INSTRUMENT LEARNING MATERIAL PETRONAS

CARIGALI

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DUTY: 02 MAINTAIN AUXILIARY INSTRUMENT DEVICES

TASK: 02.04 PERFORM LIMIT SWITCH FUNCTIONAL CHECK

DUTY 05 MAINTAIN EMERGENCY SHUTDOWN SYSTEM

TASK 05.07 PERFORM ELECTRICAL FLOW SWITCH FUNCTION CHECK

TABLE OF CONTENTS

1.0 PURPOSE OF LIMIT SWITCH 2

2.0 FUNCTION OF LIMIT SWITCH ON VALVES 2

2.1 ELECTRICAL OPERATED LIMIT SWITCH 4
2.1.1 ELECTRICAL OPERATED MECHANICAL LIMIT SWITCH 4
2.1.2 INSTALLATION OF POSITION INDICATOR HOUSING TO
ACTUATOR 5
2.1.3 CHECK ON ELECTRICALLY OPERATED MECHANICAL LIMIT
SWITCH 6
2.1.4 ELECTRICAL OPERATED PROXIMITY LIMIT SWITCH 7

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1.0 PURPOSE OF LIMIT SWITCH

Limit switches are installed on valves for the purpose to monitor valves position. It is
installed on ABVs’ actuator and some are also installed on critical control valves’
traveling stem which are essential to the process or equipment control. These limit
switches are also installed on moving equipment to prevent overshoot of the moving
movement. Example of this is the crane movement. Some vital doors on equipments or
rooms also have limit switch installed that will trigger an alarm if the doors are opened.
Usage of these limit switches are not limited to the example given here. The material
below used the valves as an example to explain the function of the limit switch.

2.0 FUNCTION OF LIMIT SWITCH ON VALVES

These limit switches are installed on valves’ actuator to monitor the valve fully open and
fully close position. The command to open and close the valve come the control
monitoring system. With limit switches installed on these valves’ actuator, it gives a
feedback to the control monitoring system on the position of these valves. A fully closed
position valve will indicate Red colour and a fully opened position valve will indicate
Green colour on the control monitoring system display screen.

Some control monitoring system even compared the output or demand signals to valve
with the feedback signals from the valve position limit switches. When the control
monitoring system gives an output signal to open the valve, it expected the valve open
limit to give a correct feedback signal. If these two signals do not match, the control
monitoring system will display yellow flashing valve indication on the display screen.

With advance programmable control monitoring system, it can configure the valve to
display other type of indication on its display screen for other mismatch signals between
demand and feedback signals.

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Some valve limit switches are tied-in to the control monitoring system for valve position
indication status only and some for both indication and sequence control of equipment
like compressors, pumps, switching of process separators and lines and etc.

In compressor sequential control, it monitors all the main ABVs for pre-start up position,
purging sequence, pressurizing sequence, fuel supply on and running condition. Any of
these main ABVs that went out of position before start-up can prevent the unit from
getting the permissive to start the unit. During starting sequence, any failure of the valve
limit switches will stop the start up sequence by incomplete starting sequence. All main
ABVs’ actuator limit switches failure will trip the compressor.

Critical Surge and Capacity control valves that protect the compressor are monitor by
the compressor control system. These control valves are stroke by the compressor
capacity and surge controllers during the start up sequence. The valve limit switches
have to be in good operating condition since these valves are required to travel from
one end of travel to the other position in less than 2 seconds.

Compressor valves position monitoring screen

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2.1 ELECTRICAL OPERATED LIMIT SWITCH

2.1.1 ELECTRICAL OPERATED MECHANICAL LIMIT SWITCH

For electrical operated limit switch, the mechanical type is the most common used.
Mechanical SPDT switches are the most common switches used due to their low cost
and proven reliability for general-purpose applications. This type of switch has the same
operating principle as any switch contacts. Each switch has three contacts, Common,
Normally Open and Normally Closed contacts.

It has a flapper or plunger on its body which when pushed against by the rotating cam
will change the contacts of the limit switch.

Two pieces of valve limit switches are required, one piece to monitor the fully open
position and the other piece to monitor the fully close position. Also two pieces of cam
on the valve position indicator’s rotating shaft. These cams are fastened to a splined
shaft and can be set by hand within a few seconds.

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These components and the terminal strip are all inside the protective cover of valve
switch housing. On top of the housing is the indicator which is also connected to same
shaft as the rotating cam. This indicator gives a local visual indication of the actuator
position.

Indicator position on the valve position indicator housing

Picture of a complete valve position indicator housing

2.1.2 INSTALLATION OF POSITION INDICATOR HOUSING TO ACTUATOR

Attached the position indicator housing to the correct mounting bracket and connect its
rotating shaft to the actuator indicating stem via piece of adaptor.

