maintenance - installation manual...the maintenance of the transmitter is described in the mm5006e...

Liquid Level Transmitter

CT801-SI, CT801-TA

Installation Manual

SAS au Capital de 2 158 244 € - 444 871 933 R.C.S. Bourges - APE : 2651B

Headquarter : 9, rue Isaac Newton - 18000 Bourges - France

Liquid Level Transmitter Installation Manual

CT801-SI, CT801-TA

1st Edition Released February 2013

TABLE OF CONTENTS

1. INTRODUCTION .............................................................................................................................. 4

2. DESCRIPTION ................................................................................................................................. 5

2.1 Pneumatic modulator .................................................................................................................. 5

2.2 Electric conditioner...................................................................................................................... 6

3. UNPACKING and INSPECTION ...................................................................................................... 6

4. INSTALLATION ................................................................................................................................ 7

4.1 Installation of the tank penetration .............................................................................................. 7

4.2 Installation of the bubbling pipe, inside the tank .......................................................................... 7

4.3 Continuation of the bubbling line ................................................................................................. 7

4.4 Installation of shut-off valves, if any, on the bubbling line ............................................................ 8

4.5 Installation of the CT801 transmitter ......................................................................................... 10

5. CONNECTIONS ............................................................................................................................. 10

5.1 Air supply .................................................................................................................................. 10

5.2 Electrical connection ................................................................................................................. 11

5.3 CT801-SI, connection of an analog or digital indicator without built-in power supply ............ 15

5.4 CT801-SI, connection of a digital indicator with built-in power supply ....................................... 15

5.5 CT801-SI, connection a MICATRANS A/D transmitter-indicator............................................... 16

5.6 CT801-SI, connection a TA3840C ........................................................................................... 16

5.7 Connection of a pressure indicator (CT080 type) ...................................................................... 17

6. INSTALLATION CONTROL – PREPARE TO RUN ........................................................................ 17

6.1 Bubbling lines ........................................................................................................................... 17

6.2 CT801 transmitter ..................................................................................................................... 18

6.3 Commissioning ......................................................................................................................... 18

6.4 Measurement check .................................................................................................................. 18

7. INFORMATIONS ............................................................................................................................ 20

7.1 Reference of Honeywell Marine Customer Service ................................................................... 20

8. PERSONAL NOTES ...................................................................................................................... 21

9. ANNEX A ....................................................................................................................................... 22

Doc No: MI5006E – Revision 5 – ENG Liquid Level Transmitter CT801-SI, CT801-TA Installation Manual 4

1. INTRODUCTION The Level Transmitter CT801 Series is designed for measuring the level of all types of liquid products in all kinds of tanks such as ballast tanks, service tanks,…, from the hydrostatic pressure of an air-flow bubbling through a pipe which reaches the bottom of the tank. This pressure is transmitted to an electronic conditioner including a pressure sensor, providing an electrical analog output signal.

Two models are available :

● CT801-SI, the standard model, providing an electric current from 4 to 20 mA in the 24 Vdc typical power supply loop. Two wires are necessary for the CT801-SI connection to the monitoring system.

● CT801-TA, designed for connection to a TA840 or EM940 Radar level transmitter : powered by the 5 Vdc source, the output signal is a voltage ranging from 0.5 to 2.5 Vdc connected to an analog input of the Radar. Three wires are necessary to connect the CT801-TA to the closest Radar transmitter, for cable saving.

These models are designed to be used in all hazardous area : the certificate is attached in annex A.

The CT801 Series are fitted with a differential pressure sensor, so even if installed on a pressurized tank, the output signal is a direct function of the liquid height.

The CT801 Series are fitted with the following mechanical interface, for the best adaptation to all installation conditions :

● Suffix B : flange PN16 DN50

● Suffix R : female threaded coupling 1" BSPP, with optional bracket

● Suffix R1/4 : female threaded coupling 1/4" NPT, with optional bracket

The transmitter is described in the MT5006E Technical Manual. The Maintenance of the transmitter is described in the MM5006E Maintenance Manual.


2. DESCRIPTION The CT801 Series is composed of two main parts : the pneumatic bubbling flow modulator and the electronic signal conditioner.

2.1 Pneumatic modulator The pneumatic bubbling flow modulator is common for both models. It is composed of :

Identification plate

Enclosure for the electronic conditioner

Overpressure protection valve

NPT 1/8" coupling for low reference pressure inlet connection (pressurised tank) or venting nipple (non-pressurised tank)

NTP 1/8" coupling for outlet connection to pressure indicator (pressure copy)

Bubbling flow generator, with air flow adjustment

NTP 1/4" coupling for air supply inlet connection

Bubbling air return protection valve

NTP 1/4" coupling for flow control

Air supply filter


2.2 Electric conditioner The electronic conditioner board, including the pressure sensor, is placed in a solid housing on top of the pneumatic modulator, ensuring the compactness of the CT801 transmitter.

