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POSITIVE
DISPLACEMENT
FLOWMETERS

(HORIZONTAL VERSION)

MOD. 110 - 112

INSTALLATION OPERATION AND MAINTENANCE

PETROL INSTRUMENTS S.r.l. - 04011- APRILIA (LT) - ITALY

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INSTALLATION OPERATION AND MAINTENANCE MANUAL

ED. 03
REV. 06 dated 18/11/2019

P.O. No. _____________

Mod. _____________
Ser. No. _____________
C. _____________

 2001 Petrol Instruments S.r.l. - Via della Tecnica, 5 - 04011 Aprilia - Latina
It is forbidden any reproduction of this document, even partial, without a previous written approval by Petrol
Instruments S.r.l.
Petrol Instruments S.r.l. has the right to make all the necessary changes to this documents without any advance
notice.
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Sect. Description Pag.

1. General 4

2. Construction 5

3. Special Conditions
6
(MID Measuring System)

4. Disposal
7
(MID Measuring System)

5. Applicable Standards
9
(MID Measuring System)

6. Limits of use,
10
Special Conditions and Atex Marking

7. Installation Instruction 11

8. Start-up and Operating Instructions 13

9. Failures Analysis 14

10. Inspection Procedures 15

11. Inner Housing Ass’y Maintenance 16

12. Spare Parts 18

13. Storage 19

14. Troubleshooting table 20

15. Drawings 22

A. Spare Parts List 26

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1
General
"PETROL" PD flowmeters are instruments capable of measuring the volume of
flowing liquids with a standard accuracy of ± 0,5% of reading for general purposes
and of ± 0,15% of reading for fiscal transactions.

“PETROL” PD flowmeters have been employed since many years by different

industries (such as ship-building, steel making, power generation plants, refineries
and depots, chemical, pharmaceutical, textile industries etc.) of many countries and
have always satisfied the users for their good performances and dependable service
during the years.

This manual has been prepared for people responsible of their installation and, at the
same time, for people responsible of their maintenance and service.

This document includes specific aspects of installation, use and maintenance aimed
at mitigating the risk of explosion associated with use in hazardous areas.
Personnel involved in installation, testing and maintenance must possess the
qualifications required by Annexes F of EN 60079-14: 2014 and EN 60079-17: 2014.
The equipment supplied already has the metallic continuity of all its parts. Once it
reaches its destination, the equipment must be connected to the protection system
by connecting the equipment's grounding conductor to the installation site's ground
system. It is the responsibility of the final installer to verify the correct equipotential
connection with the dispersant system of the installation site

INVOLVED PERSONNEL ARE KINDLY REQUESTED TO READ CAREFULLY

THE PRESCRIPTIONS CONTAINED IN THIS MANUAL, MAINLY THOSE
RELEVANT TO PD FLOWMETERS INSTALLATION BEFORE THEIR START-
UP.
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Construction

PD flowmeters are mainly composed of the measuring unit ass'y and of the
indicator unit (see dwg.1).

The indicator unit, available in different models, is that required for the specific
application.

The measuring unit ass'y is composed of three main sub-ass'y, namely:

• the outer housing;

• the inner housing ass'y;
• the coupling ass'y.

The outer housing is the part that withstands the liquid pressure and its construction
is in accordance to max. expected pressure of flowing liquid.

The inner housing ass'y is the part through which the flowing liquid volume is
accurately metered through the revolutions of the rotors. (roots type mechanism).

The coupling ass'y is the part through which the number of rotors revolutions is
transmitted to the indicator unit where are displayed the volumes metered.
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Special Conditions
(MID Measuring System)
The measuring system has been evaluated to the 2014/32/UE directive, and found to
be suitable for measuring liquids other than water with an accuracy class of 0,3
according to the Annex VII of directive.

The meter and accessories must remain full of product at all times. Upstream lines
must remain full to prevent air from entering the measuring system components. If
upstream or inlet lines are constructed in a manner which allows reverse flow, foot
valves or back checks must be installed.

To ensure proper meter and accessory installation, adhere to the following:

Flush the entire piping system prior to component installation to rid the system of all
debris. Use a liquid compatible with the construction of the Petrol Instruments
components.
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Disposal
(MID Measuring System)

The measurement system is suitable for measurements of liquids other than water
having the characteristics and environmental conditions shown on the plate of the
measuring system.

Metrological seals guarantee the measurement system from the voluntary or

involuntary alteration of the correct functioning and calibration conditions. The seals
must not be removed. Removal can be carried out by the manufacturer and/or
personnel of Surveillance Bodies.

