Valmet SMART-PULP Bedienungsanleitung

BCs160VA

Nov. 15, 1997

SMART-PULPSmart Consistency Transmitter

Operating and Installation Instructions

Contents:

1 PUTTING INTO OPERATION

1.1 Mechanical installation

1.2 Electrical connections

1.3 Setting up the transmitter

2 TRANSMITTER FUNCTIONS (MENUS)

2.1 MEASUREMENT

2.2 CONFIGURATION

2.3 CALIBRATION

2.4 Sample taking and processing

3 SMART-PULP’S OPERATION AND

CONSTRUCTION

3.1 Construction

3.2 HART® communications

4 MAINTENANCE AND DIAGNOSTICS

4.1 Troubleshooting

4.2 Error messages

4.3 Checking the operation of force measurement

and current output

4.4 Adjusting the position of the display unit

4.5 Replacing the sensor blade

5 PARTS LIST

6 TECHNICAL SPECIFICATIONS

7 APPLICATIONS

7.1 Applications of different sensors

7.2 Materials for wetted parts

WARNING!

Before disconnecting or installing the

transmitter, ensure that the process pipe is

empty and depressurized. Observe the safety

instructions specified for the process.

HART® is a registered trademark of HART Communication Foundation. We reserve the right for technical changes without prior notice.

Valmet Automation Inc., Measurements

PO Box 237, FIN-33101 Tampere, Finland

Tel +358 3 2668 111, Telefax +358 3 2668 448

1 PUTTING INTO OPERATION

BCs160VA

Nov. 15, 1997

SMART-PULPSmart Consistency Transmitter

• The transmitter must be mounted at 90Oangle to

the pump axis and on the side of the line indicated in

Figure 1.1.1a, i.e. on the side where the pulp is

discharged from the pump.

NOTE! The direction of a pipe bend downstream

from the transmitter has no effect.

WARNING !

Before installing the process coupling, make

sure that the process line is empty and

depressurized !

1.1 MECHANICAL INSTALLATION

1.1.1 Points of importance in installation

• The pipe’s inside diameter must be at least 100

mm, and flow velocity must be as shown in the

APPLICATION chapter. If required, the pipe

diameter can be altered so as to achieve the desired

flow velocity.

• Pulp flow must be laminar.

• The pipe should have sufficiently long straight

sections of uniform diameter both upstream and

downstream from the transmitter (Fig. 1.1.1a).

Figure 1.1.1a Determination of coefficient k as a function of pulp consistency and flow velocity

(see Fig. 1.1.2a)

012345678910111213141516

Minimum lengths of straight pipe sections:

L1min = k x D; L2min = 0.3 x L1min + 250 mm

v = 5 m/s

0.5

Consistency %

SMART-

PULP SMART-

PULP

NOVE

pneum

NOVE

manual

Example

D = 250 mm, Cs = 3 %, v = 2 m/s

L1min = 8.5 x 250 = 2125 mm

L2min = 0.3 x 2125 + 250 = 887 mm

L2L2

L1L1

400

BCs160VA

Nov. 15, 1997

SMART-PULP Smart Consistency Transmitter

Figure 1.1.2a Preferred mounting locations for SMART-PULP in pipework

1.1.2 Selecting the mounting location

Preferred mounting locations: 1. A, 2. B1, 3. B2

or C (D when pipe turns upward again).

Important considerations:

A. This is the preferred location in terms of the

control loop’s lag time. If the required length of

straight pipe (L1 + L2) is not provided, you can use

an installation tube (Fig. 1.1.2b) that can be welded

in place immediately after conical expansion.

NOTE! The transmitter should be mounted at 90O

angle to the pump axis (section E-E).

If the vertical section is shorter than the installation

tube or if accessibility is a problem, proceed to

alternative B1.

B1. In this alternative you install the transmitter on

the side of the line to prevent possible air from

disturbing the measurement. Notice that straight

section L1 before the transmitter is 50% longer than

in alternative A. If the straight section is too short,

you can use an installation tube or proceed to

alternative B2 or C.