Two kinds are available, one for model CT801-SI, one for model CT801-TA :

CT801-SI :

CT801-TA :

3. UNPACKING and INSPECTION Proceed carefully to the unpacking. If some damage is observed, mail immediately the necessary claim to the carrier, in the local legal conditions.

Proceed to the inspection in compliance with the order, delivery bill and Manufacturer File.

Terminals

Zero adjustment ("Z" mark)

Span adjustment ("S" mark)

Type 34052 Type 35445

Terminals

Zero adjustment ("Z" mark)

Span adjustment ("S" mark)


4. INSTALLATION Refer to the Type Installation drawings provided by Honeywell Marine.

The normal procedure is successively as follow :

1. Installation of the tank penetration for the bubbling pipe; 2. Installation of the bubbling pipe, inside the tank; 3. Continuation of the bubbling line, from the deck penetration to the CT801 transmitter; 4. Installation of the isolating valves, if any, on the bubbling line; 5. Installation of the CT801 transmitter; 6. Pneumatical and electrical connections on the CT801 transmitter, described in chapter 5; 7. Installation control, described in chapter 6.

For the best installation performance, the above procedure must be carried out step by step.

The Installation Inspection Report in ANNEX A must be fulfilled after each step of the system installation and control (see chapter 6).

4.1 Installation of the tank penetration The tank penetration is to be placed on top or side of the tank, according to the foreseen operation conditions, and in regards with the location of the selected reference level (See Technical Manual, operation).

4.2 Installation of the bubbling pipe, inside the tank The bubbling pipe inside the tank goes from the tank penetration until the reference level location.

The recommended diameter for the bubbling line is ½" diameter. In case of viscous liquid, the diameter can be increased at its bubbling outlet. It is cut at its outlet with an angle, in order to help the bubbling air to run with a regular flow in a constant direction.

4.3 Continuation of the bubbling line The bubbling line outside the tank goes from the tank penetration until the CT801 transmitter, through some valves if any, see further. The recommended diameter for the bubbling line is ¼" diameter, to be manufactured in a material compatible with the environment.

The pipes on deck have to be installed with the adequate protection.

CAUTION: The bubbling pipe must not show any low point inside the tank, liable to retain liquid or condensation, and so to introduce a measuring error..

The key-point of a correct installation for good measuring performance is the perfect watertightness of the bubbling line, from its extremity inside the tank to the CT801 bubbling outlet.


4.4 Installation of shut-off valves, if any, on the bubbling line

4.4.1 Isolating valve

Until start up and before any operation on the CT801 transmitter, the isolating valve on the bubbling line must imperatively be closed.

4.4.2 Optional service valve In case of use with muddy fluids (for instance ballast tanks), or when the bubbling line inside the tank can be obstructed by particles, a three-ways service valve can be inserted into the bubbling line, on the transmitter side, being supplied with compressed air : when the measuring signal increases, possibly due to a partial obstruction in the bubbling line, this valve can be switched so helping to dispose the suspect obstruction.

This valve can also be used to reduce the response time needed to reach the hydrostatic pressure equilibrium when starting the system.

Installation of a line for gas pressure over the liquid surface on pressurized tank. In case of pressurized tank, the gas pressure over the liquid surface, i.e. the upper part of the tank, has to be connected to the low reference pressure inlet connection (see 0).

CAUTION: Make sure that the pressure over the liquid surface doesn't overpass the overpressure limit as follow in hereunder table:

RECOMMENDATION: In all other cases, it is strongly recommended to isolate the bubbling line by inserting a valve for checking or maintenance purpose.

CAUTION: When the CT801 is installed at a place lower than the highest liquid surface level, it is essential to attach an isolating valve to the bubbling line in order to allow for the installation and removal of the transmitter, without any risk of liquid expansion.

This valve should be installed close to the transmitter, ensuring that a dead volume of 0.5 liter is preserved between the CT801 and the valve.

CAUTION: The bubbling line must not show any low point, liable to retain some liquid or condensation in the bubbling line and to introduce a measuring error. When it is not possible, it is strongly recommended to install a purge valve on the lowest point, in order to dispose the possible accumulated liquid when a measuring error is suspected.


