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5

Fill Fluids

This section discusses the process of selecting the appropriate fill fluid using vapor
pressure curves. To see the list of available Rosemount fill fluids, view the Rosemount DP
Level Fill Fluid Specifications

, or reference the Rosemount DP Level

Transmitters and 1199 Remote Seals

Product Data Sheet

.

5.1

Quality

5.1.1

Specialized processing

Emerson has implemented proprietary processes to eliminate impurities and
contaminations in the fill fluid. This additional processing ensures stable measurement
and optimal performance under extreme temperatures and vacuum conditions. The
proprietary equipment and procedures used to build remote seal systems for high
temperature/high vacuum applications are continuously improved to deliver products
that meet ever increasing application demands. Tight quality control measures such as
helium leak checking of system welds ensures the reliability of every seal system.
Additional quality checks include continual station leak and health tests to confirm the fill
quality of the finished seal system.

5.1.2

Testing

Emerson’s vapor pressure curves are derived from empirical lab testing in real devices at
both vacuum conditions and at the maximum continuous temperature at one atmosphere
of pressure. The maximum continuous temperature at one atm of pressure correlates to
the thermal stability of the fill fluid, which is the maximum temperature the fill fluid will
remain in its original molecular form. Over time, exceeding the maximum recommended
temperature may result is the decomposition or vaporization of the fill fluid, resulting in
device failure.

5.2

Fill fluid selection

Fill fluid selection is very important to the safety and reliability of your measurement
application.

5.2.1

Type of fill fluid

Different types of fill fluids exist to meet the needs of different applications. An all-purpose
fill fluid can be used in most applications. However, some processes might require a fill
fluid that is chemically inert to avoid reactions with oxygen. In the food and
pharmaceutical industries, a hygienic fill fluid may be needed that meets various industry
standards.

Reference Manual

Fill Fluids

00809-0100-4002

May 2020

Rosemount DP Level

89

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Summary of Contents for Rosemount 1199

Page 1: ...Reference Manual 00809 0100 4002 Rev EA May 2020 Rosemount DP Level Transmitters and 1199 Diaphragm Seal Systems ...

Page 2: ...gaged to meet explosion proof requirements Verify the operating atmosphere of the transmitter is consistent with the appropriate hazardous locations certifications Electical hazard Electrical shock could cause death or serious injury If the sensor is installed in a high voltage environment and a fault or installation error occurs high voltage may be present on transmitter leads and terminals Use e...

Page 3: ...l or unintentional and needs to be protected against Physical security is an important part of any security program and fundamental to protecting your system Restrict physical access by unauthorized personnel to protect end users assets This is true for all systems used within the facility CAUTION The products described in this document are NOT designed for nuclear qualified applications Using non...

Page 4: ...4 ...

Page 5: ...ng and installation 23 3 2 Gaskets 25 3 3 Tagging 26 3 4 Torque sequence 27 3 5 FFW flush flanged seal 28 3 6 RFW remote flanged seal 31 3 7 EFW extended flanged seal 34 3 8 PFW pancake seal 36 3 9 FCW flush flanged seal ring type joint RTJ gasket surface 38 3 10 RCW remote flanged seal ring type joint RTJ gasket surface 40 3 11 FUW flush flanged groove type seals 42 3 12 FVW flush flanged tongue ...

Page 6: ... range points 75 4 2 DP Level transmitter installation best practices 82 Chapter 5 Fill Fluids 89 5 1 Quality 89 5 2 Fill fluid selection 89 5 3 Fill fluid vapor pressure curves 90 Chapter 6 Maintenance and Troubleshooting 93 6 1 Cleaning 93 6 2 Troubleshooting 93 6 3 Return of materials 95 6 4 Service support 95 Chapter 7 Reference data 97 7 1 Product certifications 97 7 2 Ordering information sp...

Page 7: ...ration outlines how to range a DP Level Remote Seal System Fill Fluids describes the offering of fill fluids available with Remote Seal Systems Maintenance and Troubleshooting provides techniques for cleaning and maintaining the system as well as addressing the most common operating problems Reference data provides resources for product certifications ordering information specifications drawings a...

Page 8: ...Introduction Reference Manual May 2020 00809 0100 4002 8 Rosemount DP Level ...

Page 9: ...itions such as high and low temperatures corrosive processes viscous mediums and hygienic applications 2 2 Terminology of system components Figure 2 1 lists the basic components for seal assemblies Figure 2 1 Components on a Two and Single Seal Assembly Two seal assembly Single seal assembly A B C D E B C F A Pressure differential pressure or multivariable transmitter B Process flange C Remote dia...

Page 10: ...l on both sides However head temperature effect is still present Note Other factors that affect seal temperature effect include diaphragm thickness seal type and size capillary length and inner diameter Figure 2 3 shows how diaphragm size can affect the measurement reading at the transmitter For smaller seal sizes such as the 1 in size the amount of back pressure on the transmitter causes an addit...

Page 11: ...ransmitter Density effect will be seen in both Tuned System Assemblies and Balanced System Assemblies and will have the same impact on the transmitter regardless of where the transmitter is mounted 2 3 3 System time response and performance The time response of a system is based on the type of transmitter its sensor range the length and inner diameter ID of the capillary and the viscosity of the f...

