Ensuring the accurate operation of a DCS (Distributed Control System) requires precise instrumentation signals. To achieve this, all instruments must be installed strictly in accordance with the GBJ93-96 "Self-Control Installation Map" and the manufacturer's manual. The following are detailed installation guidelines for various types of instruments:
1. Pressure Transmitter
- The pressure and negative pressure sensors should not be installed in straight sections of the pipe, nor in areas where flow distortion may occur, such as bends, corners, or dead zones.
- When installing pressure or vacuum devices, the pressure tube should not protrude into the fluid stream and should be perpendicular to the flow direction. The pressure tap should have smooth edges to avoid turbulence.
- For gas fluids, install the pressure tube on the upper part of horizontal or inclined pipes. For liquids, install it in the lower half, within 0–45° of the horizontal centerline. For steam, install it on the upper half, also within 0–45° of the horizontal centerline.
- All pressure-receiving devices must be equipped with a single valve, and the primary valve should be close to the sensor.
- Ensure the impulse pipeline has a slope of at least 1:100 to allow air or condensate to drain. A drain valve should be installed near the pressure gauge.
- Purge the pipeline before installation and test for tightness. Fill the line with water before commissioning, avoiding any air bubbles that could affect measurement accuracy.
- Refer to the manual for smart transmitter installation instructions.
2. Temperature Transmitter
- The temperature sensor should be placed in a location that accurately reflects the medium’s temperature. Avoid placing it near valves, elbows, or dead zones.
- For pipes smaller than 76 mm in diameter, use a method to expand the pipe for proper installation.
- Install platinum resistance thermometers horizontally or slightly downward on horizontal pipes to prevent dirt from entering and to allow easy removal.
- The sensing element should be centered in the pipe, extending 50–70 mm beyond the center.
3. Electromagnetic Flowmeter
- Installation environment must meet the manufacturer’s requirements regarding temperature, humidity, and electromagnetic interference.
- Ensure sufficient straight pipe lengths upstream (10D) and downstream (3D–4D) of the meter.
- Avoid injecting chemicals upstream that could alter the liquid’s conductivity unless a reactor or long straight section is used to stabilize the flow.
- Install the flowmeter so that the measuring tube is always filled with liquid, without air bubbles. For vertical installations, ensure flow is upward.
- Grounding is essential. Use a grounding ring to connect the liquid to ground, ensuring a single-point grounding system with resistance ≤100 ohms.
- Shield the signal cables properly and ground them in the control room.
4. Vortex Flowmeter
- If the pipeline vibrates, add supports to reduce mechanical stress.
- Install vertically or at an angle if the Reynolds number is above 2×10â´.
- Place the flowmeter upstream of valves when necessary, ensuring sufficient straight pipe length before and after.
- Ensure 20D of straight pipe upstream and 5D downstream of the flowmeter.
- Position the pressure and temperature measurement points correctly for accurate readings.
5. Power Concentration Transmitter
- Install the transmitter away from vibration and mechanical damage. Place the electronic unit in a cool, ventilated area.
- Install the transmitter as close as possible to the dilution point to minimize time lag.
- Mount the transmitter on vertical or horizontal slurry tubes, ensuring alignment with the flow direction.
- Ensure minimum distances L1 = 10D and L2 = 5D between the transmitter and other components.
- Use stainless steel tubing when welding is difficult, and ensure the short tube is properly aligned with the slurry tube.
- Handle the blade carefully, and ensure it is parallel to the slurry flow.
- Use shielded cables and protect all wiring with galvanized steel conduits.
6. Flange Level Transmitter
- Install the transmitter at the bottom of the tank, away from exhaust ports and turbulent areas.
- Choose a stable location, avoiding agitators or pumps that may cause disturbances.
7. Electromechanical Interference Prevention
- Separate power and measurement wires in metal trays, grounded every 100 meters. Keep at least 2m apart between different wire types.
- Keep switchgear away from the instrumentation system to reduce interference.
- Apply the Faraday enclosure principle for shielding, using heavy-duty woven shields grounded at one end only.
8. Quantitative Cutting Valve
- Install valves with diameters 50–250mm on vertical, horizontal, or inclined pipes. Larger sizes should be installed horizontally with mechanical support.
- Clean the pipeline before installation and ensure the cutting arrow aligns with the flow direction.
- Install the electronic unit near the valve or control room, away from vibration and moisture.
9. Input Type Level Transmitter
- For stationary water, insert a steel pipe with small holes at different heights to allow water to enter smoothly.
- For flowing water, position the pipe opposite the flow direction to allow water to enter.
- Install the transmitter vertically downward, away from inlets and agitators.
- Wrap the cable around the transmitter to prevent damage from vibrations.
10. L-Type Three-Way Valve
- Before installation, confirm the valve type, specification, and flow path. Follow the manufacturer’s instructions to avoid misalignment or failure.
Following these guidelines ensures reliable performance, reduces maintenance, and improves system accuracy across various industrial applications.
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