SCALE RANGE MAXIMUM PRESSURE OVER THE LIQUID SURFACE

0-50/70 mbar 2000 mbar 0-70/350 mbar 2000 mbar 0-350/1050 mbar 2000 mbar 0-1050/2100 mbar 8000 mbar 0-2100/4100 mbar 9000 mbar

● R1 and R2 isolate the line ● R3 equalizes the pressures for start up ● R4 depressurizes the circuit in case of emergency

RECOMMENDATION: When the pressure of the gas over the liquid surface is higher than 300 mbar, a set of protection valves has to be installed as follow :

RECOMMENDATION: It is strongly recommended to isolate this line by inserting a valve for checking or maintenance purpose.

R2

R4

NPT 1/8’’ coupling for gas over liquid surface connection (ATM)

Inert gas

R1

R3


4.5 Installation of the CT801 transmitter The CT801 Series are fitted with following mechanical interface, for the best adaptation to all installation conditions:

● Suffix B : flange PN16 DN50, for installation on a counter flange or an horizontal flat support; ● Suffix R : female threaded coupling 1" BSPP, with optional fixing bracket for wall installation; ● Suffix R1/4 : female threaded coupling 1/4" NPT, with optional fixing bracket for wall

installation;

Proceed as follow: ● Install the CT801 transmitter on its support or bracket. Take care with the orientation of the

inlets, pneumatical and electrical, for best connections conditions; ● Check that all the isolating valves are closed, if present; ● Connect the bubbling line on the bubbling outlet of the CT801 transmitter, depending of the

model; ● Check the reference pressure inlet :

- When the tank is not pressurized, this inlet is fitted with a venting nipple;

- When the tank is pressurized, connect this inlet with a pipe to the upper part of the tank, in order to meet the pressure over the liquid surface.

5. CONNECTIONS

5.1 Air supply

● Connect the air supply to NPT ¼’’ inlet coupling marked with an arrow (see 0).

RECOMMENDATION: Incorporate a valve into the supply circuit, for best installation and maintenance conditions.

CAUTION: The CT801 transmitter must be supplied with instrument-quality air at a pressure of 4 to 10 bar. Do not hesitate to contact Honeywell Marine for the provision of an air dryer and oil extractor.


5.2 Electrical connection

5.2.1 CT801-SI 5.2.1.1 Supply voltage

Supply voltage on the transmitter = 12 to 28 Vdc or 16 to 28 Vdc, to be determined according to the line impedance as shown on the following diagram:

The power supply to the transmitter is the main power supply minus the voltage drop of the Zener barrier if any.

5.2.1.2 Precautions for intrinsically safe installation Ex ia

In particular, the supply source characteristics must comply with:

U (Vdc) Ii (mA) P (W)

CT801-SI £ 28 £ 120 £ 0.84

The result of such association is an intrinsically safe system, which must be certified. The certification is the responsibility of the associated device's provider.

CAUTION: The CT801-SI transmitter, certified II 1 G D Ex ia IIC T6 Ga

Ex ia IIIC T70°C Da IP66/67

Under certificate n° LCIE 02 ATEX 6182X and IECEx LCIE 12.0005X, must be associated to an intrinsically safe certified device, complying with the transmitter's intrinsic safety parameters.

The internal capacitance is £ 17 nF; the inductance is negligible.

800

400

LOAD ohms

12 20 28 Vdc

0

24

600

Power Supply Volts dc

Type 34052 Type 35445


As a consequence, a suitable Zener barrier must be installed in Safe Area, to be inserted into the line between CT801-SI and the power supply / measure acquisition device.

5.2.1.3 Procedure Two cable glands are provided:

● one for cable diameter 7 to 12 mm ● one for cable diameter 8.5 to 14.5

The connections are to be performed with power off: open the electronic module enclosure by unscrewing the cap, in order to show the terminals.

a) Installation of the cable through the flexible hose ● Remove the plastic protection caps from the flexible hose, when present; ● Introduce the cable into the flexible hose, by the conical threaded coupling side; ● Screw the flexible hose 3/4” female conic BSPT and the drain coupling on the cable protection

pipe; ● Assemble on the cable successively the items (1), (2) with (3) then (4) and (5); ● Cut the cable at the sufficient length for the best placing in the enclosure, and put off the

sheath on about 3 cm in order to free the wires; ● Introduce the cable inside the electronic module enclosure : the wires must arrive in the area of

the terminal, and the sealing gland must stay over the sheath; ● Screw the gland nut (2) in order to compress the sealing gland (5); ● Screw and block the counter nut (3); ● Screw the locking nut (6) on the gland nut (2) by using two flat wrenches.