Page 12: ...ymmetrical system that utilizes equal seals and capillary length on the high and low pressure sides of the transmitter Since the capillary lengths are the same each side ideally has the same amount of fill fluid minimizing or completely eliminating the seal temperature effect due to equal pressure on both sides of the transmitter diaphragm The balanced systems are still affected by the head pressu...

Page 13: ...s any remote seal system with unequal lengths of capillary or two different remote seals on the high and low pressure connections Due to the unequal lengths of capillary there are seal temperature effects However this seal temperature effect counters the head pressure from the oil filled capillary and reduces total temperature effects on the entire system Figure 2 6 Tuned System Assembly Head temp...

Page 14: ...ll welded vacuum construction was designed specifically for vacuum applications In this construction the sensor module gaskets are removed and a disk is welded over the sensor isolators This eliminates the possibility of air being drawn into the seal system in deep vacuum conditions This premium design is strongly suggested for vacuum pressures below 6 psia 310 mmHga 2 5 4 Transmitter mounting pos...

Page 15: ...acuum applications Silicone 705 for vacuum applications or UltraTherm 805 for vacuum applications These fluids have been specially processed to deliver the maximum vapor pressure curve performance possible For more information on Rosemount Diaphragm Seal fill fluids reference the Rosemount 1199 Fill Fluid Specifications Technical Note 2 6 Diaphragm weld types Weld type is factory determined as bes...

Page 16: ...ed A B D C E F A Material A B Material B C Upper housing D Diaphragm E TIG weld point F Seam weld point 2 6 3 Brazed design This process uses a brazing ring where the metals are brazed to attach the diaphragm to the upper housing This allows the gasket surface area to solidify as it is melted to the upper housing This option is used with Tantalum diaphragm when a metallic gasket is required A B C ...

Page 17: ...ous processes For more information refer to the Rosemount 3051S Series Product Data Sheet Figure 2 7 ERS vs Capillary Rosemount 3051S ERS Traditional capillary system A B A Non proprietary electrical cable B Oil filled capillary system 2 8 Instrument Toolkit seal ordering and application process Rosemount Instrument Toolkit Software is an instrumentation specification tool that can be used to assi...

Page 18: ...s a seal system that uses two different fill fluids to extend the operating temperature range of the system A high temperature fill fluid which is next to the hot process is kept warm enough to stay responsive A second fill fluid located on the other side of the intermediate diaphragm operates over a wide ambient temperature range The Rosemount Thermal Range Expander can operate in ambient tempera...

Page 19: ...Figure 2 9 Rosemount Thermal Range Expander Temperature Operating Range Reference Manual Remote Seal Systems 00809 0100 4002 May 2020 Rosemount DP Level 19 ...

Page 20: ... 100 C 176 F 80 C 140 F 60 C 104 F 40 C 68 F 20 C 32 F 0 C 4 F 20 C 40 F 40 C 76 F 60 C 112 F 80 C 212 F 100 C 176 F 80 C 140 F 60 C 104 F 40 C 68 F 20 C 32 F 0 C 4 F 20 C 40 F 40 C 76 F 60 C 112 F 80 C 32 F 0 C 122 F 50 C 302 F 150 C 482 F 250 C 662 F 350 C 842 F 450 C 401 F 205 C 185 F 85 C 185 F 85 C 599 F 315 C 58 F 50 C 91 F 33 C Process temperature F C Ambient temperature F C Ambient tempera...

Page 21: ...ith a thermal optimizer For example an application with an ambient temperature of 50 F 10 C and a process temperature of 300 F 149 C is within the limits a thermal optimizer can be used in this application However an application with an ambient temperature of 122 F 50 C and a process temperature of 464 F 240 C is outside of the limits These high temperatures would be detrimental to the transmitter...

Page 22: ...Remote Seal Systems Reference Manual May 2020 00809 0100 4002 22 Rosemount DP Level ...

Page 23: ...al diaphragm is not dented or damaged during seal installation 3 1 2 Capillary When unpacking or handling seal system assemblies do not lift the seal or transmitter by gripping the capillaries Avoid sharply bending or crimping the capillary tubing The minimum bending radius of the capillary tubing is 3 in 8 cm 3 1 3 Rosemount Thermal Range Expander The Rosemount Thermal Range Expander system uses ...

Page 24: ...ate the temperature slightly above the maximum ambient temperature for a consistent result To avoid accuracy effects and thermal stress the capillary should not be partially heated CAUTION NEVER attempt to disconnect the seals or capillaries from the transmitter or loosen bolts Doing so will result in loss of fill fluid and will void the product warranty Failing to recognize incorrect materials du...

Page 25: ... default gaskets are listed in Table 3 1 based on seal type The process gasket must be supplied by the end user Tantalum diaphragms are not supplied with default gasket so a gasket option must be selected when applicable If a lower housing is supplied then the following gaskets are the default gaskets for each seal unless another gasket option is selected Table 3 1 Gasket Materials Seal type Gaske...

Page 26: ...and ensuring the process temperature does not exceed the temperature limits of the gasket used Failure to properly install the gasket may cause process leaks which can result in death or serious injury 3 3 Tagging Each remote seal system is tagged in accordance with the end user requirements The remote seal model number is identified on the transmitter label shown in Figure 3 2 Figure 3 3 and Figu...

