errors during the power-on diagnostics as well as
when in the normal measurement mode. If one or more errors are present,
the vertical bar in the top left corner of the display (in the measurement
mode) starts blinking. If enabled, the error information is shown on the
display interleaved between the display of two parameters. The first line
displays the total number of errors and the second line displays the error
message. Refer to the list of Error Messages.
3.1.4 Programming or menu mode
All the configuration/settings/test functions in the form of a menu function
x.x.x are accessible in the programming mode. The operator can view or alter
the present settings, data values by the use of functions available in this
mode. All changes made in the programming mode are stored in the
nonvolatile memory after exiting the menu and have appropriate effect on
the operation of the signal convertor. While being programmed (i.e. while in
the menu), the instrument will stop making further measurements and the
current output will be frozen to the last value.

14 Steam Flowmeter
3.1.5 Error Messages
Error messages in the measurement mode
Error message Type
(display second line) Corrective action required
Description
No flow through the primary or check for
No signal from any other errors during. power-on
NO SIGNAL
the sensor diagnostics. If sensor problem, contact
Forbes Marshall Service.

Sensor frequency Check flow rate > q min else call Forbes
LOW FREQ too low Marshall Service.

Sensor frequency Check flow rate < q max else call Forbes
HIGH FREQ
too high Marshall Service.
Flow rate lower Converter will continue to display actual
LOW FLOW than minimum flow flow rate. However, accuracy of
rate q min. measurement may suffer.

Actual flow rate Corrective action depends on application

HIGH FLOW higher than q max. process. If the flow rate exceeds the max.
value it may damage the sensor physically.
Configuration data in
INV. CONFIG non-volatile memory Check entire configuration again. If error
is not valid. persists call Forbes Marshall Service.

CHECK INST Flow signal quality is bad Check that 1) Flow rate>q min if OK. 2)
Check for excessive pipe vibration and
upstream flow disturbances.
Sensor signal amplitude
LOW SIGNAL Check that 1) Flow rate>q min if OK
too low
contact Forbes Marshall Service.
Sensor signal This occurs in cases of high density
HIGH SIGNAL amplitude too high medium.
Check 1) Flow rate < qmax, if OK contact
Operating temp. Forbes Marshall Service.
LOW.TEMP.PHY.
lower than physical limit
Take corrective action depending on the
process.
HIGH.TEMP.PHY Operating temp.
higher than physical limit Take corrective action immediately. Will
cause damage to the primary as well as to
Temp. sensor/wires signal convertor!
T.SENS.SHORT short circuit

T.SENS.OPEN Temp. sensor open circuit

SteaMon 15
3.2 SteaMon Configurator (Optional)

3 5

Figure 16 SteaMon Configurator

1 Flat Ribbon Cable.
2 Configurator Display.
3 Function Keys.
4 Cable compartment.
5 Cable compartment cover.
Caution : To avoid damage to the electronics, be certain that the area around
the meter is dry before removing the electronics compartment cover.
The operating elements are accessible after removing the cover of the
electronics section using the proper special driver.
Connection of Configurator to the Signal Converter
1. Open the converter Lid by removing four no's of screw's.
2. Switch off the converter by pushing toggle switch on up side (Refer fig. for
connection).
3. Insertfiat cable of the configurator into the 10 pin socket.
4. Switch on the Signal Converter.
5. Now one can program the parameters of the signal converterthrough
configurator.

16 Steam Flowmeter
3.2.1 Description of keys with configurator

Menu structure

Measuring mode level Menu Function level Data level

Displaying Select scroll Options Numerical/
measured position Scroll through alpha-numerical
parameters/error Select function values
messages option Change the
Select function
flashing
Enter programming displayed digit/character
Enter the function. Temporarily save Change flashing
Then continue selected proposal (cursor) position
as under data then continue Stores edited
with further data value /string
level entry, if any, or
Return to sub- temporarily.
return to function Continue with
menu
further data
level or main entry, if any,or
menu level after return to
choosing YES/NO function level.
with key

Important
1. All changes made in programing mode are stored in
non volatile memory upon quitting menu.
2. Steam Flow Converter stops measurement when in
programming mode, but holds the last measured
output current.