With the actuator in closed position, lift the bottom cam and turn until the switch has
activated and then release. The spring will push the cam back onto the splined shaft.
That is, the closed position limit switch in closed contact in its loop.

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Then stroke the actuator to fully open position. Push down on the top cam and turn until
the open limit switch has activated and then release. That is, the open position limit
switch in closed contact in its loop.

Operate the actuator from one end of stroke to the other several times to confirm limit
switch operation is correct.

2.1.3 CHECK ON ELECTRICALLY OPERATED MECHANICAL LIMIT SWITCH

The field wirings are connected to the Common and Normally Open contacts of the limit
switch. When limit switch activated, the contact should closed as designed to be in
failed safe mode.

Use the multimeter’s ohm-meter or continuity range to check the status of the switch
contacts with the actuator from one end of stroke to the other end of stroke. This is for
limit switch that has its field wirings isolated.

Misalignment of the cam on the rotating shaft can cause the valve limit switch to
malfunction. This can be corrected by realignment back the cams to the splined shaft
and can be set by hand within a few seconds.

Problem with valve movement, actuator movement, loose adaptor and faulty limit switch
itself can also cause the valve limit switch not to indicate correctly.

Instrument loops are normally power by 24 volts DC and the description on this limit
switch contacts checking here is based on this voltage. The powered field wirings has
24 volts DC for open contact and 0 volt DC for closed contact.

Some other instrument loops have different supply voltage to field instruments, example
to Intrinsically Safe zone instrumentations with the usage of Intrinsically Safe safety
barriers. Refer to your equipments drawings on the type of supply voltage to your field
instruments.

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2.1.4 ELECTRICAL OPERATED PROXIMITY LIMIT SWITCH

Inductive sensors are "solid state" (without moving parts) and are the most reliable of
sensing methods, with a MTBF over 20 million cycles. Inductive Sensors have three
parts of operation - the oscillator, triggering circuit and switching amplifier. The oscillator
generates a high-frequency electromagnetic field in the sensor's target area. When a
ferrous metal target enters the electromagnetic field (target area), eddy currents created
in the target by the oscillator increase the load on the oscillator. At a specific load, the
trigger circuit senses the reduction in oscillation and signals the switching amplifier to
change the signal. Inductive Sensors consume electric power to operate, and must
have approval to be used in hazardous areas.

NAMUR inductive sensors operate without the amplifier circuitry in the sensor, allowing
use in all hazardous areas. The required signal amplifier must be installed externally in
the safe area. NAMUR Inductive Sensors are rated Intrinsically Safe and must be used
with an approved current and voltage-limiting barrier.

Pepperl & Fuchs NJ2-V3-N limit switch sensors

• 3-wires DC basic inductive proximity sensors

• 2mm sensing range
• Flush mountable
• NAMUR output
• Intrinsically safe when connected to an approved switch isolator

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This Pepperl & Fuchs NJ2-V3-N sensor gives a voltage of around 3 volts DC when
measured across its terminals if the ferrous metal target enters the electromagnetic field
(target area) of the sensor. When it is out of target area, the voltage measured is around
7 volts DC.

Wirings from the termination strips is connected to a switching amplifier on a control

panel located inside a safe area. There are types of limit switch that are available in the
market like the Magnum Barrel hermetically sealed switch shown below.

There are various type of electrical operated switch used. Important is to know the
voltage values when the electrically operated limit switch “make” and when the switch
“open”. This will greatly assist in troubleshooting with the limit switch problems.

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DUTY: 02 MAINTAIN AUXILIARY INSTRUMENT DEVICES

TASK: 02.04 PERFORM LIMIT SWITCH FUNCTIONAL CHECK

05 MAINTAIN EMERGENCY SHUTDOWN SYSTEM

05.07 PERFORM ELECTRICAL FLOW SWITCH FUNCTIONAL CHECK

TABLE OF CONTENTS

1.0 INTRODUCTION 11

2.0 USAGE OF FLOW SWITCHES 11

3.0 WORKING PRINCIPLE OF FLOW SWITCH 16

3.1 MECHANICAL TYPE FLOW SWITCH
16
3.1.1 VANE ACTUATED FLOW SWITCH WORKING PRINCIPLE
16
3.1.2 DISC ACTUATED FLOW SWITCH WORKING PRINCIPLE 19
3.1.3 INSTRUCTION FOR INSTALLATION AND ADJUSTMENT OF
MECHANICAL FLOW ACTUATED ELECTRICAL SWITCHES
20
3.1.4 CALIBRATION ON MECHANICAL TYPE FLOW SWITCH 21
3.1.5 OPTIONS AVAILABLE FOR MECHANICAL TYPE FLOW SWITCH 23
3.1.5.1 AIR OPERATED MECHANICAL FLOW SWITCHES 23
3.1.5.2 MULTIPLE ACTUATION FLOW SWITCHES 23
3.1.5.3 TIME DELAY OPTION 24
3.2 ELECTRONIC TYPE FLOW SWITCH 25
3.2.1 USING THERMAL DISPERSION WHICH OPERATES ON THE BASIS
OF HEAT TRANSFER (WORKING PRINCIPLE) 25
3.2.1.1 ADVANTAGES OF THERMAL MASS FLOW TECHNOLOGY 26
3.2.1.2 ELECTRICAL CIRCUIT BOARD ASSEMBLY FOR FT70 THERMAL
DISPERSION FLOW SWITCH 27