Page 27: ...ensure even installation Best practice is to tighten 20 to 30 percent check the gap tighten 50 to 70 percent check flange gap and uniformity and continue to tighten in the appropriate pattern until you reach 100 percent torque value Time permitting wait a minimum of four hours and repeat the torque pattern to restore any short term creep relaxation in the connection Figure 3 5 Cross Pattern Sequen...

Page 28: ...A B Process flange C Diaphragm D Flushing ring optional E Connection to transmitter F Flushing connection Note Two piece design seal assembly and process flange are separate components and can be rotated independent of each other Alignment clamp A can be ordered using option code SA Installation Reference Manual May 2020 00809 0100 4002 28 Rosemount DP Level ...

Page 29: ... will be defined here Prior to installation you will need the following Torque wrench Mounting hardware end user supplied Gasket end user supplied Note Flushing rings include an Emerson supplied gasket If an alignment clamp is used a Phillips or slotted screwdriver is required for installation Verify the gasket materials are appropriate for the application Inspect bolts to ensure the material is c...

Page 30: ...sing the applicable screwdriver tighten the screw on the clamp to hold the flushing ring in place 3 Insert end user supplied bolts in the bottom two bolt holes of the flange on the remote seal 4 Place the appropriate end user supplied gasket on the remote seal or flushing ring and align the gasket so that it is not inside the diaphragm weld as this will induce errors WARNING Failure to properly in...

Page 31: ...Connection to transmitter E Flushing connection Note Lower housing always required for RFW remote flanged seal Figure 3 9 RFW Stud Bolt Design A C D B E A Upper housing B Diaphragm C Lower housing or flushing ring D Stud bolts E Connection to transmitter Reference Manual Installation 00809 0100 4002 May 2020 Rosemount DP Level 31 ...

Page 32: ... remote flanged seal will be defined here Prior to installation you will need the following Torque wrench Mounting hardware end user supplied Gasket lower housing to process flange end user supplied Gasket remote seal to lower housing Emerson supplied Note Typically the stud bolt design includes Emerson supplied stud bolts Verify the gasket material is appropriate for the application Inspect bolts...

Page 33: ...g each nut as the bolts are installed 7 Using a torque wrench on the nut tighten the assembly in a cross pattern to ensure even installation see Torque sequence The bolts should be torqued to the applicable flange requirements Required torque is a function of the gasket material and surface treatment of the bolts and nuts which are end user supplied Consider leak checking the installation to ensur...

Page 34: ...NG Failure to properly install the gasket may cause process leaks which can result in death or serious injury 8 Install the bolts in a cross pattern and hand tighten 9 Using a torque wrench on the bolt tighten the assembly in a cross pattern to ensure even installation see Torque sequence The bolts should be torqued per Table 3 2 based on size and bolt material Consider leak checking the installat...

Page 35: ...wo bolt holes of the flange on the remote seal 3 Place the appropriate end user supplied gasket on the remote seal WARNING Failure to properly install the gasket may cause process leaks which can result in death or serious injury 4 Using the previously installed bolts attach the remote seal and gasket to the process flange Secure with nuts and hand tighten 5 Insert end user supplied bolts in the t...

Page 36: ...ting any weight 3 8 2 Process flange Emerson offers the option of supplying the process flange otherwise the process flange is furnished by the end user There is a 5 16 24 threaded connection on the back of the PFW pancake seal For certain pancake seal assemblies the Emerson supplied process flange has a machined hole through the center of the flange that corresponds to the threaded connection in ...

Page 37: ...ing ensure flushing connections are sealed before completing installation Flushing rings may be ordered with or without one or two threaded flushing connections factory supplied plugs or drain vent valves If no flushing ring was purchased proceed to Step 3 Assemble the flushing ring Emerson supplied gasket and remote seal together If using an alignment clamp option code SA attach the flushing ring...

Page 38: ...e installation to ensure a robust connection 3 9 FCW flush flanged seal ring type joint RTJ gasket surface Figure 3 12 FCW Two Piece Design Shown with Flushing Ring A C D B C A Process flange B Diaphragm C Flushing ring optional D Connection to transmitter 3 9 1 Parts required for installation The parts required to install the FCW flush flanged seal with RTJ gasket surface will be defined here Pri...

Page 39: ...t errors which can result in death or serious injury 3 Insert end user supplied bolts in the bottom two bolt holes of the flange on the remote seal 4 Place the appropriate end user supplied gasket on the remote seal or optional flushing ring WARNING Failure to properly install the gasket may cause process leaks which can result in death or serious injury 5 Using the previously installed bolts atta...

Page 40: ...t lb CS 20 NF 900 1500 2500 lb 105 ft lb 1 53 ft lb for 4 1 in diaphragm size Note This is the specification for connecting the remote seal to the lower housing not the torque specification for the lower housing onto the process flanged connection The lower housing bolts should be torqued to the applicable flange requirements 3 10 1 4 1 in 104 mm diaphragm diameter option The standard diaphragm si...

