Manual 51 28
Manual 51 28
POSITIVE
DISPLACEMENT
FLOWMETERS
51 - 11 - 12 - 22
53 - 13 - 14 - 24
MOD. 16 - 18 - 28
ED. 03
REV. 08 dated 18/11/2019
2001 Petrol Instruments S.r.l. - Via della Tecnica, 5 - 04011 Aprilia - Latina
It is forbidden any reproduction of this document, even partial, without a previous written approval by
Petrol Instruments S.r.l.
Petrol Instruments S.r.l. has the right to make all the necessary changes to this documents without any
advance notice.
Sheet n° 3 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
1. General 4
2. Construction 5
3. Special Conditions
6
(MID Measuring System)
4. Disposal
7
(MID Measuring System)
5. Applicable Standards
9
(MID Measuring System)
6. Limits of use,
10
Special Conditions and Atex Marking
7. Installation Instructions 12
9. Failure Analysis 17
10. Inspection Procedures
models 51-11-12-22-53-13-14-24 18
models 16-18-28 21
11. Maintenance
models 51-11-12-22-53-13-14-24 22
models 16-18-28 25
12. Spare Parts 27
13. Storage 28
1
General
"PETROL" PD flowmeters are instruments capable of measuring the volume of
flowing liquids with a standard accuracy of ± 0,5% of reading for general purposes
and of ± 0,15% of reading for fiscal transactions.
This manual has been prepared for people responsible of their installation and, at
the same time, for people responsible of their maintenance and service.
This document includes specific aspects of installation, use and maintenance aimed
at mitigating the risk of explosion associated with use in hazardous areas.
Personnel involved in installation, testing and maintenance must possess the
qualifications required by Annexes F of EN 60079-14: 2014 and EN 60079-17: 2014.
The equipment supplied already has the metallic continuity of all its parts. Once it
reaches its destination, the equipment must be connected to the protection system
by connecting the equipment's grounding conductor to the installation site's ground
system. It is the responsibility of the final installer to verify the correct equipotential
connection with the dispersant system of the installation site
2
Construction
PD flowmeters are mainly composed of the measuring unit assembly and of the
reading unit (see dwg.1).
The reading unit, available in different models, is that required for the specific
application.
The outer housing is the part that withstands the liquid pressure and its
construction is in accordance to maximum expected pressure of flowing liquid.
The inner housing assembly is the part that accurately measures the volume of
flowing liquid through the revolutions of the rotors (“roots” type mechanism).
The coupling assembly is the part through which the number of rotors revolutions
is transmitted to the reading unit where are displayed the volumes metered.
Sheet n° 6 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
3
Special Conditions
(MID Measuring System)
The measuring system has been evaluated to the 2014/32/UE directive, and found
to be suitable for measuring liquids other than water with an accuracy class of 0,3
according to the Annex VII of directive.
The meter and accessories must remain full of product at all times. Upstream lines
must remain full to prevent air from entering the measuring system components.
If upstream or inlet lines are constructed in a manner which allows reverse flow,
foot valves or back checks must be installed.
4
Disposal
(MID Measuring System)
The measurement system is suitable for measurements of liquids other than water
having the characteristics and environmental conditions shown on the plate of the
measuring system.
5
Applicable Standards
(MID Measuring System)
OIML R117-1 - Dynamic measuring systems for liquids other than water
Sheet n° 10 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
6
Limits of use,
Special Conditions and Atex Marking
The PD Flowmeters must be used only and exclusively within the limits shown on
the name plate, so only and exclusively for type of liquid, flow rate, temperature,
max pressure and viscosity specified on the nameplate (dwg. 1 ). IT IS NECESSARY
TO CAREFULLY CHECK THE DATA ON THE NAMEPLATE BEFORE STARTING
THE METER.
SPECIAL CONDITIONS FOR A SAFE USE
II 2G Exh IIC T6 … T3 X
II -/2D
Reading
Unit
dwg.1 - PD Flowmeters
Sheet n° 12 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
7
Installation Instructions
PRECAUTIONS
The majority of PD flowmeters failures are caused by infiltration of solid particles
from the outer housing flanges during "inoperative conditions".
It is therefore very important:
• to remove the flanges protection only immediately before the instrument
installation;
• to absolutely prevent the entering of solid particles into the measuring unit
assembly during installation.