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3.2.1.3 INSTALLATION RECOMMENDATION 28
3.2.1.4 CALIBRATION ON FT70 THERMAL DISPERSION FLOW
SWITCH 29
3.2.1.4.1 ALARM SET POINT ADJUSTMENT BY OBSERVATION 30
3.2.1.4.2 ALARM SET POINT ADJUSTMENT BY MEASUREMENT 31
3.2.1.5 MAINTENANCE AND TROUBLE SHOOTING ON FT70 SENSOR
PROBE 33
3.2.1.6 NEWER MODEL OF THERMAL DISPERSION FLOW SWITCH 34
3.2.2 CLAMP-ON ULTRASONIC FlOWMETERS – MEASURING PRINCIPLE 35
3.3 DIFFERENTIAL PRESSURE TYPE FLOW SWITCH 37
3.3.1 INDICATING SWITCH 38

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3.0 INTRODUCTION
Flow switches are use to detect low, high or reverse flow in the process and utility lines.
The flow-actuated switches commonly used in our plant are the mechanical and
electrical type of flow switch.

Another type of flow-actuated switch which is available in the market is the ultrasonic
flow meter. This meter measured flow the flow measurements are made by penetrating
the pipe with ultrasound.

Differential pressure unit that measure differential pressure or flow across a primary
element on the line is also used as a flow switch.

4.0 USAGE OF FLOW SWITCHES

Here are some examples on the usage of flow switches in our oil and gas industries.

Seal detection
Rotating equipment, such as pumps, typically use a seal system to prevent process
fluids from leaking into the atmosphere. These seals are charged with either an inert
gas or a liquid similar to glycol.

Inline flow switch is typically installed in the line feeding fluid to the pump to detect the
extremely low flow volumes consumed by a normal operating seal. When a seal
deteriorates, the leakage flow volume increases and is detected by the switch
immediately activating a set point alarm for the operator to schedule an overhaul of the
seal before actual contamination of process fluid appears.

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Pump protection
Pumping systems are extremely important to the safety and economical operation of
plants. Demand is very high for plant systems to be 100% operational with minimal
downtime. As a result, flow monitoring for reliable and trouble-free pump protection is a
necessary requirement. Flow switch detects extremely low flow rates which can prevent
the potential for pump run dry events. Preventative flow monitoring extends the pump
lifecycle and increases the intervals between scheduled maintenance. Some flow
switches features two adjustable alarms that can be set at low flow and no flow
(indicating an empty pipe). The flow switch is optimally installed in the feed line or
discharge line of the pump.

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Flare/waste gas monitoring
Flow switch can be installed to monitor flow on line to flare stacks or in feed lines to the
main flare headers as an integral part of energy conservation and emission control
systems. An optional retractable packing gland assembly permits hot tap installation
and retraction of the flow element without system shutdown.

Relief valve flow monitoring

When installed in lateral lines or downstream of relief valves feeding into the main flare
header, the flow switch can quickly and precisely indicate the source of flare gas
thereby allowing the plant operator to readily identify problems in the process. As a
relief valve monitor in flare systems or other processes, the switch can be calibrated to
detect product "blowdown" and leakage using the standard product features for sensing
wide flow ranges and two set point alarms.

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Chemical injection/additive flow monitoring
Flow switch can be installed to monitor chemical and other additive injection flow.
Optional dual switch point circuitry helps maintain product quality and process safety by
alarming both high flow and low flow conditions. Any abnormality detected by the flow
switch will be detected by the control system to stop the chemical injection pump.

Automated oil well testing systems

Flow switches have continued to play a key role in the automation of oil well testing
facilities in some plants in the United States. It monitors the flow of crude oil from the
well, so that non-producing sites can be quickly identified and corrected. In addition to
improving productivity, this efficient no-flow detection system eliminates time wasted on
the continued testing of non-producing wells.

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Reverse flow switching
Nitrogen is utilized for purging and blanketing throughout a chemical plant /refinery. The
possibility of contaminating the nitrogen supply with hydrocarbon gas exists if the
pressure at the destination becomes greater than the pressure at the source. The bi-
directional flow switch is used to shut down the supply line if flow is detected returning
back to the supply tank.