Page 41: ...ne or two threaded flushing connections factory supplied plugs or drain vent valves 2 Install the stud bolts onto the lower housing 3 Assemble the lower housing to the process flange Place the appropriate end user supplied gasket between the lower housing and process flange WARNING Failure to properly install the gasket may cause process leaks and measurement errors which can result in death or se...

Page 42: ... flanged groove type seals Figure 3 14 FUW Flush Flanged Type Seal EN1092 1 Type D C B A Process flange B Diaphragm C Connection to transmitter 3 11 1 Parts required for installation The parts required to install the FUW flush flanged groove type seal will be defined here Prior to installation you will need the following Torque wrench Mounting hardware end user supplied Gasket end user supplied Ve...

Page 43: ...te seal and gasket to the process flange Secure with nuts and hand tighten 5 Insert end user supplied bolts in the top two bolt holes of the flange on the remote seal Secure with nuts and hand tighten 6 Using a torque wrench on the nut tighten the assembly in a cross pattern to ensure even installation Torque sequence The bolts should be torqued to the applicable flange requirements Required torqu...

Page 44: ...e bottom two bolt holes of the flange on the remote seal 3 Place the appropriate end user supplied gasket on the remote seal WARNING Failure to properly install the gasket may cause process leaks which can result in death or serious injury 4 Using the previously installed bolts attach the remote seal and gasket to the process flange Secure with nuts and hand tighten 5 Insert end user supplied bolt...

Page 45: ...1 23 ft lb CS 3 8 24 NF 2500 23 ft lb SST 3 8 24 NF 2500 23 ft lb CS 3 8 24 NF 5000 53 ft lb SST 20 NF 5000 50 ft lb CS 20 NF 10000 105 ft lb 1 1500 psi MWP RTW s are only available on 4 1 in diaphragm sizes Note This is the specification for connecting the remote seal to the lower housing not the torque specification for the lower housing onto the process threaded connection Standard NPT torque v...

Page 46: ...d the lower housing to the process connection The lower housing includes a small hole designed for a spanner wrench to facilitate installation and applying the required torque The applied torque should comply with ANSI B1 20 1 for NPT connections or applicable torque requirements for pipe connections 3 Remove the protective cover from the diaphragm of the remote seal Use extreme caution during ins...

Page 47: ...ion to transmitter B Diaphragm 3 14 1 Parts required for installation The parts required to install the HTS male threaded seal will be defined here Prior to installation you will need the following Thread sealant Thread sealant must meet the requirements of the application An example thread sealant is PTFE tape Reference Manual Installation 00809 0100 4002 May 2020 Rosemount DP Level 47 ...

Page 48: ...ad 3 Thread the remote seal onto the process connection The remote seal is designed with a small hole to facilitate installation and applying torque The applied torque should comply with ANSI B1 20 1 for NPT connections or applicable torque requirements for pipe connections 3 15 SCW hygienic Tri Clover Tri Clamp seals Figure 3 18 SCW Tri Clamp Seal 2 3 and 4 in size A B 2 in size 1 in size A B A B...

Page 49: ...F 21 C 250 F 121 C 1 in 1 500 psi 103 bar 1 200 psi 83 bar 2 in 1 000 psi 69 bar 800 psi 55 bar 2 in 1 000 psi 69 bar 800 psi 55 bar 3 in 1 000 psi 69 bar 800 psi 55 bar 4 in 600 psi 41 bar 500 psi 34 bar 3 15 2 Parts required for installation The parts required to install the SCW hygienic Tri Clamp seal will be defined here Prior to installation you will need the following Clamp Gasket Wrench opt...

Page 50: ...so that it is not contacting the diaphragm as this will induce errors WARNING Failure to properly install the gasket may cause process leaks which can result in death or serious injury 3 Ensure that the SCW hygienic Tri Clamp seal is flush with the process connection 4 Install clamp and tighten to manufacturer s specifications Note EHEDG requirement on T stub installations the length L divided by ...

Page 51: ...g a new tank spud Verify the O ring material is appropriate for the application 3 16 2 Installation steps Follow these steps to install the SSW hygienic tank spud seal Procedure 1 Prepare the tank see Tank preparation 2 Weld the tank spud onto the tank per plant procedures see Welding Ensure the tank spud is not assembled to the pressure transmitter and or the remote seal prior to welding 3 Remove...

Page 52: ...t be covered Figure 3 20 Tank Preparation A Tank spud B Hole cut C Center of the hole D Weld Attempt to cut the hole as smoothly and as circular as possible A torch cut is not recommended The tank spud O D is 5 98 in 0 010 in 152 mm 0 25 mm When cutting the hole for the tank spud the gap between the hole diameter and spud O D should be held to a minimum It is recommended that the hole be no larger...

Page 53: ...ansmitter and or remote seal prior to welding Do not nick the sealing surfaces of the tank spud the inner angled surfaces where the O ring sits shown in Figure 3 22 as any irregularities may cause leaks Figure 3 22 O ring Sealing Surfaces A A Sealing surfaces With the spud centered in the tank hole make sure the inner surface of the spud is flush with the inner surface of the tank The leak detecti...

Page 54: ...ank Note The number of weld passes should be kept to a minimum while maintaining tank weld standards and sanitary requirements Additional weld passes are a significant contributor to spud distortion due to additional heat input and added filler material in beveled area of hole When fill passes are required a 1 16 in 1 58 mm diameter weld rod is recommended Note For high pressure clamps up to 1 000...