CAUTION: Remind that a proper installation requires a perfect watertightness of the electrical connections:

- Make sure to use the correct cable gland depending of the diameter of the used cable;

- Make sure to tighten the gland on the cable sheath (see hereunder).

(1) Sealing washer

(2) Gland nut (3) Counter nut

(4) Washer

(5) Sealing gland

Coupling with drain holes (6) Locking nut Flexible hose

Conical coupling ¾"


b) Connection ● strip the two wires and connect them to the terminals as shown on following diagram ● Don’t connect the grounding shield; it is to be connected on the ground only on the supply

side.

● Carefully screw the threaded cap.

5.2.2 CT801-TA

5.2.2.1 Supply voltage The CT801-TA is designed to be powered by the 5 Vdc source from the Radar transmitter. The 0.5 to 2.5 Vdc output signal is connected to an analog input of this Radar transmitter.

5.2.2.2 Precautions for intrinsically safe installation Ex ia

U (Vdc) Ii (mA) P (W)

£ 8 £ 540 £ 1.1

The result of such association is an intrinsically safe system, which is certified accordingly.

The CT801-TA transmitter, certified II 1 G D Ex ia IIC T6 Ga

Ex ia IIIC T70°C Da IP66/67

under certificate n° LCIE 02 ATEX 6182X and IECEx LCIE 12.0005X, must be associated to the TA840 or EM940 transmitter, intrinsically safe certified, complying with the transmitter's intrinsic safety parameters.

The internal capacitance is £ 7.2 µF; the inductance is negligible.

+

-

POWER SUPPLY CABLE

+

Type 34052

Type 35445


Procedure Two cable glands are provided:

● One for cable diameter 7 to 12 mm ● One for cable 8.5 to 14.5

The connections are to be performed with power off: open the electronic module enclosure by unscrewing the cap, in order to show the terminals.

a) Installation of the cable through the flexible hose the procedure is similar to this one for the CT801-SI (see 5.2.1.3 a)

b) Connection

● Strip the three wires and connect them to the terminals as shown on following diagram ● Don't connect the grounding shield; it is to be connected on the ground only on the radar side.

● Carefully screw the threaded cap.

CAUTION: Remind that a proper installation requires a perfect watertightness of the electrical connections:

- Make sure to use the correct cable gland depending of the diameter of the used cable;

- Make sure to tighten the gland on the cable sheath (see hereunder).

CABLE TOWARD AN ANALOG INPUT OF TA840

+ 5 Vcc

0 Vcc

Signal 0.5 - 2.5 Vcc


5.3 CT801-SI, connection of an analog or digital indicator without built-in power supply

5.4 CT801-SI, connection of a digital indicator with built-in power supply

RECOMMENDATION: For installation in hazardous area, a Zener Barrier is to be inserted in the diagram.

CAUTION: For installation in hazardous area, a Zener Barrier is to be inserted in the diagram.

Signal 4-20 mA + -

+ -

Power supply

Digital or analog indicator

Fuse 0.05 A

Signal 4-20 mA

+ -

Digital or analog indicator

Power supply output 4-20 mA input

+ -


5.5 CT801-SI, connection a MICATRANS A/D transmitter-indicator

5.6 CT801-SI, connection a TA3840C

CAUTION: For installation in hazardous area, a Zener Barrier is to be inserted in the diagram.

RECOMMENDATION: For installation in hazardous area, a Zener Barrier is to be inserted in the diagram.

Connection to terminals 4-20 mA

To Monitoring System

MICATRANS A/D

+ -

Power Supply 115/230 V - 50/60 Hz

Signal 4-20 mA

Connection to terminals 4-20 mA

To Monitoring System

+ -

Power Supply 24 Vcc

Signal 4-20 mA


5.7 Connection of a pressure indicator (CT080 type) Connect the pressure indicator to the NPT 1/8’’ coupling marked “R” (see 2.1) according to the following diagram:

6. INSTALLATION CONTROL – PREPARE TO RUN The Installation Inspection Report in ANNEX A must be fulfilled after each step of the system installation and control.

6.1 Bubbling lines ● Check the integrity of the bubbling lines on deck : no shock, no crushing, no bend which could

reduce the internal section. The pipes on deck have to be installed with an adequate protection.

● Check the pipes profile : no low points on the continuation of any pipe between the bubbling point and the arrival in the area of the transmitter.

● Check the line identity correspondence between each tank or space and each transmitter, according to the Manufacturer File.

