Emerson Rosemount 3410 Series Programming manual

Maintenance and Troubleshooting manual

00809-0200-3104, Rev AA

April 2022

Rosemount™ 3410 Series Gas Ultrasonic Flow

meters

Models 3415, 3416 and 3417

Safety and approval information

This Rosemount product complies with all applicable European directives when properly installed in accordance with the

instructions in this manual. Refer to the EU declaration of conformity for directives that apply to this product. The EU declaration

of conformity, with all applicable European directives, and the complete ATEX Installation Drawings and Instructions are available

on the internet at www.emerson.com or through your local Emerson support center.

Information affixed to equipment that complies with the Pressure Equipment Directive, can be found on the internet at http://

www.emerson.com.

For hazardous installations in Europe, refer to standard EN 60079-14 if national standards do not apply.

Other information

Full product specifications can be found in the product data sheet. Troubleshooting information can be found in the user manual.

Product data sheets and manuals are available from the Emerson website at http://www.emerson.com.

Return policy

Follow Emerson procedures when returning equipment. These procedures ensure legal compliance with government

transportation agencies and help provide a safe working environment for Emerson employees. Emerson will not accept your

returned equipment if you fail to follow Emerson procedures. Return procedures and forms are available on our web support site

at Emerson.com, or by phoning the Emerson Customer Service department.

Emerson Flow customer service

Email:

•Worldwide: http://[email protected]

•Asia-Pacific: http://[email protected]

Telephone:

North and South America Europe and Middle East Asia Pacific

United States 800 522 6277 U.K. 0870 240 1978 Australia 800 158 727

Canada +1 303 527 5200 The Netherlands +31 (0) 704 136 666 New Zealand 099 128 804

Mexico +41 (0) 41 7686 111 France 0800 917 901 India 800 440 1468

Argentina +54 11 4837 7000 Germany 0800 182 5347 Pakistan 888 550 2682

Brazil +55 15 3413 8000 Italy 8008 77334 China +86 21 2892 9000

Central & Eastern +41 (0) 41 7686 111 Japan +81 3 5769 6803

Russia/CIS +7 495 981 9811 South Korea +82 2 3438 4600

Egypt 0800 000 0015 Singapore +65 6 777 8211

Oman 800 70101 Thailand 001 800 441 6426

Qatar 431 0044 Malaysia 800 814 008

Kuwait 663 299 01

South Africa 800 991 390

Saudi Arabia 800 844 9564

UAE 800 0444 0684

Contents

Chapter 1 Maintenance..............................................................................................................5

1.1 Precautions for meter maintenance.............................................................................................5

1.2 Field hydrostatic pressure testing procedures..............................................................................6

1.3 Routine maintenance.................................................................................................................. 7

Chapter 2 Troubleshooting...................................................................................................... 13

2.1 Meter status alarms................................................................................................................... 13

2.2 Troubleshooting the meter........................................................................................................16

2.3 Troubleshoot maintenance log files and trend files.................................................................... 36

Chapter 3 Meter repairs........................................................................................................... 41

3.1 Precautions prior to repairs........................................................................................................41

3.2 T-Slot transducer removal and installation.................................................................................44

3.3 T-Slot transducer holder removal and installation...................................................................... 53

3.4 T-200 transducer assembly removal and installation..................................................................58

3.5 T-200 transducer capsule assembly removal and installation..................................................... 61

3.6 T-200 transducer housing removal and installation....................................................................66

3.7 Transducer cable removal and installation................................................................................. 68

3.8 Replace the meter electronics....................................................................................................74

3.9 Acquisition Module replacement............................................................................................... 85

Appendix A Conversion factors................................................................................................... 91

A.1 Conversion factors per units of measurement............................................................................91

A.2 K-Factor and inverse K-Factor conversions.................................................................................92

Appendix B Engineering drawings.............................................................................................. 93

B.1 Rosemount™ 3410 Series Ultrasonic Flow Meter Drawings.........................................................93

Maintenance and Troubleshooting manual Contents

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Rosemount 3415, 3416 and 3417 3

Contents Maintenance and Troubleshooting manual

April 2022 00809-0200-3104

4 Emerson.com/Rosemount

1 Maintenance

1.1 Precautions for meter maintenance

This section includes discussion of the maintenance of Rosemount™ 3410 Series Ultrasonic

Meters.