Page 55: ...spud seal Procedure 1 Remove the plastic cover from the diaphragm of the remote seal 2 Weld the tank spud onto the tank per plant procedures see Welding WARNING Ensure the tank spud is not assembled to the pressure transmitter and or the remote seal prior to welding 3 Remove the protective cover from the diaphragm of the remote seal Use extreme caution during installation to ensure the diaphragm i...

Page 56: ...ial is compatible with industry standards per the application such as ASME PCC 1 3 18 2 Installation steps Follow these steps to install the EES hygienic flanged tank spud extended seal Procedure 1 Prepare the tank see Tank preparation 2 Weld the tank spud onto the tank per plant procedures see Welding Ensure the tank spud is not assembled to the pressure transmitter and or the remote seal prior t...

Page 57: ...hould be torqued to the applicable flange requirements Required torque is a function of the gasket material and surface treatment of the bolts and nuts which are end user supplied Consider leak checking the installation to ensure a robust connection 3 19 VCS Tri Clamp in line seal Figure 3 26 VCS Tri Clamp In line Seal 3 19 1 Parts required for installation The parts required to install the VCS hy...

Page 58: ...ight be required depending on clamp style 4 Place the second appropriate end user supplied gasket for the application on the remote seal WARNING Failure to properly install the gasket may cause process leaks which can result in death or serious injury 5 Align the other end of the VCS hygienic Tri Clamp seal with the process piping 6 Attach the clamp and tighten to manufacturer s specifications wre...

Page 59: ...DG approved gasket if EHEDG conformance is needed 3 20 2 Installation steps Follow these steps to install the SVS VARIVENT seal Procedure 1 Remove the protective cover from the diaphragm of the remote seal Use extreme caution during installation to ensure the diaphragm is not damaged 2 Place the appropriate gasket for the application on the remote seal WARNING Failure to properly install the gaske...

Page 60: ... 1 Parts required for installation The parts required to install the SHP Cherry Burrell seal will be defined here Prior to installation you will need the following Clamp end user supplied Gasket end user supplied Wrench optional depending on clamp Verify the gasket material is appropriate for the application 3 21 2 Installation steps Follow these steps to install the SHP Cherry Burrell seal Instal...

Page 61: ...SLS dairy process connection female thread seal per DIN 11851 Figure 3 29 SLS Hygienic Dairy Process Connection Female Thread Seal per DIN 11851 A B 3 22 1 Parts required for installation The parts required to install the SLS dairy process connection seal will be defined here Prior to installation you will need the following Gasket end user supplied Wrench optional depending on clamp Verify the ga...

Page 62: ...ection 4 Tighten the nut onto the process connection per DIN 11851 Care should be taken not to overtighten Note EHEDG requirement on T stub installations the length L divided by the diameter D of the tee is to be less than 1 i e L D 1 D L 3 23 WSP saddle seal Figure 3 30 WSP Saddle Seal 3 in line size and smaller 4 in line size and larger A A B B A Connection to transmitter B Diaphragm 3 23 1 Part...

Page 63: ...supplied Gasket Emerson supplied Cutting and welding equipment required if installing a new saddle lower Verify the gasket material is appropriate for the application Reference Manual Installation 00809 0100 4002 May 2020 Rosemount DP Level 63 ...

Page 64: ...ket for the application on the remote seal WARNING Failure to properly install the gasket may cause process leaks which can result in death or serious injury 4 Insert the WSP saddle seal into the saddle lower 5 Install the bolts in a cross pattern and hand tighten 6 Using a torque wrench on the bolt tighten the assembly in a cross pattern to ensure even installation see Torque sequence The bolts s...

Page 65: ...e amount of fill required during weld and minimize the number of weld passes These best practices will decrease heat input and help mitigate distortion 3 Position the lower housing weld spud in the vessel hole place heat sink and tack the housing in place using the welding sequence shown in Figure 3 32 Cool each section with a wet cloth before proceeding to the next section CAUTION Do not place th...

Page 66: ...e diaphragm of the remote seal Use extreme caution during installation to ensure the diaphragm is not damaged 6 Place the gasket into the lower housing make sure the gasket is properly aligned on the gasket sealing surface WARNING Failure to properly install the gasket may cause process leaks which can result in death or serious injury 7 Insert the UCP union connection seal into the lower housing ...

Page 67: ... a hole in the process vessel to accept the lower housing The diameter for a lower housing with a heat isolator groove is 1 32 in 33 4 mm The hole should produce a tight uniform fit when coupled with the lower housing 2 Bevel the edge of the vessel hole to accept filler material see Figure 3 34 An angle no larger than 37 5 is recommended see ASME B16 25 for more details Bevels can be made on one o...

Page 68: ... to cool between weld sections Weld should be cooled to 350 F 177 C or less after each pass while being cool to the touch is preferred Use of a damp cloth or compressed air is allowed if rapid cooling is desired Repeat procedure on the outside of the tank Note The number of weld passes should be kept to a minimum while maintaining tank weld standards and process requirements Additional weld passes...