Fire water sprinkler system

Flow switches are used to monitor flow on fire water sprinkler lines whenever sprinkler
bulb has been broken when fire has occurred inside a room. These flow switches are
normally tied-in to the Fire and Gas panel and when the flow switch triggered, the panel
will activate platform alarm and fire water pump to kick-in.

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5.0 WORKING PRINCIPLE OF FLOW SWITCH

5.1 MECHANICAL TYPE FLOW SWITCH

Mechanical flow actuated switches are simple mechanical devices activated by flow.
The desired flow indication - increase, decrease, reverse - is transmitted mechanically
from the line media by deflection of the paddle through the stem and bellows or flexure
tube assembly, causing micro-switch actuation and resultant electrical contact for
transmission of signal to whatever ultimate point desired.
Movement and friction are quite minute, giving longer life with accurate repetition. It is
designed with minimal pressure drop, available in any electrical rating desired, any type
of connection, various type of paddles shapes, wide ranges of pressure rating, made of
most type of metals and also available in Teflon® and plastics materials.

5.1.1 VANE ACTUATED FLOW SWITCH WORKING PRINCIPLE

Flow through the horizontal pipeline causes the pivoted vane assembly to swing in the
direction of the flow. The vane assembly lifts an attraction sleeve which in turn causes
the magnet to pull in and actuate the switch.

The o-ring sealed adjusting screw in the top of the enclosing tube compresses the
range spring located above the attraction sleeve. Turning the adjusting screw clockwise
increases the flow rate at which the switch actuates.

Adjustments can be made while the flow switch is in service. The switch can be Mercury
Switch or Micro Switch.

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Below is another picture of vane actuated flow switch which has the same working
principle as the vane switch described above.

The flow of liquid or gas through a pipeline applies a force to a flow vane of flow switch
that inserted into the pipeline. Sufficient flow through a pipeline causes the pivoted vane
assembly to swing in the direction of the flow or parallel to the flow. This movement
causes an attraction sleeve to move into the field a magnet.

This in turn raises the magnetic sleeve, within its sealed non-magnetic enclosing tube
into the field of the switch magnet, located outside the enclosing tube, actuating the
attached mercury switch mechanism or Micro Switch.

The o-ring sealed adjusting screw in the top of the enclosing tube compresses the
range spring located above the attraction sleeve. Turning the adjusting screw clockwise
increases the flow rate at which the switch actuates.

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Cut-a-Way of PEECO Flow Switch Model ET

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5.1.2 DISC ACTUATED FLOW SWITCH WORKING PRINCIPLE
The flow of liquid or gas through a pipeline applies a force to a flow disc on the flow
switch body that is inserted into the pipeline. Sufficient flow through a pipeline causes
the flow disc assembly to lift up in the direction of the flow.

The flow disc moves the attraction sleeve up within the field of a switch magnet, drawing
it in tightly to the enclosing tube. This causes the Micro Switch to make or break an
electrical circuit. When the flow rate drops, below the rate for which the flow disc is
calibrated, the attraction sleeve is pulled downward until, at a predetermined low flow
rate, the Micro Switch magnet releases and swings outward, away from the enclosing
tube, causing a reversal of the switching action. The switch can be Mercury Switch or
Micro Switch.

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5.1.3 INSTRUCTION FOR INSTALLATION AND ADJUSTMENT OF MECHANICAL
FLOW ACTUATED ELECTRICAL SWITCHES
(Taken from PEECO manual)

A. - Micro Switch Adjusting Rod

B. - Return Spring
C. - Micro Ball Bearings

1. Optimal installation will allow straight run of pipe for 10 diameters upstream and 5
diameters downstream. The switch can be successfully installed in less than
optimal conditions. The additional turbulence can be compensated for by careful
attention to selection of return spring and perhaps shorter paddle length (see
note 5).
2. Switch can be mounted in any position rotational on the axis of the pipe. If
vertical piping - adjust for gravity with spring tension (B).
3. Tee models install directly in the pipe run. Do not alter paddle.
4. Screwed models are to be installed with a weld-a-let, thread-a-let, or half
coupling.
5. Cut paddle length to within approximately 1/2" clearance from the bottom of the
pipe. Contour corners as necessary to insure no contact with pipe. The flexible
paddle should always be within the run of pipe. If a riser is present, the 3/8"
round stem should run the length of the riser before the point of paddle
attachment.
6. Mount switch with conduit connection downstream (pointing in the direction of
flow).
7. IMPORTANT - BEFORE CONNECTING CURRENT, COVER MUST BE
TIGHTLY CLOSED.

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8. Switch adjustment (see note 9) should be made in the middle of the physical
range of movement.