SteaMon 17
3.2.2 Functionality of keys
The cursor position is indicated by an "inverse video" character.
To start operator control
Measuring mode Operator control mode

Please note when 'Yes' is set under the entry code of Fct.3.2.2 then on pressing the key
will prompt you to enter the Entry Code 1 which is fixed. Here, the software is modified
in such a way that thekey is taken as the first key out of the nine and you have to enter
the remaining eight keys in the sequenceThis will take you to the function level.
To go to the next function

Pressing thekey will result in scrolling through all the functions sequentially as given in
the menu level chart. Here the right most digit of the function goes on incrementing.

Pressing thekey when the middle digit is selected will result in an increment of that
second LSB. Logically, the function should go to Fct.1.2.1. However, Functions 1.2.1 up to
1.2.5 do no exist on the menu level chart. Hence, on pressing the key, the function will go

4/2Here pressing thekey results in incrementing the left most digit. Logically, the
function should go to Fct.2.1.1. However, since Fct.2.1.1 does not exist on the menu level
chart, the function will go to the next function which is Fct.2.1.2
To select the function
To modify any menu, first make that function available on the display. Then press the key
to confirm the function selected. Next, press the key to enter that function. To scroll
through the different options available, use thekey. To select the option chosen, press
the key. You are then prompted with the CONT YES/NO. On selecting YES, you will
proceed to the next menu level. If you select NO, it will update the data you entered and

18 Steam Flowmeter
3.3. Programme Functions for SteaMon with configurator

3.3.1 Programme organisation and programming chart

Manu
Levels :- ACTUAL DISPLAY

MEASURING MODE LEVEL FUNCTION LEVEL DATA LEVEL

SteaMon 19
3.3.2 Programme function description
The programme functions are described below in a numerical order.
1.1.1 MEAS. INST
Set the instrument to measure the volumetric or the mass flow rate as per the options:
x VOLUME
x MASS
Usually, this function is used only once - initially. If you need to change the measurement type
later on, you should reprogram MAX. FLOW and MIN. FLOW
1.1.2 MAX. FLOW
Enter the flow measurement unit, followed by the maximum flow rate required. The
maximum flow must not exceed the maximum flow specified in the Sizing Sheet. The current
output range (4-20 mA) corresponds to zero flow and the max flow respectively. If the flow
rate exceeds the MAX. FLOW, an error HIGH FLOW is annunciated on the display with an error
symbol flashing at the top left corner.
The following units are available.
For volumetric flow For mass flow
x M3/HR KG/HR
x M3/MIN KG/MIN
x M3/SEC KG/SEC
x LITRE/HR T/HR
x LITRE/MIN T/MIN
x LITRE/SEC T/SEC
x CUFT/HR LB/HR
x CUFT/MIN LB/MIN
x CUFT/SEC LB/SEC
x FT3/HR SPECIAL
x FT3/M I N
x FT3/SEC
x CFT/HR
x CFT/MIN
x CFT/SEC
x US GAL/HR
x US GAL/MIN
x US GAL/SEC
x UK GAL/HR
x UK GAL/MIN
x UK GAL/SEC
x SPECIAL
For SPECIAL-
The base units are m3/hr and kg/hr respectively for Volume and Mass. For units other than the
specified units, replace the base unit with the user unit by changing the literal text.
Coefficients of the user unit need to be enetered with respect to the base unit as shown
below:
Formula to be used: [User Unit] * [Al coeff] + [A0 offset] = Base unit
Example
If the user unit is litre/hr, Al coeff = Base unit/ User unit = 1/1000 = 0.001 and AO offset = 0
1.1.3 MIN. FLOW