The plate of the measurement system contains the following information:

This equipment has been evaluated to the Equipment For
Potentially Explosive Atmospheres Directive, 2014/34/EU,
and found to be suitable for use in surface (not mines)
II 2G locations where a high level of protection is provided
against flammable gases, vapours, or liquids which may
exist during normal operation.
MX 0476 This equipment has been evaluated to the 2014/32/UE
directive, Annex VII and found to be suitable for measuring
X
liquids other than water by a Notified Body identified with
number 0476.
FLUID The intended process fluid.
The minimum flow range for which the meter is designed
FLOW MIN./MAX.
to operate.
The minimum and maximum working pressure to which
PS MIN./MAX.
the equipment should be subjected on a normal basis.
Weights & Measures field indicating the minimum
MMQ measured quantity. This is the smallest volume that can
be accurately delivered.
The minimum and maximum viscosity of fluid to which the
VISC. MIN./MAX.
accuracy is guaranteed.
The maximum flow range for which the meter is designed
FLOW MAX.
to operate.
TEMP. MIN./MAX. Maximum temperature for Weights & Measure purpose.
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ACCURACY Weights & Measures field for category of approval.

The minimum and maximum density of fluid to which the
DENS. MIN./MAX.
accuracy is guaranteed.
Environmental conditions class for mechanical, EMC and
ENV.
humidity which the meter is designed to operate and the
MECH./EM./HUM. CL.
accuracy is guaranteed.
This equipment has been evaluated to the Pressure
Equipment Directive 2014/68/EU and found to be suitable
PED. CAT.
for the category noted with regards to volume-pressure
limitations found within the equipment itself.

The measurement system must be used according to the instructions and conditions
contained in this manual. Inspection, maintenance and repair operations must be
performed following the instructions given in this manual by qualified personnel to
guarantee the metrological conformity of the measurement system.
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Applicable Standards
(MID Measuring System)

Directive 2014/32/EU - Harmonization of the laws of the Member States relating to

the making available on the market of measuring instruments

Directive 2014/34/EU - Equipment For Potentially Explosive Atmospheres Directive

Directive 2014/68/EU - Pressure Equipment Directive

Directive 2014/30/EU — EMC Directive

OIML R117-1 - Dynamic measuring systems for liquids other than water
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Limits of use,
Special Conditions and Atex Marking

The PD Flowmeters must be used only and exclusively within the limits shown on
the name plate, so only and exclusively for type of liquid, flow rate, temperature,
max pressure and viscosity specified on the nameplate (dwg. 1 ). IT IS NECESSARY
TO CAREFULLY CHECK THE DATA ON THE NAMEPLATE BEFORE STARTING THE
METER.
SPECIAL CONDITIONS FOR A SAFE USE

1. it is forbidden to use the equipment with an empty pipe

2. the installer/user must ensure that the installation position is respected as
declared by the manufacturer for the equipment for which a specific position is
envisaged

ATEX/CE MARKING on the PD flowmeters:

II 2G Exh IIC T6 … T3 X
II -/2D

: It’s the symbol of EC marking and it represents that the equipment is compliant
with 2014/34/UE directive. An EC declaration of conformity is included in the
documentation
: It’s the symbol of Ex, and it represents that the equipment is according to IEC
60079, and the ATEX guideline
II: It’s intended as Group II, electrical equipment for use with an explosive gas
atmosphere other than mines susceptible to firedamp.
2G: It identifies the equipment category; 2G is suitable for use in zone 1 in presence
of explosive gas and vapours inside the equipment but, outside, it is not suitable for
atex zones
2D: It identifies the equipment category; 2D is suitbale for use in zone 21 and 22 in
presence of dust
Exh: It identifies the protection for mechanical construction
IIC: It’s a subdivision of Group II, it identifies the nature of explosive gas atmosphere.
In this case the typical gas is hydrogen.
T6 … T3 It indicates the range of the maximum surface temperature, which shall be
between 85 °C and 200 °C
Ambient Temperature is: -20°C ≤ Tamb. ≤ +40°C
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Installation Instruction
PRECAUTIONS

The majority of PD flowmeters failures are caused by infiltration of solid particles

from the outer housing flanges during "inoperative conditions". It is therefore very
important:

• to remove the flanges protections only immediately before the instrument

installation;
• to absolutely prevent the entering of solid particles into the measuring unit ass'y
during installation.

INSTRUCTIONS

1. During flowmeter installation avoid that deformation and/or stresses are induced
into the outer housing from the connecting pipes. IF THE PD FLOWMETER IS
EQUIPPED WITH ANCHORING PLATES, BOLT THEM STRONGLY TO AVOID
VIBRATIONS.

2. Check that actual flow direction is the same indicated by the arrow on the
flowmeter outer housing and/or in accordance to the "in" and "out" name-plates
attached to the inlet and outlet flanges of the flowmeter.

3. For the measure of very viscous liquid at ambient temperature it is recommended

to provide heating for both the line and the flowmeter (if necessary jacketed type
PD flowmeters are available).

4. It is recommended to provide enough space on the front side of flowmeter for

front cover removal as well as for inner unit assembly removal.