Page 69: ...al A B A Connection to transmitter B Diaphragm 3 26 1 Parts required for installation The parts required to install the CTW chemical tee seal will be defined here Prior to installation you will need the following Torque wrench Mounting hardware end user supplied Gasket end user supplied Verify the gasket material is appropriate for the application Inspect bolts to ensure the material is compatible...

Page 70: ...nsure even installation see Torque sequence The bolts should be torqued to the applicable flange requirements Required torque is a function of the gasket material and surface treatment of the bolts and nuts which are end user supplied Consider leak checking the installation to ensure a robust connection 3 27 TFS wafer style In line seal Figure 3 36 TFS Wafer Style In Line Seal A B A Connection to ...

Page 71: ... nuts and hand tighten 4 Place the second appropriate end user supplied gasket for the application on the other end of the remote seal WARNING Failure to properly install the gasket may cause process leaks which can result in death or serious injury 5 Align that end of the TFS wafer style In line seal flush with the process flange 6 Insert end user supplied bolts secure with nuts and hand tighten ...

Page 72: ...ng to process flange end user supplied Gasket remote seal to lower housing Emerson supplied Verify the gasket material is appropriate for the application Inspect bolts to ensure the material is compatible with industry standards per the application such as ASME PCC 1 3 28 2 Installation steps Follow these steps to install the WFW flow thru flanged seal on an existing process piping system Procedur...

Page 73: ...uld be torqued to the applicable flange requirements Required torque is a function of the gasket material and surface treatment of the bolts and nuts which are end user supplied Consider leak checking the installation to ensure a robust connection 8 Remove the protective cover from the diaphragm of the remote seal Use extreme caution during installation to ensure the diaphragm is not damaged 9 Ass...

Page 74: ...Installation Reference Manual May 2020 00809 0100 4002 74 Rosemount DP Level ...

Page 75: ... zero based 2 Closed tank non zero based Zero trim via Field Communicator Re range via zero button Re range via Field Communicator Scale display Figure 4 1 Remote Seals ATM open to atmosphere Balanced equal capillary length and size seal Tuned unequal capillary length Direct mount Remote capillary 2 Zero based means 4 mA equals 0 inH2O Reference Manual Configuration 00809 0100 4002 May 2020 Rosemo...

Page 76: ...in the minimum level of process above the high pressure seal and typically the 4 mA lower range value SGF specific gravity of fill fluid SGP specific gravity of process fluid Tank span Lmax SGP Lmin SGP 108 in 0 75 0 in 0 75 81 inH2O 4 mA Lmin SGP dH SGF 0 in 0 75 0 in 0 934 0 inH2O 20 mA Lmax SGP dH SGF 108 in 0 75 0 in 0 934 81 inH2O Span 81 inH2O 81 to 0 inH2O Note Both installations would have...

Page 77: ... Lmin the minimum level of process above the high pressure seal and typically the 4 mA lower range value SGF specific gravity of fill fluid SGP specific gravity of process fluid Tank span Lmax SGP Lmin SGP 108 in 0 75 0 in 0 75 81 inH2O 4 mA Lmin SGP dH SGF 0 in 0 75 60 in 0 934 56 04 inH2O 20 mA Lmax SGP dH SGF 108 in 0 75 56 04 inH2O 137 04 inH2O Span 81 inH2O 137 04 to 56 04 inH2O Note Silicone...

Page 78: ... and typically the 4 mA lower range value SGF specific gravity of fill fluid SGP specific gravity of process fluid Tank span Lmax SGP Lmin SGP 108 in 0 75 81 inH2O 4 mA Lmin SGP dH SGF 0 in 0 75 120 in 0 934 112 08 inH2O 20 mA Lmax SGP dH SGF 108 in 0 75 120 in 0 934 31 08 inH2O Span 81 inH2O 112 08 to 31 08 inH2O Note The height of the transmitter Hd Sg should not be greater than approximately 39...

Page 79: ...y the 20 mA lower range value Lmin the minimum level of process above the high pressure seal and typically the 4 mA lower range value SGF specific gravity of fill fluid SGP specific gravity of process fluid Tank span Lmax SGP Lmin SGP 108 in 0 75 81 inH2O 4 mA Lmin SGP dL SGF 0 in 0 75 120 in 0 934 112 08 inH2O 20 mA Lmax SGP dL SGF 108 in 0 75 120 in 0 934 31 08 inH2O Span 81 inH2O 112 08 to 31 0...

Page 80: ...ically the 20 mA lower range value Lmin the minimum level of process above the high pressure seal and typically the 4 mA lower range value SGF specific gravity of fill fluid SGP specific gravity of process fluid Tank span Lmax SG 108 in 0 75 81 inH2O 4 mA Lmin SGP dL SGF dH SGF 0 in 0 75 60 in 0 934 60 in 0 934 112 08 inH2O 20 mA Lmax SGP dL SGF dH SGF 108 in 0 75 60 in 0 934 60 in 0 934 31 08 inH...

Page 81: ...f process above the high pressure seal and typically the 4 mA lower range value SGF specific gravity of fill fluid SGP specific gravity of process fluid Tank span Lmax SG 108 in 0 75 81 inH2O 4 mA Lmin SGP dL SGF dH SGF 0 in 0 75 180 in 0 934 60 in 0 934 112 08 inH2O 20 mA Lmax SGP dL SGF dH SGF 108 in 0 75 180 in 0 934 60 in 0 934 31 08 inH2O Span 81 inH2O 112 08 to 31 08 inH2O Note Silicone 200 ...