5.1.4 CALIBRATION ON MECHANICAL TYPE FLOW SWITCH

New flow switches are normally pre-set at the factory as per our ordering specification.
We have to specify the flow trip set point and other important parameters like, the
medium passing through the flow switch, the operating pressure and temperature and
the nominal flow through the switch.

On site calibration or checking can be carried out as these flow actuated electrical
switch is completely field adjustable. Another flow measuring device is required to
monitor the actual flow rate on the same line as the flow switch. Example of these flow
measuring devices are a flow transmitter, Kenco gauge on suction of chemicals pump to
measure the pump discharge flow. With these flow measuring devices, we can counter
check the flow trip setting during checking on the flow switch.

If there is no other flow measuring device available, the flow switch needs to be
removed from site and test in the workshop.

Procedures below based on PEECO flow actuated electrical switches.

a. Disconnect current for those using the electrical micro switch contacts.
NOTE : For these flow switches tied-in to plant shutdown system, we are
required to put it on inhibit before testing the flow switch.
b. Remove switch cover and remove the wirings from the switch.
c. Connect multimeter to terminal block and measure the resistance of
switch either in open contact or close contact depend of system
requirement.
d. Apply process flow at desired set point to the pipeline. This can be counter
check by using an flow rate measuring device.
e. Screw actuating rod (A) in or out to point at which micro switch clicks or
the contact changes. Insert a screwdriver into the adjustment screw and
turn screw clockwise until break an electrical circuit. If the micro switch is
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already open contact, turn the screw counterclockwise until the micro
switch closes contact and vice versa. These adjustments increases or
decrease tension on return spring as necessary to overcome spring
balance.
f. Adjustments can be made while the flow switch is in service.
g. All turns should be done carefully and in small steps.
h. Retest the flow switch again to ensure that its flow trip setting has good
repeatability and also it can reset.
i. After completing the checking, terminated back the wirings and screw
cover on tightly before reconnection current.

Return springs (B) may be changed as needed for greater or lesser tension (higher or
lower flows). Springs are color coded only as to varying weight or tension - not as to
quantitative flow range.

Do not disassemble switch components before relieving pressure.

Time delay of the pot can be adjusted by screwing in (shortening time) or out
(lengthening time) the small orifice plug at rear of cylinder on the Dashpot. Do not
tamper with any other part of the dashpot.

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5.1.5 OPTIONS AVAILABLE FOR MECHANICAL TYPE FLOW SWITCH

5.1.5.1 AIR OPERATED MECHANICAL FLOW SWITCHES

Where electrical contacts are not permitted or where pneumatic operation is preferred,
air operated switching mechanism is available in the market. It used the principle of
flapper and nozzle to trigger the pneumatic signal.

It is identical in function and specification to conventional electrical micro-switch

actuation units.

5.1.5.2 MULTIPLE ACTUATION FLOW SWITCHES

By special use of two or more (up to 6) micro-switches, flow actuated electrical switches
will indicate such combinations as:
(1) Flow / No flow
(2) Two different flow actuation points.
(3) Independently or simultaneously adjustable.
(4) Flow / Reverse flow

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5.1.5.3 TIME DELAY OPTION
Modular Time Delay used where operations require an integral unit with longer delay
before actuating and completing circuitry. Self-resetting timer allows delay from 6
seconds to 24 hours -- as required.

Micro switches can be used independently of and/or in conjunction with time delay. Fire
water sprinkler system used this type of time delay option flow switch to prevent
spurious alarm when there is fluctuation in fire water supply when firewater pumps kick-
in.

Other option available to prevent the pulsating action of positive displacement pumps on the

process line is to use stem dampeners. It have damping action on the stem itself with a special

built-fully adjustable dampener.

This is an improved, more rugged method of damping turbulence, pulsations, and

surges, thereby preventing false actuation signals.

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5.2 ELECTRONIC TYPE FLOW SWITCH

The materials for this electronic type flow switch is taken from Fluid Components
International LLC flow switch model FR70 which is used at Baronia’s Water Injection
module. The fundamental principle of thermal dispersion flow switch is explained below
which is similar to other type of thermal dispersion flow switch.

5.2.1 USING THERMAL DISPERSION WHICH OPERATES ON THE BASIS OF

HEAT TRANSFER (WORKING PRINCIPLE)

The probe consists of two separate sensor components, both RTDs. One RTD is the
reference and measures the temperature of the fluid where the probe is immersed. The
second RTD is self-heated at a constant power. This creates a temperature difference
between the two RTDs. Varying the set point changes the power to the heated RTD
which enables the user to adjust the set point for the specific Application.

The set point is increased to provide a temperature difference under a low flow or no
flow condition. As the flow rate increases, there is a cooling effect due to the fluid
moving past the heated sensor; the more flow, the more the cooling.