For reference, you may download the MeterLink Quick Start Manual from:

emerson.com/en-us/catalog/measurement-instrumentation/meterlink.

CAUTION

SURFACE TEMPERATURE HAZARD

The meter body and piping may be extremely hot or cold.

Wear appropriate personal protective equipment when coming in contact with the meter.

Failure to comply may result in injury.

CAUTION

TRANSPORTATION HAZARD

When moving the meter, do not insert the forks of a forklift into the bore.

Inserting the forks may cause the meter to become unstable, resulting in injury or damage

to the bore and sealing face.

CAUTION

TRIPPING HAZARD

Clear all obstacles or obstructions from the work area when transporting, installing or

removing the meter.

Failure to clear the work area may cause injury to personnel.

Maintenance and Troubleshooting manual Maintenance

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Rosemount 3415, 3416 and 3417 5

WARNING

CRUSHING HAZARD

Do not remove flange stabilizers.

Attempting to do so could allow the meter to roll, resulting in serious injury or equipment

damage.

A. Flange stabilizers

CAUTION

ESCAPING FLUIDS HAZARD

The purchaser of the meter is responsible for the selection of Rosemount components/

seals and materials compatible with the chemical properties of the measurement fluid.

Failure to select suitable meter components/seals may cause escaping fluids, resulting in

injury or equipment damage.

WARNING

HEARING DAMAGE

Wear proper hearing protection before approaching a metering system that is generating

a large amount of audible noise. Obey all facility safety rules.

Failure to comply could result in temporary or permanent hearing loss.

1.2 Field hydrostatic pressure testing procedures

CAUTION

LEAKAGE OR PRESSURE CONTAINING PARTS FAILURE

Use precautions to eliminate hazards to personnel in the event of leakage or failure of the

gas ultrasonic meter pressure containing parts or failure of the test equipment and to

prevent over-pressurization during the test procedure.

Failure to comply may result in injury to personnel or cause damage to the equipment.

Maintenance Maintenance and Troubleshooting manual

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6 Emerson.com/Rosemount

1.2.1 T-Slot transducer assembly and mount

Procedure

1. Slowly vent all line pressure on the 3410 Series Gas Ultrasonic Meter to atmosphere.

2. Disconnect transducer cable from the transducer holder.

3. Loosen the T-Slot transducer assembly with a 1 1/4 inch (32 mm) wrench or socket.

Carefully remove the T-Slot transducer assembly.

4. Place a label on the transducer assembly to marks its location. Port locations are

marked on the transducer cable as well as on cast meter housings.

5. Apply a small amount of Nickel antiseize compound (P/N 3-9960-134) to the

threads of the Hydrotest plug from Hydrotest kit and install it into the mount.

Required kit part numbers are listed below.

Model 3415 Quantity 1 x 1-360-01-220

Quantity 1 x 1-360-01-221

Model 3416 Quantity 1 x 1-360-01-220

Quantity 1 x 1-360-01-222

Model 3417 Quantity 2 x 1-360-01-220

6. Repeat Step 3 through Step 5 for the other transducer(s) being careful to note the

location of each transducer in the meter assembly.

7. Run the field hydrostatic test.

8. Reverse the steps above to reinstall the transducers into their appropriate ports.

Before reinstalling the transducer assemblies, ensure the transducer ports, mounts,

and transducer holders are clean and free of debris. Apply a small amount of Nickel

antiseize compound to the outer threads of the transducer holders before installing

them into the mounts.

1.2.2 T-200 transducer assembly

The T-200 transducer assembly has full-metal structure and can remain in place during

field hydrostatic pressure test.

Procedure

1. Leave T-200 transducers installed on the 3410 Series Gas Ultrasonic Meter while the

line is pressurized.

2. Run the field hydrostatic test.

1.3 Routine maintenance

Routine maintenance operations requires adherence to all applicable regulations and laws

and safety training for personnel to perform the maintenance operations. Review your

organization's best practices procedures before performing routine maintenance.