INSTRUCTIONS
1. During flowmeter installation avoid that deformation and/or stresses are induced
into the outer housing from the connecting pipes. If threaded holes for anchoring
purpose are available on the PD flowmeters outer housing, provide for a strong
anchoring to avoid vibrations;
2. Check that actual flow direction is the same indicated by the arrow stamped on
the flowmeter outer housing and/or is in accordance to the "in" and "out" name-
plates attached to the inlet and outlet flanges of the flowmeter itself;
3. The PD flowmeter must be mounted with the rotor shafts in horizontal position
and the counter dial must be in a vertical position (see dwg. 1a). In any case, on
the glass of the counter are glued several drawings which clearly show the
correct mounting position of the PD flowmeter. In case the counter dial is
required to be positioned horizontally or inclinated at 45°, the flowmeter will be
equipped with a proper 90° or 45° angle adaptor.
dwg.1a
Sheet n° 13 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
dwg. 2b
dwg. 2a
dwg. 2c dwg. 2d
dwg. 2e
7
Installation Instructions
4. For the measure of very viscous liquid at ambient temperature it is
recommended to provide heating for both the line and the flowmeter (if
necessary jacketed type PD flowmeters are available).
5. It is recommended to provide enough space on the rear side of flowmeter (i.e.
on the opposite side of the reading unit) for rear-cover removal as well as for
inner housing assembly removal (dwg. 2a).
6. It is good practice to install a strainer just before the flowmeter. However if plant
configuration does not permit the direct coupling of flowmeter and strainer, it is
imperative to clean thoroughly, before flowmeter installation, the spool pipe
used for strainer and flowmeter connection.
7. In case of new lines and specially in case of new and long lines, flush
accurately the lines themselves, by pumping liquid, before flowmeter
installation, should such operation be impractical, remove the inner housing
assembly from outer housing during the start-up.
INSTALLATION EXAMPLES
8
Start-up and Operating Instructions
1. For new lines let the liquid flow through the by-pass in order to completely wash
away any scale trace. Scale remaining in the lines might cause unusual wear of
bearings and of timing gears;
3. To start-up flowmeter open first the inlet valve and then open slowly the outlet
valve.
AVOID TOO HIGH FLOW RATES AS WELL AS TOO SHORT OPENING AND/OR
CLOSING CYCLES.
Sheet n° 16 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
8
Start-up and Operating Instructions
4. During initial service periods check frequently the strainer screener, eventually
cleaning it to avoid clogging.
6. If flowmeters are installed in cold places and so coben measuring water in such
cold places, it is recommended, once the measuring cycle has been completed,
to drain completely, through the proper drain plugs, the liquid remained inside
the instrument to avoid damages to the housing and/or rotors deformations due
to liquid freezing.
9
Failure Analysis
Failure of the flowmeter reading unit may be caused by:
10
Inspection Procedures
models 51-11-12-22-53-13-14-24
dwg. 3a
dwg. 3b
dwg. 3c
dwg. 3d
10
Inspection Procedures
models 51-11-12-22-53-13-14-24
3. At contrary, should the rotation of timing gears be not free and uniform, it is
necessary to pull-out the inner housing assembly from the outer housing and to
proceed to its inspection.
lnner housing assembly is pulled-out from the outer housing taking it from the
timing gears (dwg. 3c).
Should such operation results difficult, do not force on timing gears because
the bearings might be damaged. In this case please use the two threaded
holes, worked-out in the inner rear cover close to the timing gears, on which
the bolts of the outer housing rear cover may be mounted. Once the inner
housing assembly is removed it is possible to provide to its maintenance in
accordance to the procedures mentioned under item 9.
4. The PD flowmeter re-assembly is made just reversing the disassembly
procedures.
It is the case to point-out that the inner unit assembly is equipped with an its
own "anti-rotational" pin having its seat in the outer housing front cover. In re-
positioning the inner housing assembly inside the outer housing it is necessary
that this coupling is correctly made. Furthermore before mounting the rear
cover of the outer housing check that the counter is properly operating by
rotating the timing gears with the hands.
lt is also recommended to replace the PD flowmeter gaskets before its
mounting.
Sheet n° 21 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
10
Inspection Procedures
models 16-18-28
To check the reading unit, mainly composed of the reduction gear assembly
and of the counter, disassembly the adaptor of the counter (82) unscrewing
the relevant fixing bolts (81). In this way either the reading unit either the
magnetic transmission are removed and can be therefore easily inspected.
It is just the case to mention that the counter is disassembled from the
reading unit unscrewing the relevant four fixing bolts.
Should the reading unit and the magnetic transmission be properly operating
it is necessary to check the measuring unit. To do that it is necessary to
remove the outer front cover (72) of the PD flowmeter, unscrewing the
relevant fixing bolts (79).
In this way either the fork-type movement transmission system either the
timing gears of the inner housing assembly can be inspected. It is therefore
possible to check if the timing gears rotate freely and steadily.