Page 82: ...tal values after being installed For these reasons a re range function is common practice after all installations Figure 4 8 Installation Example Pressure transmitter Pressure transmitter with remote seals A Primary fill B Secondary fill What is important is the calculated span level height specific gravity of the process After the transmitter is mounted it is common and best practice to re range ...

Page 83: ...re ranged so that the 0 value 4 mA would equal the installed value The 100 percent 20 mA would be adjusted to the required calculated span 4 2 3 Open tank example zero based lower range value with Field Communicator Perform a zero trim via Field Communicator after installation for zero based lower range values Figure 4 9 Open Tank ATM open to atmosphere Reference Manual Configuration 00809 0100 40...

Page 84: ...Figure 4 10 Before Zero Trim Using Field Communicator Figure 4 11 After Zero Trim Using Field Communicator Configuration Reference Manual May 2020 00809 0100 4002 84 Rosemount DP Level ...

Page 85: ...he seal assemble apply pressure 4 mA 0 inH2O 20 mA 81 inH2O 2 Install the tuned system by assembling the seals to the process taps Common practice is to mount the high pressure side seal to the low process tap and the low pressure side seal to the high process tap 3 Wire and apply power to the transmitter 4 If the transmitter has a zero button see Figure 4 13 and Figure 4 14 push the Zero button T...

Page 86: ...d Communicator to see the change Figure 4 13 Zero and Span Buttons on Rosemount 2088 2051 and 3051 A A Zero and span buttons Figure 4 14 Zero and Span Buttons on Rosemount 3051S Plantweb Junction box A B A B A Zero B Span 5 If the transmitter does not have a Zero button use a Field Communicator to re range the transmitter Example 2 Re range using a Field Communicator Transmitter is ranged per Figu...

Page 87: ...nt to configure the output to an engineering unit other than the standard defaults go to Scale display with Field Communicator 4 2 5 Scale display with Field Communication After the transmitter is installed you can scale the display to match the DCS or PLC as required but often 0 to 100 percent is sufficient As an example in Figure Figure 4 12 the display should be 0 to 81 inH2O This can be done u...

Page 88: ...ion select Linear 3 Enter Pressure value position 1 enter 112 08 4 Enter Scaled Variable position 1 enter 0 5 Enter Pressure value position 2 enter 31 08 6 Enter Scaled Variable position 2 enter 81 7 Enter Linear Offset enter 0 00 8 Go to Display under manual setup 9 Pressure OFF 10 Scaled Variable ON 11 Module Temperature OFF 12 Percent of range OFF Note The transmitter is ranged 112 08 to 31 08 ...

Page 89: ...h tests to confirm the fill quality of the finished seal system 5 1 2 Testing Emerson s vapor pressure curves are derived from empirical lab testing in real devices at both vacuum conditions and at the maximum continuous temperature at one atmosphere of pressure The maximum continuous temperature at one atm of pressure correlates to the thermal stability of the fill fluid which is the maximum temp...

Page 90: ...s each fill fluid has a specific vapor pressure curve The vapor pressure curve indicates the pressure and temperature relationship where the fluid is in a liquid or vapor state Safe and reliable system operation requires the fill fluid to remain in a liquid state Figure 5 1 Liquid vs Pressure State Under Vacuum The thermal stability point of a fill fluid is equal to its maximum temperature at one ...

Page 91: ... and a maximum pressure of 700 Torr SYLTHERM XLT would be recommended However say the process pressure drops to 200 Torr and 284 F 140 C at one point during the process cycle then Silicone 200 for vacuum applications would be recommended because it is the fill fluid farthest to the right that the process falls into 5 3 3 Fill fluid specifications Rosemount fill fluid properties vapor pressure curv...

Page 92: ...Fill Fluids Reference Manual May 2020 00809 0100 4002 92 Rosemount DP Level ...

Page 93: ...s 1 See the troubleshooting section of the transmitter manual for more extensive information 2 Check for adequate voltage to the transmitter 3 Check the milliampere rating of the power supply against the total current being drawn for all transmitters being powered 4 Check for shorts and multiple grounds 5 Check for proper polarity at the transmitter terminal 6 Check loop impedances CAUTION Do not ...

Page 94: ... to Instrument Toolkit seal ordering and application process for more information 6 2 4 Output reads negative pressure Potential cause Mounting effect Recommended actions The output will read negative as the remote fill fluid is applying pressure to the low side See Configuration 6 2 5 No response to change in pressure Potential cause Damaged diaphragm Recommended actions Remove seal and inspect d...

Page 95: ... return process outside of the United States contact the nearest Emerson representative Within the United States call the Emerson Instrument and Valves Response Center using the 1 800 654 RSMT 7768 toll free number This center available 24 hours a day will assist you with any needed information or materials The center will ask for product model and serial numbers and will provide a Return Material...

Page 96: ...Maintenance and Troubleshooting Reference Manual May 2020 00809 0100 4002 96 Rosemount DP Level ...