20 Steam Flowmeter
determined from the Sizing Sheet. If the measured flow is below the MIN. FLOW, an error
LOW FLOW is annunciated on the display with an error symbol flashing at the top left corner.
1.1.4 TIMECONST.
Enter a low-pass filter time constant in seconds to be applied to the flow rate. A value of zero
indicates that the low-pass filter is not to be applied. With this function, it is possible to
tradeoff between a steady indication (on the display/current output) and the response time
(to flow changes). It should normally be within 0-20 sec. The factory set value is 2 sec. You may
increase it if you observe abnormal fluctuations on display.
1.2.6 ERROR MSG.
Select YES so that the error messages appear between the display of parameters in the normal
measuring mode, otherwise select NO.
1.2.7 CYCLE DISP
YES means the display will cycle automatically. This means a measured parameter is displayed
in the selected units for about 6 seconds and then the next parameter in the display cycle is
shown for 6 seconds and so on. NO (non-cyclic display) means a parameter is continuously
shown on the display. You may see error messages in between the move from one parameter
to next if error(s) are present and
1.2.6 ERROR MSG. is YES.
1.3.2 RANGE I
You can select one of the three possible range options for the current output as follow:
- 4-20
- 4-20/22E
- 4-2013.55E
Select 4-20 for no error indication. Select 4-20/22E or 4-2013.55E to enable error indication so
that current output will give 22 mA or 3.55 mA as an error output if any error(s) are present in
the instrument.
2.1.2 TEST I
Caution: During this test, the current output will change to the test values so appropriate
actions should be taken depending on the purpose for which the current output is used.
Place the current meter in series with the current loop. Selecting any value given below will
cause that current to flow so that you can check it on the meter. Select CONT. YES to test other
current values or to exit the TEST I mode. On exiting this Menu, the normal current value
depending on the flow rate and the programming of the current output function will be
restored.
- 4 mA
- 8 mA
- 12 mA
- 16 mA
- 20 mA

SteaMon 21
3.1.2 K-FACTOR
Enter the primary constant k-factor value. This value is stamped on the instrument label in
units of pulses/m3.
3.2.2 CODE 1
Select YES if the password needs to be entered to access the complete menu. Use the 9-digit
password to prevent configuration changes by an unauthorized person. Answering NO means
the password is not required to enter the menu. (The password is normally available to the
Forbes Marshall Service Engineer)
3.2.4 LOCATION
Enter an alphanumeric string up to 10 characters to describe the location of the installation.
This input has no bearing on the performance of the instrument in any way and it merely
serves as a means of identification.
3.3.4 SET GAIN
The gain of the signal preamplifier can be changed to alter the sensitivity of the amplifier.
The values available are:
GAIN
x 1
x 1.5
x 2
x 3
x 6
x 11
x 16
The factory set value is 11 for steam.
3.5.1 FLUID
This value is factory set to STEAM and is not changeable.
3.5.2 MEDIUM
This value is factory set to SAT STEAM and is not changeable.
3.5.3 SAT. P/T
This value is factory set to SAT TEMP and is not changeable.
3.5.4 TEMP. OPR. and 3.5.5 PRES. OPR.
User must set only one of the above two process values. The other parameter value will be
set, based on saturated steam and can be viewed on the display.
3.5.4 TEMP. OPR.
Enter the mean (average) operating temperature of the steam. The option available for
units are.
UNITS
x DEG C
x DEG F
x KELVIN
x SPECIAL

22 Steam Flowmeter
To have SPECIAL unit, all the literal characters, coefficient and offset must be entered as
shown in 1.1.2.
Base unit is Deg C
Here the selection of the Temperature Display can be
done. DISP ON displays whichever unit is selected
OFF No Temperature Display
3.5.5 PRES. OPR.
Enter the mean (average) operating pressure of the steam. The factory set unit for the
temperature is KG/CM2 G.
UNITS
x KG/CM2 G KG/CM2ABS
x IN HGG IN HGABS
x MM HG G MM HGABS
x MM WATER G MM WAT. ABS
x PAG PAABS
x KPAG KPAABS
x ATM G ATM ABS
x BAR G BARABS
x MILLI BARG MILLI BARA
x PSI G PSI ABS
x LBF/FT2 G LBF/FT2A
x SPECIAL
SPECIAL
The base unit for pressure is Pascal. Enter all the characters, coefficients, and offset to obtain
other units desired. Refer to the example for temperature given in Fct.3.5.4.
Here the selection of the Pressure Display can be
done. DISP ON displays the pressure in selected
unit.
OFF No Pressure Display
3.6.1 T-SENSOR
If the inbuilt temperature sensor is to be used for density compensation, set this to YES. If the
user selects NO, then the temperature value as indicated by (or set under) 3.5.4 will be used
for density compensation.