5. It is good practice to install a strainer just before the flowmeter. However if plant
configuration does not permit the direct coupling of flowmeter and strainer it is
imperative to clean throughly, before flowmeter installation, the spool pipe used
for strainer and flowmeter connection.
In case of new lines and specially in case of new and long lines, flush accurately
the lines themselves, by pumping liquid in the piping, before flowmeter installation
or, should such operation be impractical, remove the inner housing ass'y from
outer housing when flushing the lines.
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Installation Instruction

INSTALLATION EXAMPLES

1. Wherever possible install the flowmeter on a by-pass, as shown in dwg. 2a and

2b, for its easier disassembly and inspection.

2. When an appreciable quantity of solid particles is expected to be present in the

flowing liquid, install two strainers in parallel for alternate use as shown in dwg. 3.

3. In case gas bubbles are expected in the flowing liquid, install a suitable deaerator
as shown in dwg. 4.
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Start-up and Operating Instruction
1. For new lines let the liquid flow through the by-pass in order to completely wash
away any scale traces. Scale remaining in the lines might cause unusual wear of
bearings and of timing gears.

2. In case the PD flowmeter is not installed on a by-pass or in case the line deesn’t
have a by-pass, remove the inner housing ass'y from the PD flowmeter outer
housing flanged to the piping and let the liquid flow through the line until the line
itself is completly clean and any trace of scale has been washed away.
Once the line flushing has been completed, install the inner housing ass`y into
the outer housing and proceed with the PD flowmeter start-up.

3. To start-up the flowmeter open first the inlet valve and then open slowly the outlet
valve.

AVOID TOO HIGH FLOW RATES AS WELL AS TOO SHORT OPENING

AND/OR CLOSING CYCLES.

4. During initial service periods check frequently the strainer screener, eventually
cleaning it to avoid clogging.

5. PD flowmeters maintain an high accuracy for long periods of time when operating
within the flow rate range for which they have been realized. It is recommended to
operate the flowmeter only within the flow rate limits specified in the name-plate.

6. In case flowmeters are installed in cold places and specially when metering water
in such cold places it is recommended, once the measuring cycle has been
completed, to drain completly, through the proper drain plugs, the liquid remained
into the flowmeter to avoid damages to the housing and/or rotors deformations
due to liquid freezing.

7. Should the line where the PD flowmeter is installed be subject to periodic

flushing with high temperature steam and/ or vapor, it is strongly recommended,
during the flushing phase, that inner housing ass'y is removed from the outer
housing flanged to the piping, to avoid that sudden mechanic and thermic shocks
may damage the components of the measuring mechanism.
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Failure Analysis
Failures of the flowmeter counter may be caused by:

1. Solid particles inside the inner housing ass'y;

2. Rotors interference due to excessive wear of bearings and of timing gears;

3. Failure of coupling ass'y due to excessive wear of fork-type coupling.

4. Failure of indicator unit.

In case of flowmeter counter failure it is necessary to inspect the instrument

following step by step the inspection procedures listed under item 7, replacing,
where needed, damaged parts with new parts.
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Inspection Procedures
To check the inner housing ass'y it is at first necessary to control whether the
rotation of timing gears is regular or not.
It is therefore necessary to remove the front cover of PD flowmeter outer housing
(see dwg. 1) un-screwing the relevant fixing bolts and nuts.
The front cover of the outer housing may be removed together with the counter unit.
During such an operation particular care must be used to avoid any damage of the
"fork type" coupling system existing between the inner housing ass'y and counter unit
itself.
Once removed the front cover, the timing gears of the inner housing ass'y may be
inspected and their rotation may be checked by hands or with an adeguate wrench.

• Should the rotors rotation be normal or uniform it is necessary to check the

movement transmission system between inner housing ass'y and counter unit.
The transmission system components are integrally mounted with the front cover
and in the actual situation may be easily inspected without particular instructions.

• Should the rotors rotation be not normal or uniform it is necessary to pull-out the
inner housing ass'y from the outer housing to proceed to relevant inspection and
maintenance.
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Inner Housing Ass’y Maintenance
The inner housing ass'y is shown in dwg. 5 as an ass'y and in dwg. 6 as exploded
view.

The numbers printed in the two (2) above mentioned drawings, are those identifying
the components listed in the legenda of drawing 6.
To disassembly the rotors it is recommended to proceed in the following way.

1. remove the front cover (50), side timing gears, taking-out the relevant fixing screws
(66).
2. remove the shaped rotors plate (48) taking-out the relevant fixing screws (64).
3. mark the relative position of timing gears by making a recognizing sign on them.
Such marking is necessary for the correct re-assembly of rotors.
4. pull-out the rotors from inner housing ass'y, using the timing gears as pullers.

