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Ensuring the accurate operation of a DCS (Distributed Control System) requires precise instrumentation signals. To achieve this, installations must strictly follow the guidelines outlined in GBJ93-96 "Self-Control Installation Map" and the manufacturer's instrument manual. Below are detailed installation requirements for various instruments:
1. Pressure Transmitter
- Do not install pressure or negative pressure sensors on straight sections of piping where turbulence or vortices may distort static pressure readings.
- The pressure tap should be smooth, without sharp edges, and the connecting pipelines should be clean with no burrs.
- For gas media, install the pressure tube on the upper part of horizontal or inclined pipes. For liquid media, install it in the lower half of the pipe, between 0° and 45° from the centerline. For steam, place it on the upper half of the pipe.
- All pressure-receiving devices must have a primary valve close to the sensor.
- Ensure the impulse line 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.
- Clean and purge the pipeline before installation. Test the valves for tightness and conduct a final pressure test after installation. Fill the line with water before commissioning, avoiding air bubbles.
- Refer to the manufacturer’s manual for smart transmitter installation instructions.
2. Temperature Transmitter
- Place the temperature sensing element where it can accurately represent the medium's temperature. Avoid dead zones near valves or elbows.
- If the pipe diameter is less than 76 mm, use a pipe expansion method for installation.
- Install platinum resistance thermometers horizontally or slightly downward for easy maintenance and to prevent dirt from entering.
- Position the sensing part of the thermometer at the center of the pipe, extending 50–70 mm beyond the center.
3. Electromagnetic Flowmeter
- Ensure environmental conditions (temperature, humidity, electromagnetic field) meet the manufacturer’s specifications.
- Provide sufficient straight pipe length upstream (10D) and downstream (3D–4D) of the flowmeter.
- Avoid injecting chemical additives upstream, as they may affect conductivity. If necessary, ensure a stable mixing section before the meter.
- Install the flowmeter so that the measuring tube is always full of liquid, with no air bubbles. For vertical installations with solids or slurry, ensure the flow direction is upward.
- Grounding is crucial. The flowmeter should have a grounding ring, and the system should follow single-point grounding principles with a resistance ≤100 Ω.
- Shielded cables should be grounded in the control room and connected through a ground bus.
4. Vortex Flowmeter
- Add supports if the pipeline experiences vibration.
- Install vertically or at an angle if the Reynolds number is above 2×10â´.
- Install the flowmeter upstream of the valve with at least 20D of straight pipe before and 5D after. If the valve is upstream, maintain 20D before and 5D after the flowmeter.
- Ensure 20D of straight pipe upstream and 10D downstream for any elbow or contraction/expansion sections.
- Take pressure measurements between 2–7D downstream of the flowmeter.
5. Power Concentration Transmitter
- Install the transmitter in a location free from mechanical damage and vibration. Keep the electronic unit cool, ventilated, and protected from moisture.
- Install the transmitter close to the dilution point to minimize time lag.
- Mount the transmitter on vertical or horizontal slurry pipes, ensuring alignment with the flow direction.
- Consider minimum distances L1 = 10D and L2 = 5D. Adjust based on actual flow rate and concentration.
- Ensure the short tube is properly aligned with the slurry pipe, avoiding raised edges during welding.
- Use stainless steel tubing for carbon steel pipes to simplify installation.
6. Flange Level Transmitter
- Install the transmitter at the bottom of the tank, away from exhaust ports.
- Choose a location with stable liquid levels, avoiding areas with agitators or pumps.
7. Electromechanical Interference Prevention
- Separate power and signal wires in metal conduits, grounded every 100 meters with at least 2m distance between them.
- Keep switchgear away from the instrumentation system, ideally on a separate stand.
- Apply Faraday cage shielding principles—use heavy-duty shields covering 80% of the conductor and ground only at one end.
8. Quantitative Cutting Valve
- Install valves with diameters 50–250mm on vertical, horizontal, or inclined pipes. For larger sizes, install on horizontal pipes and adjust upwards.
- Clean the pipeline before installation, and ensure the cutting arrow aligns with the flow direction.
9. Input Type Level Transmitter
- For stationary water, insert a steel pipe with small holes at different heights to allow water entry.
- For flowing water, position the pipe opposite the flow direction to allow water to enter.
- Install the transmitter vertically downward, away from inlets, outlets, and agitators.
10. L-Type Three-Way Valve
- Verify the valve type, size, and flow path before installation. Follow the manufacturer’s instructions to avoid misalignment or failure.
Following these guidelines ensures reliable and accurate performance of instrumentation systems in industrial environments.
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