In case the rotation of the timing gears is not free and steady it is necessary
to pull-out the inner housing assembly from the outer housing to proceed to
the relevant inspection and maintenance.
Sheet n° 22 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
11
Maintenance
models 51-11-12-22-53-13-14-24
dwg. 4a
dwg. 4b dwg. 4c
11
Maintenance
models 51-11-12-22-53-13-14-24
In case even the front cover of the inner unit assembly has to be inspected, it is
enough to remove it unscrewing the relevant fixing bolts. In making the
maintenance of the inner housing assembly it is recommended not to
desynchronise the rotors, if possible. To do that and in case it is necessary to
check and/or to replace the timing gears, it is convenient to clamp on a vise the
sub-assembly rear cover-rotors (dwg. 4a), inserting between the rotors a thickness
gauge of some centesimal units, that, in case of need, may be also replaced by a
simple paper. In case the rotors have to be disassembled, for example for their
replacing and/or to check the uniformity of the rotors shafts dimensions and/or to
check the dimensions of the rotors themselves and/or for rear cover bearings
replacement, it is suggested to proceed as follows when re-assembling the inner
housing assembly.
1. install separately the two rotors inside the inner housing and check that they
rotate freely;
2. install contemporarily the two rotors inside the inner housing and check that they
do not interfere;
3. in the conditions of the above item 2) mount the first timing gear on its shaft;
4. to mount the other timing gear proceed as follows:
a) block the rotor on which the first timing gear has been already mounted with
a soft material;
b) push with hands the rotor on which the timing gear has to be mounted
against the other rotor, inserting between them a thickness gauge of about
0.1 mm;
c) in the conditions of the above item b) mount the second timing gear;
d) check that the clearances between the rotors and between the rotors
themselves and the inner housing are uniform;
e) In case the bearings have been replaced it is recommended that the same
are aligned with a proper lapping bar (dwg. 4b) and that the inner surface of
the covers has been made perfectly plane (dwg. 4c).
Sheet n° 25 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
11
Maintenance
models 16-18-28
The inner housing is shown as exploded view in dwg. B. To disassembly the rotors
it is recommended to proceed in the following way:
• remove the inner cover (50), timing gears side, unscrewing the relevant fixing
bolts (66);
• remove the shaped rotors plate (48) unscrewing the relevant fixing bolts (49).
To do that it is necessary to slightly push upward the rotors to avoid that the
plate may damage, by blowing, the centering pins between body and cover
(13);
• mark the relative position of timing gears by making a recognizing sign on them.
Such marking is necessary for the correct re-assembly of rotors;
• pull-out the rotors from inner housing assembly, using the timing gears as
pullers.
The actual conditions of the rotors and the wear conditions of the timing gears and
of the bearings may now be properly evaluated.
It is just the case to mention that rear cover is disassembled following the same
procedures mentioned hereinabove.
The purpose of the timing gears is to synchronise the rotors and their relative
position is established by the centering pins (34).
Should timing gears be replaced it is recommended to use particular care in the re-
positioning of the new gears.
The timing gears are removed by unscrewing the relevant fixing bolts (37).
Sheet n° 26 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
11
Maintenance
models 16-18-28
Should be necessary to replace the bearings (22, 59), those must be removed from
the relevant covers together with the bearing holders (23, 60). To facilitate such
operation it is, recommended to mount a screw on the threaded holes of the
bearing holder and to use them to remove the system bearing/ bearing holder.
lnner housing re-assembly procedures are just the reverse of rotors disassembling
procedures above mentioned.
However the utmost care and attention must be placed to the following points:
• check that the clearances, i.e. the distance between the rotors and the distance
between the rotor and the inner unit body are uniform;
• check that rotor position is that corresponding to the recognizing marks
previously made on the timing gears.
The PD flowmeter re-assembly procedures are just the reverse of the disassembly
procedures above mentioned for the check of the measuring unit assembly and of
the reading unit.
The utmost care must however be put in re-assembly the outer front cover to avoid
damages to the fork-type coupling (43, 45) between the inner housing assembly
and the reading unit.
Sheet n° 27 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
12
Spare Parts
Parts found weared or damaged must be replaced with new parts, to order spare
parts make reference to the attached exploded-view drawings.
13
Storage
PD flowmeters are normally supplied packed inside wooden cases that may be
easily handled without damaging the instruments.
For cases handling all types of motor machinery and/or hand machinery generally
available at storage houses may be used.
It is in any case imperative that at least the measuring units are removed from the
outer housings and duly checked according to their specific maintenance
procedures, before PD flowmeters start-up.
Sheet n° 29 of 42
Doc. n° IEM/08/E (PED-ATEX-MID)
14
Troubleshooting Table