Page 97: ...ional drawings click Data Sheets Bulletins and select the appropriate Product Data Sheet 7 3 Spare parts Table 7 1 Flush Flanged FFW and Pancake PFW Lower Housings Material Size Part number One in Two in One in Two in 316 SST 2 in DP0002 2111 S6 DP0002 2121 S6 DP0002 2112 S6 DP0002 2122 S6 3 in DP0002 3111 S6 DP0002 3121 S6 DP0002 3112 S6 DP0002 3122 S6 4 in DN 100 DP0002 4111 S6 DP0002 4121 S6 DP...

Page 98: ...rgin PTFE GHB GRAFOIL Gylon 3510 316 SST 2 in DP0007 0201 TT DP0007 0201 TF DP0007 0201 GF DP0007 0201 GY 3 in DP0007 0301 TT DP0007 0301 TF DP0007 0301 GF DP0007 0301 GY 4 in DN 100 DP0007 0401 TT DP0007 0401 TF DP0007 0401 GF DP0007 0401 GY DN 50 DP0007 0601 TT DP0007 0601 TF DP0007 0601 GF DP0007 0601 GY DN 80 DP0007 0801 TT DP0007 0801 TF DP0007 0801 GF DP0007 0801 GY Table 7 3 Alignment Clamp...

Page 99: ...n steel 1 in DP0004 1100 Z1 DP0004 1111 Z1 DP0004 1121 Z1 DP0004 1112 Z1 DP0004 1122 Z1 1 in DP0004 1600 Z1 DP0004 1611 Z1 DP0004 1621 Z1 DP0004 1612 Z1 DP0004 1622 Z1 DN 25 DP0004 1700 Z1 DP0004 1711 Z1 DP0004 1721 Z1 DP0004 1712 Z1 DP0004 1722 Z1 DN 40 DP0004 1900 Z1 DP0004 1911 Z1 DP0004 1921 Z1 DP0004 1912 Z1 DP0004 1922 Z1 Alloy 400 1 in DP0004 1100 M4 DP0004 1111 M4 DP0004 1121 M4 DP0004 111...

Page 100: ... DP0070 1112 S6 DP0070 1122 S6 DP0070 111A S6 DP0070 112A S6 3 8 18 NPT DP0070 1201 S6 DP0070 1212 S6 DP0070 1222 S6 DP0070 121A S6 DP0070 122A S6 14 NPT DP0070 1301 S6 DP0070 1312 S6 DP0070 1322 S6 DP0070 131A S6 DP0070 132A S6 14 NPT DP0070 1401 S6 DP0070 1412 S6 DP0070 1422 S6 DP0070 141A S6 DP0070 142A S6 1 11 5 NPT DP0070 1501 S6 DP0070 1512 S6 DP0070 1522 S6 DP0070 151A S6 DP0070 152A S6 1 1...

Page 101: ...A Z1 DP0070 132A Z1 14 NPT DP0070 1401 Z1 DP0070 1412 Z1 DP0070 1422 Z1 DP0070 141A Z1 DP0070 142A Z1 1 11 5 NPT DP0070 1501 Z1 DP0070 1512 Z1 DP0070 1522 Z1 DP0070 151A Z1 DP0070 152A Z1 1 11 5 NPT DP0070 1601 Z1 N A N A N A N A 1 11 5 NPT DP0070 1701 Z1 N A N A N A N A G A DIN 16288 DP0070 1901 Z1 DP0070 1912 Z1 DP0070 1922 Z1 DP0070 191A Z1 DP0070 192A Z1 Alloy 400 18 NPT DP0070 1101 M4 DP0070 ...

Page 102: ...WP DP0007 24 01 K4 TBD DP0007 24 01 GY DP0007 24 01 GF N A N A N A 10000 psi MWP DP0007 24 01 K4 N A N A N A N A DP0007 24 03 M4 DP0007 24 03 HC Table 7 10 Plugs for Threaded RTW Lower Housings Material in in SST 01199 7000 0502 01199 7000 0504 Alloy C 276 01199 7000 0602 01199 7000 0604 Table 7 11 Sanitary Tank Spud Seal SSW Parts Part description Part number Sanitary tank spud 2 in extension 011...

Page 103: ...140 Table 7 13 Sanitary Thin Wall Tank Spud Seal STW Parts Part description Part number Thin wall spud 01199 0073 0001 Clamp 01199 0526 0004 Ethylene Propylene O ring 01199 7001 1003 Table 7 14 Sanitary Pipe Mount Seal UCP and Sleeve Seal PMW Parts Part description Part number PTFE gasket package of 12 02088 0078 0001 316 SST weld spud for UCP 02088 0295 0003 316 SST plug heat sink for UCP 02088 0...

Page 104: ...witzerland 41 0 41 768 6111 41 0 41 768 6300 RFQ RMD RCC Emerson com Asia Pacific Regional Office Emerson Automation Solutions 1 Pandan Crescent Singapore 128461 65 6777 8211 65 6777 0947 Enquiries AP Emerson com Middle East and Africa Regional Office Emerson Automation Solutions Emerson FZE P O Box 17033 Jebel Ali Free Zone South 2 Dubai United Arab Emirates 971 4 8118100 971 4 8865465 RFQ RMTMEA...

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