B2. This method may be considered if the straight

length of horizontal pipe is too short for alternative

B1. Installation on the top side of the pipe always

requires careful consideration, because a substantial

buildup of air in the pipe may affect the

measurement accuracy. We do not recommend this

installation method.

C. You may consider this option when horizontal and

vertical sections before the transmitter are too short.

The double bend before the measurement point will

cause problems when L’ < L1. The whirling flow

produced by the double bend has to be eliminated

with installation tube. In addition, you have to

consider the control loop’s lag time which is

considerably longer in this alternative than in

alternative A.

D. In this method you install the transmitter on the

side of a pipe bend’s outer curve. Distance from pipe

bend is L1. Measurement lag: refer to C.

Other considerations:

F. If a globe valve that will not be continuously fully

open has to be installed between pump and

transmitter, the valve’s axis must be parallel to the

pump’s axis to eliminate whirling flow. The valve

manufacturer’s specifications must be taken into

account.

NOTE! Do not change the pipe diameter between

the pump's conical outlet section and the

transmitter's mounting location + L2 distance.

Valve and

pump axes

parallel

90o

Section E-E

SMART-

PULP

axis

L1 L2

1.5 x L1 L2

BCs160VA

Nov. 15, 1997

SMART-PULPSmart Consistency Transmitter

Figure 1.1.2b Installation tube assembly

Low consistencies (SMART-PULP UL)

Low consistencies (see Section 7.1, Sensor Types)

are measured with sensor option UL. To measure

extremely low consistencies as accurately as

possible we recommend a bypass installation that

will provide the required flow velocity and stabilized

flow. You should be able to limit the flow velocity

between 0.1 and 1 m/s. This installation is illustrated

in Figure 1.1.2e.

The bypass line is connected to the process line with

20 mm pipes for max. 2% Cs consistency, and with

30 mm pipes for max. 3% Cs consistency. At higher

than 3% Cs consistencies you use 40 mm pipe.

Deflector must not be used with the UL sensor.

NOTE! Due to the risk of plugging, this installation is

not suitable for unscreened pulp.

High consistencies (SMART-PULP HL)

SMART-PULP HL, the transmitter for high

consistencies, is installed on the small-diameter pipe

section following the stock pump. This will ensure

sufficient flow velocity. See Figure 1.1.2d. This pipe

section usually includes other devices, such as a

flowmeter and control valve. Recommended

installation order is shown in Fig. 1.1.2d.

To protect the sensor, the deflector blade supplied

with the transmitter must always be installed in high-

consistency applications where standard process

coupling is used. In digester blow line installations

you have to use the blow coupling shown in Figure

1.1.3d. In that case you will not need a separate

deflector in front of the sensor. Figure 1.1.2d Installation of SMART-PULP HL

(4 to 16% consistency range) after MC pump

Figure 1.1.2c

Profile tape to shape the coupling before welding

FLOW

2xDN

155 DN 500

300 300 155

90O ±0.5

1/3 x DN

*) Number of deflector plates

**) Other dimensions available on order

ISO

100

125

150

200

250

300

350

400

500

600

DxS

**)

114.3x2

139.7x2

168.3x2

219.1x3

273.0x3

323.9x3

355.6x3

406.4x4

508.0x4

609.6x4

1000

1125

1250

1500

1750

2000

2250

2500

3000

3500

αα

α/o

22.5

ββ

β/o

180

Weight

kg 9

124

180

250

Pmax.

bar

BCs160VA

Nov. 15, 1997

SMART-PULPSmart Consistency Transmitter

Figure 1.1.2e Low-consistency measurement with bypass line (SMART-PULP UL)

ςς5

1.699

STE AM

POW ER

FLOW

Option DN100

min. 1000

min. 1500

B40

<2 %Cs: DN25 pipe

<3 %Cs: DN32 pipe

>3 %Cs: DN40 pipe

BCs160VA

Nov. 15, 1997

SMART-PULPSmart Consistency Transmitter

Figure 1.1.3a Installation of SMART-PULP LL/LS/GL/RL/HL

1.1.3 Installation of process

couplings and deflectors

SMART-PULP LL/LS/GL/RL/HL

Using the welding guide shown in Fig.