A reduction in temperature difference between the two RTDs indicates that the flow rate
exceeds the set point. When the flow rate drops, there is less cooling causing an
increase in the temperature difference.

Example above shows twin RTD sensors to sense process change in flow application.
One sensor measures surrounding process temperature to provide a temperature
reference. The second sensor is self-heated to establish a temperature differential
above the reference temperature.

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In flow application when there is an increase in velocity, the cooling effect of contacting
media reduces the temperature difference between the RTDs. The decrease in
temperature differential triggers a relay action.

The Sensor Probe Assembly is constructed of 316 stainless Steel with Nickel Braze and
designed for easy in-line installation (available in a variety of process connections).

Newer models sensing element contains two thermowell-protected precision platinum

Resistance Temperature Detectors (RTDs).

When placed in the process stream. The temperature differential has an exponential
relationship with the mass flow rate of the process media. The sensitivity of this device
is such that minute changes in the process media flow rate will alter the heat transfer
path between the heater and active sensor. Change in temperature differential is
measured by a bridge balance circuit and output as an analog voltage signal.

5.2.1.1 ADVANTAGES OF THERMAL MASS FLOW TECHNOLOGY

It supports virtually all gas or air measurement needs. It is especially well suited for dirty
gas because of its no-moving parts design with no orifices, bearings, or seals,
constructed with all welded materials, no pressure drop since no paddle on the line,
offer wide flow range and has low flow capability. It also has a field adjustable switch set
point.

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5.2.1.2 ELECTRICAL CIRCUIT BOARD ASSEMBLY FOR FT70 THERMAL
DISPERSION FLOW SWITCH
The basic functions of the control circuit are to provide power to the flow element,
measure the DR between the two RTDs, condition the sensing point signals, and
provide relay alarm contacts for customer uses.

Single pole double throw (SPDT) or double pole single throw (DPST) relay(s) are
available in the instrument for connections to the customer alarm systems. The relay
outputs can be programmed to be either open or closed when the sensing point is low
or no flow and closed or open when the sensing point is at high flow.

The place where the relays change state will vary depending on the type of media as
well as air or liquid turbulence. Therefore the instrument has field adjustable alarm set
points.

The standard FR70 electrical assembly (C.B. #5181) provides one SPDT relay that can
be field adjusted to switch at any signal level. An LED (Light Emitting Diode) on the
circuit board will indicate if the actual flow signal is above the switch point setting. The
relay can be energized or de- energized at no-flow. Energization of the relay is easily,
changed by moving a pluggable jumper on the circuit board.

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An optional Electrical Assembly (C.B. #5281) is available that provides two independent
Field Adjustable Switch Point relays. With two switch point relays, a high and low flow
alarm system can be setup two stage alarm, or a fail- safe alarm system. This assembly
also has pluggable jumpers to select relay energization.

5.2.1.3 INSTALLATION RECOMENDATION

Install the flow element in the process piping at the desired location. When the flow
element is mounted horizontally verify that the flat surface that has the flow arrow is
mounted up and level. The flow is to be in the direction of the arrow. When the flow
element is mounted vertically verify that flow is in the direction of the flow arrow.
(Downward flow is not recommended.)

All FR70s in horizontal flow liquid service MUST have a vent/bleed port.
Insertion type of thermal dispersion flow switch

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Inline type of thermal dispersion flow switch

5.2.1.4 CALIBRATION ON FT70 THERMAL DISPERSION FLOW SWITCH

New flow switches are normally pre-set at the factory as per our ordering custom
calibration specification. If the order included custom factory calibrations and alarm set
points, keep all settings unchanged. The instrument is ready for service without
changes.

If the factory calibrations were not ordered, on-site calibration or checking can be
carried out as it is field adjustable.

If precise measurement is desired, FCI recommends that an FM71 Monitor/Calibrator

be used. Then the precise measurement of the signal voltage versus flow rate can be
calculated for the alarm set points.

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5.2.1.4.1 ALARM SET POINT ADJUSTMENT BY OBSERVATION
Alarm set point can be adjusted by observation and the following procedure is for FR70
flow switch with electrical assembly (C.B. #5181) that provides one SPDT relay (one
alarm set point).
1. Flow the pipeline at the desired rate of flow. Flow rate can be counter check with
another flow measuring device or the used of Kenco gauge on the suction of
chemicals pump to measure the pump discharge flow.
2. Apply power to the instrument and allow 15 minutes for the sensing element to
become active and stabilize.
3. Locate the potentiometer (R5) and the red LED on the control circuit. (See Figure
FR70 electrical assembly C.B. #5181)
4. Choose A or B below depending on the purpose of the flow switch.