Maintenance and Troubleshooting manual Maintenance

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Rosemount 3415, 3416 and 3417 7

1.3.1 Maintenance logs and reports

To monitor the performance health of the meter, and ensure it is operating within

acceptable specifications, routine diagnostics should be performed. Collecting a

maintenance log gives you a snapshot of the current health of the meter and you can

compare the inspection reports from previously saved logs. Use the Logs/Reports menu

and click Maintenance Logs and Reports. MeterLink™ displays the Maintenance Logs and

Reports dialog box. Choose the time duration, log format and collection rate for the

output file and click the Start button. You can open the file immediately after it is

generated or view it at a later time. It is recommended that a Maintenance log be

collected after an upset in the system.

In establishing a baseline to be used for the trending of the meter diagnostics, it is very

helpful if a set of log files are collected immediately after the meter has been installed in

the field. Preferably, collect the log files at several velocities within the operating range of

the meter. This helps establish that the flow profile is relatively constant throughout the

meters operating range (except velocities below 3 ft/sec where the profile may vary).

Maintenance log collection

Figure 1-1: Maintenance log collection parameters

Trend maintenance log collection

Merging the results of two or more Maintenance logs into a single file, allows you to build

a historical database of the meter's performance. Trending the logs indicates changes

Maintenance Maintenance and Troubleshooting manual

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8 Emerson.com/Rosemount

from the original installation of the meter, or over time. Looking at a single inspection

report, that is either collected monthly or quarterly, can give you an indication of the

meter's health.

Figure 1-2: Trend log collection

This is important since many diagnostics change slowly overtime. Trending the

maintenance logs helps identify these changes and makes problems much more obvious

than merely viewing a single inspection report. The Trending feature is integral to

MeterLink™ which allows all important parameters to be trended. MeterLink supports

trending files in a Microsoft® Excel ® workbook from multiple 3410 Series meter

maintenance logs. Some parameters like gain, signal level,and noise level may show a shift

over time which can be useful in detecting changes in the meter and the installation.

Maintenance logs or Trend files to be trended must all have matching column headings.

This means the logs must be in the same units (i.e. U.S. Customary or Metric), must have

the same pressure type (i.e. gage or absolute), and must have the same time base (1/

second, 1/minute, 1/hour, 1/day). If not, an error message will be displayed stating the

column headings do not match and the file will not be added to the Workbook to trend

list.

Archive log collection

Archive logs may be collected and the options include:

•Daily log - generated every 24 hours on the Contract Hour

•Hourly log - generated every hour at the top of the hour

•Event log - collects the alarm and event log records

Maintenance and Troubleshooting manual Maintenance

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Rosemount 3415, 3416 and 3417 9

Figure 1-3: Archive log collection parameters

The logs may be collected in a single file or you can choose to collect one type of log. Each

of the Meter Archive logs include the Meter Configuration file.

1.3.2 Pipe cleaning maintenance

WARNING

BURST HAZARD

Before pipeline cleaning and maintenance ("pigging operations"), remove straightening

vanes or flow conditioners.

Failure to comply may cause excessive pressure in the meter system, resulting in death,

serious injury or equipment damage.

Figure 1-4: 3410 Series Gas Ultrasonic Flow Meter with flow conditioner for uni-

directional flow

A. Flow Conditoner: Rosemount™ Profiler, CPA 50E or CPA 55E

Figure 1-5: 3410 Series Gas Ultrasonic Flow Meter with flow conditioner for bi-

directional flow

1. Flow Conditioner: Rosemount Profiler, CPA 50E or CPA 55E

2. Flow Conditioner: Rosemount Profiler, CPA 50E or CPA 55E

Straightening vanes or flow profilers must be removed during pipeline cleaning

maintenance operations (“pigging operation”). If the meter run is pigged with a flow

conditioner in line, pressure may build up and cause the pipes and flanges to burst and

severely injure personnel. The excessive pressure may damage the meter or the

Maintenance Maintenance and Troubleshooting manual

April 2022 00809-0200-3104

10 Emerson.com/Rosemount

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