Once rotors have been removed the actual conditions of the rotors themselves and
the wear conditions of the timing gears and of the bearings may be properly
evaluated. It is just the case to mention that the rear cover is disassembled following
the same procedures mentioned under item 1).

• TIMING GEARS
The purpose of timing gears is to synchronize the rotors and their relative position
is established by the centering pins (34). Should timing gears be replaced, it is
recommended to use particular care in the re-positioning of the new gears. The
timing gears are removed by unscrewing the relevant fixing screws (37).

• BEARINGS
Should be necessary to replace the bearings (22, 59), those must be removed
from relevant covers together with the bearing holders (23, 60). To facilitate such
an operation it is recommended to mount a screw on the threaded holes of the
bearing holders and to use them to remove the system bearing/bearing-holder.

Inner housing unit re-assembly procedures are just the reverse of rotors
disassembling procedures above mentioned.
However the utmost care and attention must be placed to the following points.
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Inner Housing Ass’y Maintenance

1) check that the "clearances", i.e., the distance between the rotors and the distance
between the rotors and the inner unit body are uniform;

2) check that rotor position is that corresponding to the recognizing marks previously
made on the timing gears.

The PD flowmeter re-assembly procedures are just the reverse of disassembly

procedures above mentioned for inner unit ass'y check.
The utmost care must however be placed in re-mounting the front cover to avoid
damages to the "fork type" coupling (43, 44, 45) between inner unit ass'y and counter.
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Spare Parts
To order spare parts make reference to the attached exploded-view drawing.

When placing the order please specifiy:

a) flowmeter model, printed on name-plate (see dwg. 1)

b) flowmeter serial number, printed on name-plate (see dwg. 1)

c) item number and description of parts as specified in the attached exploded-view

drawing
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Storage
PD flowmeters are normally supplied packed inside wooden cases that may be easily
handled without damaging the instruments.

For cases handling all types of motor machinery and/or hand machinery generally
available at storage houses may be used.

It is however recommended to avoid the superimposing of cases except in case of

equal dimensions and similar gross weight.

No special precautions have to be taken for short periods of storage. It is however

recommended that cases are possibly stored in a closed warehouse and anyway not
left in open areas exposed to rain, sand and wind.

In case of long periods of storage, cases must be stored in a closed warehouse. In

addition, PD flowmeters maintenance procedures must be strictly followed
immediately after equipment unpacking and/or immediately before their installation
and/or start-up.

It is in any case imperative that at least the measuring unit is removed from the
outher housing and duly checked according to its specific maintenance procedures,
before PD flowmeter start-up.
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Troubleshooting Table

FAILURES FOR PD FLOWMETERS WITH MECHANICAL COUNTER

FAILURE CAUSE SOLUTION

Check the correct operation
Mechanical counter failure
of the mechanical counter
Connection between Check the correct operation
The liquid flows regularly
magnetic transmission of the reduction gear
but the PD flowmeter
and mechanical counter assembly
does not count
Connection between PD Check the correct operation
flowmeter and reduction of the magnetic
gear assembly transmission
Disassemble and inspect
Rotors failure
the rotors
Foreign bodies stuck Remove foreign bodies and
The liquid does not flow
between the surfaces of restore the surface of the
through the PD
the rotors rotors.
flowmeter
Check the correct operation
Timing gears blocked
of the timing gears
Strainer clogged Clean the strainer
The liquid leaks from the
O-ring damaged; cover Replace the O-ring and
junction between the
screws not properly tighten the screws of the
front cover and / or rear
screwed covers
and the body
Bushings and / or timing Replace the bushings and /
Lack of accuracy
gears worn or timing gears
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FAILURES FOR PD FLOWMETERS WITH ELECTRONIC COUNTER

FAILURE CAUSE SOLUTION

Check the correct operation
Electronic counter failure
of the mechanical counter
Connection between
The liquid flows regularly Check the correct operation
magnetic transmission
but the PD flowmeter of the pulse transmistter
and mechanical counter
does not count
Connection between PD Check the correct operation
flowmeter and reduction of the magnetic
gear assembly transmission
Disassemble and inspect
Rotors failure
the rotors
Foreign bodies stuck Remove foreign bodies and
The liquid does not flow
between the surfaces of restore the surface of the
through the PD
the rotors rotors.
flowmeter
Check the correct operation
Timing gears blocked
of the timing gears
Strainer clogged Clean the strainer
The liquid leaks from the
O-ring damaged; cover Replace the O-ring and
junction between the
screws not properly tighten the screws of the
front cover and / or rear
screwed covers
and the body
Bushings and / or timing Replace the bushings and /
Lack of accuracy
gears worn or timing gears
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Drawings

Drawing n.1
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Drawing n.2a

Drawing n.2b
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Drawing n.3

Drawing n.4
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50
60
59

62

48

Drawing n.5
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“A” Spare Parts List

models 110-112
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