SteaMon 23
4. Description of Program Menu Functions with configurator
4.1 Numerical format
x Display of numerical values
Real (i.e. fractional) values are displayed in the first line of the display consisting of 8
digits. The number is displayed in the floating point format except the totalizer
which is in an integer format (max. value... 4294967295) otherwise an exponent
notation is used. See the examples given below.
Floating format: 1234.5678, 100.00
Exponent format: 1234E-10, 12345E12
In most practical applications, it is very rare that the parameters need be
displayed in the exponent format.
x Input of numerical values
Entering a numeric value is very flexible. Enter a positive or a negative number in
the floating point format or the exponent format as required or as convenient.
Example: 1.2345678, -1234.567, 0.0001234
123456E1, -12345E4, 1234E-4

4.2 Display
Organization: The display consists of the following two fields.
Field 1 : 10-character, 5x7 dot matrix alphanumeric display used primarily for showing
numeric values and also for messages.
Field 2 : 10-character, 5x7 dot matrix alphanumeric display used for showing units,
messages, etc.
Programming: The measurement mode settings are as follows:
- To allow the selection of the units for all the measured parameters Refer to Fct 1.1.2,
3.5.4 and 3.5.5
- Select display mode (cyclic/non-cyclic) and the error messages to/not to appear in the
display cycle.
Refer to Sect. Fct 1.2.6 to 1.2.7
Measurement mode: The display shows the measured parameter(s) in its selected unit.
The parameter is displayed continuously in the non-cyclic mode. [Fct 1.2.7]. To select
other parameter(s) of the display cycle, if any, use the key. In the cyclic mode, all the
parameters selected in the display cycle are displayed in a sequence one after another
every 6 seconds.
Programming mode: The numeric line indicates the menu/functions level such as Fct 1.1.1
[current menu level digit blinks] and the alpha-numeric line indicates the menu/function
title such as MEAS_INST.

24 Steam Flowmeter
Error indications: A blinking bar at the upper left corner in the measurement mode
indicates that error(s) are present. Error messages are displayed interleaved between
changing from one display parameter to another, if FcL 1.2.6 ERROR.MSG is YES. For
description of the error messages, refer to Sect. 4.1.5.
4.3 Flow range and meter size
The flow rate (min. flow to max. flow) that the flowmeter will be able to measure
depends on the primary data (3.1.x functions) and the application data (3.5.x functions).
Thus, the flow range specified under the Fct 1.1.2 MAX. FLOW and Fct 1.1.3 MIN. FLOW
must be within the measuring range.
The flow range for any given application is determined by the sizing of the meter for that
application. When the flow rate exceeds the max flow, an error condition -HIGH FLOW- is
generated. When the flow rate falls below the min. flow, an error condition -LOW
FLOW- is generated. The sensor signal is weak at this condition and if the flow rate
reduces further, signal related errors such as CHECK INST., LOW SIGNAL will occur.
4.4 Primary information
The primary data gives STEAM FLOW METER the basic information about the primary
sensor. Use Fct 3.1.1 NOMINAL.DIA for specification of the nominal DN/ANSI size and Fct
3.1.2 K-FACTOR for the calibration factor of the primary.

4.5 Application information

This is the data of the process medium, its operating conditions and physical properties. It
consists of:
- Process medium Fct 3.5.1 FLUID and Fct 3.5.2 MEDIUM
- Operating temperature and pressure conditions. Refer Fct 3.5.4 TEMP. OPR and Fct
3.5.5 PRES. OPR.
4.6 Current (analog) output I
The current output gives an analog representation of the flow rate. An output of 20 mA
always corresponds to Max Flow 100% and that of 4 mA to Zero flow 0%. The current
output between Zero flow 0% & min flow is 4 mA.
FOR Qmin Programmed < = Qmin from Sizing

SteaMon 25
TESTING OF CURRENT OUTPUT I
Fct 2.2 TEST I can be used to check the current output. Integer values between 4 and 20
mA are possible to be monitored on a current meter. During the test, the current output
changes to the test value(s). The normal current value is restored automatically (as per
programming of the current output) when the measurement mode is resumed.