A. Detecting No Flow or Decreasing Flow Rate

If the LED is off, turn the potentiometer clockwise until the LED turns on. If the LED is
on, turn the potentiometer counterclockwise until the LED turns off, then turn the
potentiometer clockwise until the LED just turns on.

With the LED on, turn the potentiometer slowly counterclockwise until the LED just turns
off. Turn the potentiometer one-half turn past the point at which the LED just turns off.
Be aware that the potentiometer may have up to one quarter turn of hysteresis. If the
mark is overshot, the procedure should be repeated. (See Figure FR70 electrical
assembly C.B. #5181)

B. Detecting Maximum Flow or Increasing Flow Rate

If the LED is on, turn the potentiometer counterclockwise until the LED turns off. If the
LED is off, turn the potentiometer clockwise until the LED turns on, then turn the
potentiometer counter clockwise until the LED just turns off.

With the LED off, turn the potentiometer slowly, clockwise until the LED just turns on.
Turn the potentiometer one-half turn past the point at which the LED just turns on. Be
aware that the potentiometer may have up to one quarter turn of hysteresis. If the mark
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is overshot, the procedure should be repeated. (See Figure FR70 electrical assembly
C.B. #5181)

Setting Alarm Set Points

5.2.1.4.2 ALARM SET POINT ADJUSTMENT BY MEASUREMENT

The following procedure is for FR70 flow switch with electrical assembly (C.B. #5181)
that provides one SPDT relay (one alarm set point).

The FM71 Monitor/Calibrator is an extremely useful tool for calibrating and monitoring
FCI FT70 flow switches. In the Monitoring mode, the unit displays precise millivolt
readout of the output signal produced by the flow switch. The output signal level is a
function of the flow’s rate and is used to determine the flow velocity.

Using the Calibrate mode, the actual output signal can be overridden with a calibration
test signal which can be used to verify the switch point settings and operation of the
interface circuitry. The FM71 plugs directly into the electrical assembly circuit board with

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a 10 foot cable and operates off, power from the flow switch (NO external power
required).
1. Turn power ON and allow 15 minutes for the sensors to stabilize.
2. Depending on your option selections, you may have 1 or 2 switch point
relays that can be set to activate at any signal level through your flow
range.

Record the switch point settings (signal voltages) that you have chosen for the switch
point relays to actuate at the required flow trip set point. This data will be quite useful in
the future when it is necessary to verify proper operation of the switch.
It good also to record the reset switch point.

Record Your Findings

Flow Setting Flow Setting
Tripped Reset

SWITCH POINT SIGNAL LEVELS IN MILLIVOLT

Switch Point No.1 (Red LED)

SETTING SWITCH POINTS

1. Switch point Relay No 1 is adjusted by potentiometer R5. A red LED (light
emitting diode) will indicate when the flow rate is above the switch point. In ALL
cases, the LED’s will be ON when the output signal is higher than the switch
point setting.
2. The switch point relay have the option of being de-energized or energized at No-
Flow by means of a pluggable jumper located on the circuit board.
3. To set a switch point relay for a specific flow, establish the desired flow rate and
allow the output signal to stabilize while maintaining that flow rate.

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4. If the LED is ON, turn the adjustment potentiometer counter-clockwise until the
LED goes OFF.

Slowly turn the, adjustment potentiometer clockwise until the LED just turns ON and
stop. The switch point is now set to activate at the signal produced by that flow rate.

The Switch Point setting will have a 5 mV dead band one turn on the potentiometer will
equal approximately 100 Mv. You may seal the Switch Point Potentiometer(s) after the
final adjustments have been made.

5.2.1.5 MAINTENANCE AND TROUBLE SHOOTING ON FT70 SENSOR PROBE

To check the sensor probe assembly, turn power and remove the circuit Board. The
Circuit Board is plugged into a 12 Pin Socket; pull outward on the transformer handle
while gently rocking from side to side. With the Circuit Board removed, measure the
resistance of the sensors and heater with an ohmmeter. It may take a few minutes for
the sensors to cool and stabilize at the process temperature.

Sensors ===> 4000 ohm (approx. value at sensor probe). Variation of ±100 ohms from
nominal is to be expected, depending on temperature.

Reference Sensor is on Socket Terminals No.8 and 9. Active Sensor is on Socket

Terminals No.7 and 8.

The Active and Reference Sensor resistance should not be equal. Please refer to FCI
manual for the correct resistance value based on the model used. Below is an example
of flow element resistances In ohms.

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*Resistance varies with temperature. These values should be ±5 ohms at 70 °F (21 °C).
Heater ===> 221 ohm 1% (at the sensor probe) Heater is on Socket Terminals No.7
and 10.

This is a good method to verify that the sensor probe is in Working order. If the
measurements are out of tolerance, or indicate an open or short circuit in any of the
elements, the Sensor Probe Assembly will require repair or replacement.

