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Tokico SOP

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0% found this document useful (0 votes)
49 views11 pages

Tokico SOP

Uploaded by

Darul walidi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Tokico Flow Meter Installation Guide

Refer to the arrow at the bottom


part of the flow meter for flow
direction, to determine the inlet and
outlet.

Outlet Inlet

Install the strainer on the inlet of the flow


meter. There must be no inter-piece
between the flow meter and strainer. This is
to prevent foreign material from the inter-
piece from getting into the flow meter and
damage the rotors.

Correct

Incorrect

Note:

It is strongly advised that Tokico Flow Meter to be used together with Tokico Bucket Strainer for optimum
performance and long lasting durability. Tokico bucket strainer provides various mesh sizes for the flow
meters depending on the size of the flow meter.

Seacom Process Instruments Sdn. Bhd. | Tokico Flow Meter Installation Guide v1 1
Piping instructions

1. As shown in Figure 3 and 4, install a strainer at the inlet of the flow meter and provide a
bypass for the convenience of flow meter disassembly and inspection. The flow meter
should be installed on the bypass side since the dirt in the outlet piping flows back when the
flow direction is from bottom and top.

Figure 3: Horizontal piping Figure 4: Vertical piping

2. Where much foreign matter exists, install strainers in parallel as shown in Figure 5, so that
they are used alternately. Another way is to use a double strainer.
3. If fluid may contain air bubbles, install an air eliminator as shown in Figure 6. This is a must
for the flow meter for transactions. It should be noted, however the air eliminator must not
be used if the inside pressure is lower than the atmospheric pressure, such as on the
suction side of a pump.
4. For highly-viscous crude oil or C heavy oil, lag or heat the piping (for example, though
steam trace). The lagging or heating should be carried out keeping for the ease of
disassembly and inspection.

Figure 5: Two strainers to be used alternately Figure 6: Air Eliminator in the pipeline

Seacom Process Instruments Sdn. Bhd. | Tokico Flow Meter Installation Guide v1 2
Warning: Make the piping arrangement for releasing the liquid volume expansion by the
ambient temperature rise in order to avoid abnormal pressure rise in the piping.

Inspection prior to installation

One of the most typical problems that occur in the metering section is that the rotors will not
rotate because foreign matter went into flow meter includes during piping. This problem may
be prevented by taking the following precautionary steps.

1. Remove the blank plugs in the flanges of the body immediately before piping.
2. Make sure no foreign matter can get into the flow meter during piping.

Caution: Be sure not to allow dusts and mists to get into the piping to prevent the flow meter
from the breakage.

Hints for installation

1. Flush every pipe before piping. Warranty does not cover damages resulting from the scale
or foreign matter in the piping during operation. Therefore a suitable piping plan is required.
2. Avoid unreasonable installation which will give the body piping distortion.
3. Install the flow meter according to the arrow on the body which is same with the direction
of flow.
4. Install the flow meter as shown in Figure 7, where the rotor shaft is kept horizontal. An
attachment is available if the indicator section must be faced 45 degrees upward of exactly
upward.
5. Although oil drain is carried out after the flow meter is tested for instrumental errors, there
is still only a small amount of oil left. Keep the flow meter away from fire during both piping
and installation.
6. Air purging can cause an excess amount of fluid to the flow meter. Take care that the
maximum flow rate on the nameplate is never exceeded.
7. When hydraulic-testing the piping system including the flow meter, replace the flow meter
with a short pipe. After testing, drain the flow meter positively, remove the internal
components of the flow meter, and apply a sufficient amount of corrosion inhibitor.

Warning: Use of fire near the flow meter is prohibited as oil may remains inside the flow
meter.

Seacom Process Instruments Sdn. Bhd. | Tokico Flow Meter Installation Guide v1 3
Caution:

1. Install the meter to the piping keeping the rotor shaft horizontally. If not, the meter may
have problems.
2. Use a waterproof type cable connector for the pulse transmitter for outdoor usage in order
to prevent the water from disrupting the function of the transmitter.
3. Use a flameproof type cable connector for the pulse transmitter for hazardous area usage. If
standard type cable connector other than flame proof type cable connector is used, flame
proof structure cannot be maintained.

Seacom Process Instruments Sdn. Bhd. | Tokico Flow Meter Installation Guide v1 4
Tokico Flow Meter Maintenance Guide
Maintenance and Inspection.

In maintenance, the flow meter should be inspected according to Table 1.

Inspection items
Monthly Yearly
Metering section 1. Check the flow rate, temperature 1. Check for instrumental errors.
pressure, and fluid (viscosity) specified on 2. Check the bearing and driving gears
the nameplate. If no changing factors for wear. Wear will cause interference
exist, the initial check is all that required. between the rotors or between the
2. Check the packing for leakage. rotors casing, this leading to
3. Check the o-rings for leakage. unfavourable instruments errors or
4. Check for noises due to rotor defective operation.
interference. 3. Check the magnetic coupling assembly
for leakage.
Indicator section 1. Check that the pointer is moving 1. Lubricate the gears and bearings
smoothly. (twice a year)
2. Check that the counter Is moving 2. Check the bearings for looseness.
normally 3. Check that the transmitter is working
3. Check that the transmitter is working normally, check for transmission.
normally
4. Check for rainwater penetration (loose
packing or loose bolts on the casing)
Strainer 1. Clean the screen. For new piping, clean 1. Check the screen for breakage.
more frequently at the beginning of 2. Check the packing for damage.
operation because clogging is likely to
occur often. The frequency may be once
every 2 or 3 months if clogging is found
less frequent. (The pressure difference
must be limited to 0.15MPa at the most).
2. Check the packing for leakage.
Table 1: Maintenance guide

Troubleshooting

Maintenance is required so that the flow meter provides long-term precision or accuracy. Since
the working section is placed in fluid, its sliding parts tend to wear after long-term usage.
Therefore, the flow meter must be sometimes inspected and repaired if necessary.
Seacom Process Instruments Sdn. Bhd. |Tokico Flow Meter Maintenance Guide v1 1
In case measurement is found incorrect or the flow meter is unstable in operation, carry out an
immediate inspection and take appropriate action. Table 2 gives some typical troubles of the
flow meter, their possible causes, and actions to be taken, make the most of this
troubleshooting chart as a guide in carrying out routine maintenance and detecting faults in
their stages.