1.1.3f, you weld the process coupling

exactly at right angles (90O ±0.5) to the

pipe as shown in Fig. 1.1.3a. (Welding

instructions are supplied in the kit. Also

refer to Fig. 1.1.2c).

Procedure:

- Make a Ø71 mm hole in the pipe.

- Attach the process coupling to the

welding guide.

- Equalize the height adjustment at both

ends of the guide to ensure that the

guide is supported steadily on its end

pieces and will not rock on the coupling.

- Attach the welding guide to the process

pipe with mounting straps.

- Weld the coupling at 4 points on the

pipe.

- Remove the guide and complete the

welding.

Deflector distances L3 and L4 for types

LL/LS/GL/RL: L3 = L4 = 300 mm; and for

type HL: L3 = L4 = 150 mm.

The deflector downstream from the

sensor is only installed in applications

with a risk of back flow that might

damage the sensor (e.g. when stopping

or starting the process). The deflectors

must be centered exactly in line with the

process coupling. The deflectors have

Ø5 mm holes to facilitate installation; for

instance, you may insert a piece of wire

through the holes. In exceptional cases,

when process pressure exceeds 10 bar

and/or there is exceptionally strong

vibartion, it is advisable to reinforce the

mounting of the process coupling with a

reinforcing ring (Fig. 1.1.3b). Deflector’s

inlet to the pipe should also be reinforced

in the same way.

SMART-PULP UL

Installation in bypass line (Fig. 1.1.2e):

Install the process coupling as described

above, but exclude the deflectors. When

installing in the actual process line you

may require an installation tube (Fig.

1.1.2b) without deflectors.

SMART-PULP WS

Install the process coupling as shown in Figure 1.1.3c. Cut a 9

mm by 182 mm bevelled hole for the deflector on the pipe.

Place the coupling on the pipe and draw the outline of the

coupling’s bore on the pipe. Then cut out the mounting hole.

Remove all burrs from the hole, and round the edges of the

hole. Weld the coupling. Install the backflow deflector in line

with the coupling’s center line.

90O ±0.5

Weld 95

120

Weld Flow

4 Weld

*) This optional protection blade must be ordered separately.

BCs160VA

Nov. 15, 1997

SMART-PULPSmart Consistency Transmitter

SMART-PULP HL in digester blow

line installations

Install the blow line coupling with single bevel weld

at right angles against the pipe, as shown in Figure

1.1.3d. See that the deflector is exactly in line with

the pipe’s center line. The coupling’s lower edge

should be level with the pipe’s inner wall.

Regulations concerning pressurized vessel

installations must be observed when welding the

coupling.

SMART-PULP JL

Installation of the process coupling on fiberglass-

reinforced plastic pipe is illustrated in Figure 1.1.3e.

First make a bevelled hole in the pipe. Then

laminate the process coupling carefully on the pipe

in accordance with lamination instructions.

Figure 1.1.3c Installation for SMART-PULP WS

Figure 1.1.3b Reinforcing the process coupling

D = pipes inside diameter

s = pipes wall thickness

Io = width of reinforcing ring

h = thickness of reinforcing ring

NOTE! If the pipes wall thickness is greater than

that given in the table, the thickness of the

reinforcing ring can be correspondingly smaller.

60 95

120

420

115

180

303 **)

FLOW

*) Plate thickness 4 mm

**) Plate thickness 8 mm

Weld

4 Weld

Weld

hIo

min.

6 mm

250

400

500

p max.

bar

T max.

100

BCs160VA

Nov. 15, 1997

SMART-PULPSmart Consistency Transmitter

Figure 1.1.3f Process coupling welding guide

Figure 1.1.3g Mounting parts for SMART-PULP

Figure 1.1.3e Installation for SMART-PULP JL

Installing the transmitter

Place PTFE gasket in the groove on the

transmitter’s coupling flange (Fig. 1.1.3g). Attach the

transmitter to the process coupling with mounting

clamp. Before tightening the screws, ensure that the

transmitter’s sensor blade is parallel to the direction

of flow (±1O ). Use a ruler placed against the bottom

of the aligning slot to align the sensor. Apply 25 N

torque to tighten the screws.