26 Steam Flowmeter
5. Technical Data
5.1 Technical Specifications - Flowmeter
Field of application Flow measurement of Steam
Operating method / measuring Shedding Frequency
principle
Measured value
Primary measured value: Shedding frequency
Secondary measured value: Operating volumetric flow, mass flow
Measuring accuracy
Accuracy ± 2% of reading for flow rate maeasurement
Operating conditions
Ambient temperature -20 to 70°C
Operating temperature -20...+ 210°Cmax
Process products Dry Saturated Steam
Density Compensation Internal for Saturated Steam
Product Pressure limit max. 17.5 bar
Installation requirements
Inlet run ³ 20 x DN
Outlet run: ³ 5 x DN
Dimensions and Weights see table 8/1, 9/1
Materials
Sensor CF8
Electronics casing Aluminium

Type of Meter
Sandwich version DN 25, DN 40, DN 50, DN 80, DN 100
Protection category
Protection category IP 65

Approvals IBR
EMR
EMI / EMC (Criteria A) as per IEC 61000-4-2 to 6 &
8
IP 65
Vibration IEC 60068-2-6

SteaMon 27
5.2 Technical Specifications - Signal Convertor
Full-scale range Units text of 10-characters freely programmable. Conversion
factor coefficient and intercept (offset) programmable for
accepting any unit required.
Power supply U, (2-wire) 15-36 V DC
Current output terminals, 4-20 mA, DC, 2-wire

UB- 15V
Maximum load resistance RB= -----------------
20 mA
R (ohms)

Mass flow measurement Online for saturated steam 210 deg. C. Temperature sensor
standard built-in with STEAM FLOW SENSOR primary.
Temp measurement Accuracy ± 0.3°C of measured value
Current output Operating data programmable, galvanically isolated from
power terminals
Current 4-20 mA corresponding to zero and the maximum flow value
programmed
Accuracy ± 0.02 mA
Temperature coefficient ± 0.002 mAper °K change
Power Supply influence + 0.0001% of full-scale range for 15-36 V variation in the voltage

28 Steam Flowmeter
6. SteaMon Sizing Sheet

SteaMon 29
7. Dimensions & Weight

Size ocl oOD A L W (kgs)

1” 24 60 353 65 2.7
1 ½” 38 80 370 65 3.4
2” 50 100 386 65 4
3” 74 130 413 65 4.7
4” 97 158 438.5 65 5.6

30 Steam Flowmeter
8. Function Checks
This section describes some functional checks that can be performed without using any
special equipment. It must be noted that these checks are very preliminary and do not
check the total functionality of the primary head or the signal converter. These can be
done using configor only.
8.1 Current output check
Fct. 2.1.2 TEST I can be used to test the current output function of STEAM FLOW
CONVERTER. With this function, it is possible to generate following test values:
8/12116/20 mA. Refer to section 1.2 for the connection diagram.
The current output electronics is factory-calibrated and should be within + 0.02 mA.
Otherwise re-calibration of the current output is necessary by Forbes Marshall Service.
8.2 Primary Head Functional Checks
8.2.1 Steam sensor
To perform the preliminary testing of the Steam piezo sensor, the signal cable of the
piezo sensor should be disconnected from the signal converter electronics. To do this:
always switch OFF the power source before commencing work!
I. remove the cover & facia plate from the electronic compartment. Ensure that the
screw threads of the electronic compartment cover are well greased at all times!

1
7
6
2
5
4

3
I. Facia Plate.
2. Connector for Configurator.
3. +24 VDC Supply Terminals.
4. Power ON Indication.
5. Power ON Switch.
6. Temp. Sensor Input.
7. Piezo Sensor Input.

Do the following tests

Capacitance between the centre pin and each outer pin is from 3.3 to 4.3 nF
Resistance between the centre pin and each outer pin >200 M ohm. Also, the resistance
between each sensor wire pin and the earth should be >200 M ohm.
2. Reassemble the converter in the reverse order

SteaMon 31
8.2.2 Temperature sensor
The PT-1000 temperature sensor can be checked by measuring its resistance.

Always switch OFF power source before commencing work!

Follow the step 1 i.e. the same as in the above

3. Remove the temperature sensor cable at the location Y of the preamplifier board.
Pull the cable by its end connector and not by the cable itself!
4. Resistance between the 2 pins should be within 1K [0°C] — 1.193k [50°C] depending
on the ambient temperature. For other temperatures resistance values as per
DIN43760.
5. Reassemble the converter in the reverse order.