Symptom Problem Possible cause Action


Unfavourable Excessive 1. Insufficient viscosity Wrong specification 1. Replace calibration
instrumental flow rate 2. Insufficient flow rate gear
error 2. Increase flow rate or
use smaller flow meter
3. Worn driving gear Wear 1. Replace driving gear
4. Worn rotor bearing Intrusion of foreign 2. Replace rotor bearing.
(noise due to rotor matter Use finer screen of the
interference) Excessive flow rate strainer
Decrease flow rate or
use larger flow meter
Insufficient 1. Excessive viscosity Wrong specification Replace calibration gear
flow rate 2. Intrusion of air or steam 1. Defective piping 1. Take measures to
2. Fluid viscosity is prevent air intrusion
high and bubble 2. Provide large reservoir
remain in piping
3. Piping is empty 3. Install air eliminator.
immediately before
or after metering.
Little fluid flows and pointer 1. Strainer clogging Strainer screen unclean Clean the screen of the
does not deflect strainer
2. Foreign matter exists 1. Piping leaning 1. Remove flow meter
between rotors insufficient and flush piping
3. Foreign matter exists in 2. Broken strainer 2. Replace the screen of
driving gear teeth screen the strainer
3. Poor selection of 3. Clean driving gears
strainer screen and rotors, apply sand
mesh paper, check for
smooth operation and
make an assembly.
4. Worn driving gear Wear 1. Replace rotor bearing
5. Worn rotor bearing Excessive flow rate 2. Replace driving gear
(may stop if pressure Decrease flow rate or
difference is insufficient) use larger meter
6. Rust or precipitate on Poor maintenance Dissemble and clean
driving hear teeth during downtime Replace with jacket type
Fluid solidification flow meter
Fluid flows but Metering 1. Worn transmission gear Aging and wear Replace transmission gear
pointer does not section (Rotor or coupling gear) (Rotor or coupling gear)
deflect Indicator 1. Wear or scuffing of No oil Lubricate and replace
section bearing or gear Cover clamping Use care during assembly
2. Rust insufficient
3. Magnetic coupling de- Slip due to increase 1. Replace magnetic
magnetized. resistance in indicator coupling
2. Re-magnetize
Table 2: Troubleshooting guide

Note: It is advised that the user do not perform any modification or alteration on the parts of
Tokico flow meter for the purpose of maintenance. Inappropriately modify/alter the parts of

Seacom Process Instruments Sdn. Bhd. |Tokico Flow Meter Maintenance Guide v1 2
Tokico may result in more damage to the flow meter and ultimately cause the flow meter to be
beyond repairs.

Seacom Process Instruments Sdn. Bhd. |Tokico Flow Meter Maintenance Guide v1 3
Tokico Flow Meter Operations Guide
Structure of Tokico Flow Meter

Reading of the Indicator:


Note: Reading of the pointer is 100 liters/revolution

Example 1:

Seacom Process Instruments Sdn. Bhd. | Tokico Flow Meter Operations Guide v1 1
Example 2:

Additional operations guide:

1. The flow meter should be used under the conditions meeting the fluid (viscosity), flow rate,
pressure and temperature specified on the nameplate. Be sure to check the nameplate
before operation.
2. At the initial operation after the flow meter is installed, allow fluid to flow first through the
bypass so that the dirt or foreign matter in the piping is flushed away. At the beginning of
the flushing clean the screen of the strainer frequently to prevent clogging.
3. When making a test run of the flow meter, first open the inlet valve and then slowly open
the outlet valve. Finally close the bypass valve while watching how the flow meter is
operating. After the test run, repeat the same procedure with the bypass valve closed so
that fluid begins to flow slowly to start the flow meter. Adjust the outlet valve of the flow
meter to provide the proper flow rate.
4. Clean the screen of the strainer at regular intervals. (The pressure difference resulting from
clogging must be limited to 0.15MPa at the most)
5. Use in cold districts: when the flow meter is not in use, extract the remaining liquid at the
drain plug. Otherwise, freezing can cause the rotors to be distorted due to the volume
expansion of the remaining liquid.

Seacom Process Instruments Sdn. Bhd. | Tokico Flow Meter Operations Guide v1 2
6. For high fluid temperature, first open the inlet valve. Only after the internal components of
the flow meter become as hot as the fluid, slowly open the outlet valve to let the fluids flow
out. For the flow meter intended for use with high temperature fluid, the bolts of the front
and rear covers are retightened in the factory. They may, however, become loose due to
the expansion and contraction when the fluid temperature cycles between high and normal
values. Therefore, the bolts should be retightened at the initial operation.

Seacom Process Instruments Sdn. Bhd. | Tokico Flow Meter Operations Guide v1 3
Flow Meter Selection Guide
Application

• Totalizer
• Rate

1. Max temperature
2. Max pressure

Flow meter
construction material

• Minimum flow rate / maximum


flow rate
• Viscosity
• Specific gravity

Connection size

Connection type

• ANSI
• JIS
• PN
• BS

Other
requirements:

• Output signal
• Mechanical
/LCD display
• Batch

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