Note! When required, the process coupling can be

shut with a blind flange.

Figure 1.1.3d

Installation of SMART-PULP HL in digester blow line

welding

1. Process coupling

2. Gasket

3. Mounting clamp

4. Plug

5. Aligning slot

Ø90

80 FLOW

90O ±0.5

45O

26 65

Lamination

*) Plate thickness 4 mm

BCs160VA

Nov. 15, 1997

SMART-PULPSmart Consistency Transmitter

1.2 ELECTRICAL CONNECTIONS

1.2.1 Power supply and wiring

SMART-PULP’s wiring connections are shown in

Figures 1.2.1a and b.

Figure 1.2.1e shows the test meter connection and

the possible connections of 275 HART® user

interface.

With the standard display unit the current loop and

optional binary input connections must be done

under the display.

When using the remote display the connections

must be done in the remote operator terminal. The

fixed connection cable must be connected to the

terminals of the transmitter.

The transmitter’s minimum supply voltage is

determined by the load resistance. Figure 1.2.1d

shows the load resistance as a function of supply

voltage. Load resistance refers to the sum of the

resistances of the current loop’s test resistors, cable

resistance, and power supply resistance. The

following additional requirements are applied to the

power supply if HART® communications are in use:

• Minimum load resistance: 250 Ω

• Ripple: 47 to 125 Hz 0.2 Vpp max.

• Noise: 500 to 10,000 Hz 2.2 mV RMS max.

• Impedance: 500 to 10,000 Hz 10 Ω max.

Making the connections:

• Open the display cover by turning it

counterclockwise.

• Turn the display unit slightly counterclockwise, then

pull it out carefully.

• Insert the cable through the inlet. Use the inlet that

points to the side or downwards. Leave an extra loop

of cable outside the transmitter as reserve and to

conduct drain water out. Tighten the inlet nut and

ensure that the inlet is properly sealed.

• Make the connections as shown in Figures 1.2.1a

and b. Connect the groundings in accordance with

the control system’s instructions. The remote

operator terminal cable shield must be grounded

inside the inlet gland of the transmitter.

• Replace the display unit and make sure that the

flat cable folds properly under the unit. (Push home

at 45Oangle, then turn 45O clockwise.)

• Check the O-ring on the display cover. Then close

the cover tightly.

• Cut the DCS cable shield at the transmitter/remote

operator terminal end, and insulate inside the metal

inlet.

Figure 1.2.1a SMART-PULP’s wiring connections

(2-W). The connections are the same when

remote operator terminal is in use.

Figure 1.2.1b SMART-PULP end of the connection

cable wiring for remote operator terminal.

24 V

+Digital inputs *)

LOAD

4-20 mA

76543

-4321

=Recipe

0 = Sampling on

1 = Sampling off

*) 0V = 0 and 24V = 1

The signal wires are numbered and the cable shield

grounding wire end must be between the two metal

washers in contact with transmitter body.

Tighten the gland nut properly for good locking and

to keep moisture out from the terminal box.

Washer 1

Washer 2

Shield

roundin

wire

Gland

Terminal

strips

Cable

Signal Wires

5678

BCs160VA

Nov. 15, 1997

SMART-PULPSmart Consistency Transmitter

Figure 1.2.1d Load capacity

Load resistor

min 250 Ω

3.25 %Cs

COMM COMM

MODEENTER

ESC

+ -

ΩΩ

Ω Load resistance

Supply voltage V

840

750

500

415

250

017.5 20 21 23 28 30 35

1088

Operating zone

Figure 1.2.1e SMART-PULP’s Test and

HART® connections

Test

+Test

Figure 1.2.1c SMART-PULP electrical connections

SMART-PULP end of the connection cable wiring for remote operator

terminal, if the remote operator terminal is used.

SMART-PULP's operator terminal wiring connections,

remote or local.

*) open = 0, closed = 1

Load

Recipe

selection *)

Transmitter

housing

To control system

open = sampling ON

closed = sampling OFF To NOVE

Sample valve ON/OFF

8765

1234

76543

7654

321

TE 24 V

8 =

recipe

number

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