● Check the absolute leak proof of each line. The best method is to pressurize each pipe using at least 6 bar compressed air, from nearness of the transmitter to the bubbling point, after plugging it; no pressure drop should be observed after several minutes.

● Close temporarily all the isolating valves, if any.

CAUTION: Before connecting the pressure indicator, imperatively close the isolating valve of the bubbling probe when the tank is not empty.

Isolating valve

CT801

Pressure indicator with overpressure valve

NPT 1/8’’ Female coupling « R »


6.2 CT801 transmitter ● Check the wiring of the transmitter. ● Check the perfect watertightness of the packing gland: the rubber gland must be

tightened on the cable sheath. ● Check the quality of air supply : it must be Instrument quality air, dry and clean. Close

temporarily the shut-off valve.

6.3 Commissioning The operation of the CT801 transmitter is described in the Technical Manual MT5006. The calibration has been carried out in factory. For another calibration, refer to the Maintenance Manual.

For start-up, proceed as follow :

a) Switch the electric power ON b) Open the air supply valve c) Settle the pneumatic connection with the bubbling probe :

● On non-pressurised tank : open the isolating valve of the bubbling probe ● On low-pressurised tank : open the isolating valve of the gas pressure over the liquid surface ● On high-pressurised tank (see 0), use following sequence :

- Open the valve R3 - Open the valve R2 - Close the valve R3 - Open the valve R1

6.4 Measurement check

6.4.1 Check in dynamic state Compare the height of the liquid in tank and the value displayed from the transmitter.

6.4.2 Check in static state Note : This check can be easily performed with Honeywell Marine' test kit.

● Close the isolating valve of the bubbling probe, as well as the isolating valve of the gas pressure over the liquid surface.

● Close the isolating valve of the air supply. ● Open the valve R4 if present (see 0). ● Open the electronic module enclosure by unscrewing the cap. ● Complete the pneumatic and electrical connections as shown on the following diagram.

CAUTION: In case of a new installation, the air supply line must be purged before connection, in order to avoid internal moisture or condensation to enter the transmitter.


● Switch the power supply ON

● Compare the generated pressure with the measuring signal 4-20 mA or 0.5 - 2.5 Vdc, according to the operating range explained in the chapter "Operation" in the Technical Manual MT5006.

● After testing, reassemble and seal the removed connections.

IMPORTANT NOTES: Honeywell Marine guarantees the correspondence between hydrostatic pressure and output signal 4-20 mA, as defined in the order.

Any errors due to improper installation, improper utilization, signal treatment, density deviations, gauging curves and leaks in lines cannot in any way be engage the responsibility of Honeywell Marine.

Air supply

Bubbling line

Calibrated pressure generator

Pressure copy outlet "R"

Current 4 - 20 mA meter for CT801-SI, in curent loop Power supply

Voltage 0.5 - 2.5 Vdc meter for CT801-TA, on S terminal


7. INFORMATIONS

7.1 Reference of Honeywell Marine Customer Service

Address :

Honeywell Marine 9, rue Isaac Newton

Z.A. Port Sec Nord

18000 BOURGES

Telephone : +33 2 48 23 79 18

Fax : +33 2 48 23 79 02

E-mail : [email protected]

mailto:[email protected]


8. PERSONAL NOTES


9. ANNEX A

CT801 Series INSTALLATION INSPECTION REPORT Vessel : ........................................................... Location : ........................................................

Owner or Shipyard : ..........................................................................................................................

CT801 P/N : ..................................... S/N : .....................................

1. Deck pipes integrity ..................................................................... : No shock, no crushing, no excessive bend, adequate protection.

2. Bubbling lines profile ................................................................... : No low points

3. Bubbling lines identity ................................................................. : Check with Manufacturer File.

4. Bubbling lines leakproof test ...................................................... : Absolute leakproof of bubbling lines.

5. Bubbling lines isolating valves closing until start-up ................. :

6. Transmitter wiring ........................................................................ :

7. Perfect watertightness of the packing gland .............................. :

8. Quality of air supply ..................................................................... : Instrument air dry and clean, water purged. Close the shut-off valve until start-up.

NAME : DATE :

QUALITY : SIGNATURE :

Honeywell Marine SAS 9, Rue Isaac Newton 18000 Bourges France Tel + 33 (0) 2 48 23 79 01 Fax + 33 (0) 2 48 23 79 03 E-mail: [email protected] www.honeywellprocess.com

MI5006E-rev05-ENG February 2013 © 2013 Honeywell International Inc.






maintenance - installation manual...the maintenance of the transmitter is described in the mm5006e...

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