NOTE: The resistance value of an RTD sensor will increase slightly at temperatures
above 70 degrees F.

5.2.1.6 NEWER MODEL OF THERMAL DISPERSION FLOW SWITCH

Newer model of thermal dispersion flow switch, example FCI’s FLT93 Series has
temperature compensation that allows the alarm set points to be set for seasonal
operating temperature ranges or start-up conditions. Thus it prevents false alarms or
alarm failure.

It also has built in inherent thermal time delay to prevent false alarms caused by flow
pulsation which eliminates the need for auxiliary time delay relays.
Newer Control Circuit Functional Diagram (C.B 5294)

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This control circuit has dual alarms setting which are field-configured to fail-safe when
used for flow rate. Set points may be configured to provide failure information of sensing
element assembly as well as control circuit electronic failure.

5.2.2 CLAMP-ON ULTRASONIC FlOWMETERS – MEASURING PRINCIPLE

The flow measurements are made by penetrating the pipe with ultrasound. Time
differences, frequency variations or phase shifts of the ultrasonic signals caused by the
flowing liquid are subsequently evaluated.

The measurement of flow is based on the principle that sound waves traveling in the
direction of flow of the fluid require less time than when traveling in the opposite
direction. The difference in transit times of the ultrasonic signals is an indication for the
flow rate of the fluid.

Since ultrasonic signals can also penetrate solid materials, the transducers can be
mounted onto the outside of the pipe.

Fast digital signal processors and sophisticated signal analysis guarantee reliable
measuring results even under difficult conditions where previously ultrasonic flowmeters
had failed.
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Transit-time principle.
Transit-time flowmeters utilize two transducers, which function as both ultrasonic
transmitters and receivers. The transducers are clamped to the outside of a closed pipe
at a specific distance from each other. This distance is calculated by the flowmeter after
all pipe and medium parameters have been entered into the instrument.

Reflection Mode Diagonal Mode

The transducers can be mounted in reflection or in diagonal mode. This selection is
based on pipe and liquid characteristics.

The flowmeter operates by alternatively transmitting and receiving ultrasonic signal

pulses between the two transducers. The ultrasonic signals are first transmitted in the
direction of the fluid (1) and then against fluid flow (2). Since sound energy in a moving
liquid is carried faster when it travels in the direction of flow than against it, a time

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difference (3) between the signals' time-of-flight will occur. If the fluid is not moving, the
time difference is zero and the flowmeter will indicate zero flow.

The transit-time (or time-of-flight) of the signals is accurately measured in both flow
directions and the difference in time calculated. The time difference of the ultrasonic
signals is proportional to the flow velocity in the pipe. The measured flow velocity is
multiplied with the cross-sectional area of the pipe; hence the flow rate of the fluid can
be calculated.

Using the transit-time technique, accuracies of 1 % of measured value can be achieved

without process calibration.

5.3 DIFFERENTIAL PRESSURE TYPE FLOW SWITCH

This type of flow switch used the differential pressure unit where high pressure is
tapped upstream and low pressure is tapped downstream of a primary element. The
primary element has the correct orifice size specification to suit the working range of the
differential pressure unit.

Most of this flow or differential pressure (DP) switches come with a local flow indicator
on it but some without any indicator, known as blind DP switch. Various operating
pressure ratings and DP ranges are available.

Example for this differential pressure type flow switch is taken from Prime (Formerly
known as Barton) differential pressure indicating-switches manual.

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The built-in switches energize either single or dual alarm circuits when the measured
differential pressures exceed predetermined limits. These limits may be either maximum,
minimum or both.

Switch Components for Dual alarm

Main components on this DP indicating switch consists of the indicating switch and the
differential pressure unit (DPU)

5.3.1 INDICATING SWITCH

Rotating of DPU torque tube shaft is coupled through connecting linkage within the
switch case to move the pointer across the scale plate. An actuating cam, directly
connected to torque tube shaft, rotates with the motion of the shaft.

Two cam follower roller / actuator arm assemblies, one for each switch, respond to
torque tube rotation by opening and closing the switches as they ride on and off the cam.

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The levels of DP at which the switches actuate are adjustable with high and low alarm
switch adjustments on the scale plate.

Standard models can have one or two alarm switches. Each switch can be connected to
operate normally opened or normally closed. The direction switch contacts are
adjustable over a scale range of 5 to 95 % nominal.

Dual Switch Actuation Example

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Notes : Cam rotates counter-clockwise with increased pressure Calibration check to
carry out during maintenance to ensure the unit is within factory-set calibration
tolerances. This check included the indication calibration.

If the unit is out of calibration, the unit switch mechanism required to be inspected and
followed by the complete calibration procedures.

The DP indicating switch allowed the flow switch set point to be changed by moving the
index pointer on the unit.

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