32 Steam Flowmeter
9. Trouble-shooting
9.1 Trouble-shooting hints with configurator
It is assumed in this section that the flowmeter has already been installed. (for installation
details, refer to Sections 2 and 3).
Given below are some trouble-shooting hints.
SYMPTOM: A non-zero flow indicated when no actual flow in the pipe.
x Mains interference due to improper earthing.
The protective earth PE terminal should be properly grounded
x Excessive mechanical vibration in the pipe. If so, support the pipeline near the flowmeter
perpendicular to both the axis of the pipe and the axis of the bluff body.
x This problem can be solved by reducing the factory set gain.
For e.g. Factory set gain for Steam is 11. This can be reduced to 6 for Steam.

Caution: By reducing the gain, the minimum measurable flow rate will go up by the factor
which is approx. equal to square root of ratio of the gains. (old gains/ new gain). If the min.
flow with reduced gain is above the min. flow which is required to be measured, then
reducing the gain is not the permanent solution. Then the installation should be corrected
and also the vibrations should be eliminated.

SYMPTOM: 'CHECK INST.' error is displayed when no flow in the pipe.

The display should normally indicate 0.0 flow rate, LOW FLOW and LOW SIGNAL errors when
there is no flow in the pipe. The additional CHECK INSTALL error (flow rate = 0.0 or some
steady or fluctuating value) is an indication of:
x Improper/inadequate earthing
x Excessive pipe vibration

SYMPTOM: Flow rate indicated is 0.0 even with flow in the pipe.
x The Steam sensor cable disconnected or is not properly connected.
x Flow sensor faulty — some checks are given in Sect. 10.1 & 10.2
x Change the gain setting through the configurator.

SYMPTOM: The flow indicated responds to changes in the flow but the indicated value does
not correspond to the actual flow rate. Also 'CHECK INST.' error may appear intermittantly
x Check the programming of Fa 3.1.2 K-Factorwhich should be same as that on the name
plate
x The meter is not properly centered on the pipeline. The axis of the meter bore should be
aligned with that of the pipe.
x Gaskets at the meter are protruding into the pipe bore. The gaskets must not project into
the effective cross-section of the pipe.
x Irregularities on the surface of the pipe bore. The pipe bore should be free from
irregularities at the welded joints, dirt, deposits and excessive surface roughness.
x The Steam signal is falsified due to a bi-phase medium. Bi-phase media are not
permitted. Use a moisture separator for wet steam applications to remove the moisture
droplets from the steam. Use suitable filters in gas applications to remove solid
particles from the flowing gas.
x Incorrect angular position of the meter.Refer to Sect. 2.10 for the allowable mounting
positions.

SteaMon 33
10. Do's & Don't's
Precautions for "Safe and Desired" operation of
SteaMon Signal Converter
Do
x Ensure that sufficient upstream and downstream straight
lengths are provided
x Check that the housing of the primary head is perfectly centred
between the process flanges
x Provide proper supports to the pipeline at both ends of the meter
to keep the pipe vibration level well below the maximum limit
specified
x Ensure that the unit is installed in the process pipeline with
fasteners securely and firmly tightened causing no leakage of the
process fluid through the gaskets
DO NOT
x Use the meter with the process fluid being bi-phase like Gases-
Vapours with liquid droplets or solid particles.
x Install the meter where the process medium is pulsating with
fluctuations in the process pressure
x Allow any of the parameters like Flow-Density-Pressure-
Temperature-specified for the meter on the Nameplate and the Test
and Guarantee Certificate
x Tamper with any parts of the primary head of the meter
x Replace the fasteners with any other make or brand without the
consent of the manufacturer
x Allow the process pressure to exceed the pressure rating.

Disclaimer:
This information is strictly proprietary and legally privileged. All contents herein shall be the property of Forbes
Marshall Pvt Ltd and having protection under the intellectual property rights. No part of this information or data may
be distributed or disclosed in any form to any third party. Any dissemination, use, review, distribution, printing or
copying is strictly prohibited, if you are not the intended recipient or user of this information.

Forbes Marshall Pvt Ltd

Manufacturing: B-85, Phase II Chakan Indl Area, Sawardari, Chakan
Tal. Khed, Dist, Pune 410 501. Tel: +91(0)2135 393400
Sales: Opp 106th Milestone, Bombay Pune Road, Kasarwadi,
Pune 411034 Tel.: +91 (0)20 39858555
CIN No: U28996PN1985PTC037806

Email : [email protected] www.forbesmarshall.com

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