EMERSON Rosemount 1199 DP Level Transmitters and Diaphragm Seal Systems User Guide
- June 4, 2024
- Emerson
Table of Contents
- EMERSON Rosemount 1199 DP Level Transmitters and Diaphragm Seal Systems
- Introduction
- Preface
- General handling overview
- Mechanical installation
- Flanged type seals
- Pancake-type seal options
- Threaded type seals
- Hygienic type seals
- Saddle type seals
- TFS wafer style in-line seal
- Ranging the transmitter
- Rosemount 1199 seal types
- Rosemount 1299 Seal Types
- References
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
EMERSON Rosemount 1199 DP Level Transmitters and Diaphragm Seal Systems
Introduction
A remote seal system consists of a pressure transmitter, a remote seal, and either a direct mount or capillary style connection filled with a secondary fill fluid. During operation, the thin, flexible diaphragm and fill fluid separate the pressure sensor of the transmitter from the process medium. The capillary tubing or direct mount flange connects the diaphragm to the transmitter. When process pressure is applied, the diaphragm is displaced, transferring the measured pressure through the filled system, by way of the capillary tubing, to the transmitter. This transferred pressure displaces the sensing diaphragm in the pressure sensor of the transmitter. This displacement is proportional to the process pressure and is converted electronically to an appropriate output current and/or digital protocol.
Path of Pressure in a Standard DP Level Seal System
- A. Pressure
- B. Process isolating diaphragm
- C. Transmitter diaphragm
- D. Fill fluid
- E. Transmitter pressure sensor
Preface
This guide is designed to assist with general handling and installation instructions for the Rosemount DP Level Transmitters and both 1199 and 1299 Diaphragm Seal Systems. The Rosemount DP Level Transmitters and Diaphragm Seal Systems Reference Manual contains supplemental information about the seal system assemblies that are not covered in the corresponding transmitter manuals.
General handling overview
Check if equipment received conforms to the order. If any issues, contact your local Emerson sales representative immediately. When unpacking or handling seal system assemblies, do not lift the seal or transmitter by gripping the capillaries, doing so could result in disconnecting the seal and/or capillary from the transmitter, which will void the warranty. The material of a remote seal is designed to withstand pressure and wear from process material, but outside of process connection conditions, remote seals are delicate and should be handled with care. The protective cover should remain on the seal until the moment before installation. Try to avoid touching the diaphragm with fingers or objects and refrain from setting the diaphragm side of the seal down on a hard surface. Even minor dents or scratches in the diaphragm material may impair the performance of the seal system assembly. Avoid sharply bending or crimping the capillary tubing. The minimum bending radius of the capillary tubing is 3-in. (8 cm). When using heat or steam tracing, exercise caution if PVC coating is added onto capillary. The PVC coating on the armor will break down at temperatures around 212 °F (100 °C). Best practice for heat and steam tracing is to regulate the temperature above the maximum ambient temperature for a consistent result. To avoid accuracy effects and thermal stress, the capillary should not be partially heated.
Mechanical installation
NOTICE
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.
Mounting the seal system in vacuum applications
Mounting the pressure transmitter at or below the bottom vessel tap is an
important factor to ensure a stable measurement with vacuum applications. The
static pressure limit for a differential pressure transmitter is 0.5 psia (25
mmHgA), which ensures the transmitter sensor module fill fluid remains within
the liquid phase of the vapor pressure curve. If the vessel static limit is
below 0.5 psia, mounting the transmitter below the bottom tap provides a
capillary fill fluid head pressure on the module. A general rule in vacuum
applications is to mount the transmitter approximately 3 ft. (1 m) below the
bottom tap of the vessel. Capillaries are to be securely fastened in order to
avoid false readings.
Insulation considerations with a Thermal Range Expander seal system
The Thermal Range Expander System uses the heat from the process in order to
keep both fluids within the system functioning properly, therefore insulation
is not always required. However, it is always best practice to insulate
systems to keep them functioning with optimum performance. The Thermal Range
Expander should never be insulated above the line marked on the seal itself,
see the figure below for reference.
Thermal Range Expander System Insulation Considerations
Flanged type seals
Gaskets
When installing remote seal systems which employ a gasket or a gasket and
flushing connection ring, make sure the gasket is aligned properly on the
gasket sealing surface. Failure to properly install the gasket may cause
process leaks, which can result in death or serious injury. In addition, make
sure the gasket does not press down upon the diaphragm face. Anything pressing
on the diaphragm will be read by the transmitter as pressure. A misaligned
gasket may cause a false reading or damage the diaphragm. The diaphragm gasket
is supplied when a lower housing or flushing connection is provided. The
default gaskets are listed below, 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
Gasket Materials
Seal type | Gaskets |
---|
Flanged seals assemblies
FFW| Klinger C-4401
RFW| Klinger C-4401
Seal type | Gaskets |
---|---|
EFW | No gasket is supplied |
PFW | Klinger C-4401 |
FCW | No gasket is supplied |
RCW | Klinger C-4401 |
FUW/FVW | No gasket is supplied |
Threaded seal assemblies
RTW| Klinger C-4401
HTS| No gasket is supplied
Hygienic seal assemblies
SCW(1)| No gasket is supplied
SSW| Ethylene propylene O-ring
STW| Ethylene propylene O-ring
EES| No gasket is supplied
VCS(1)| No gasket is supplied
SVS(1)| No gasket is supplied
SHP| No gasket is supplied
SLS(1)| No gasket is supplied
MLS(1)| No gasket is supplied
Specialty seals
WSP| Klinger C-4401
UCP| Barium-Sulfate filled PTFE O-ring
CTW| No gasket is supplied
TFW| No gasket is supplied
WFW| Klinger C-4401
1299 does not come with a default gasket, it must be specified in the model number or ordered as a spare.
Maximum working pressure (MWP)
Verify the MWP as marked on the transmitter neck label meets or exceeds the
expected maximum process pressure the transmitter/seal assembly could
experience once installed. If a flushing ring is , its MWP should also be
verified.
Bolt torquing
When connecting the process and mating flange, 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 customer
supplied.
Pancake-type seal options
Capillary support tube
A common option for the pancake-type seal (PFW) is the capillary support tube.
Due to the side capillary-to-seal connection, the support tube provides a
handle for aligning the pancake seal during installation. The support tube
should not be used for supporting any weight above that of the remote seal.
Process flange
Emerson offers the option of supplying the process flange, otherwise, the
process flange is furnished by the customer. For certain pancake seal
assemblies, the Emerson supplied process flange has a machined hole through
the center of the flange. This hole corresponds to a threaded connection in
the back of the pancake seal upper housing. The flange can, therefore be
connected to the seal prior to installation to make handling easier.
Threaded type seals
Lower housing installation procedure
The lower housing of the remote seal has either a male or female thread
connection for attachment to a process pipe nipple. When threading the lower
housing to the process pipe, care should be taken not to overtighten. The
applied torque should comply to ANSI B1.20.1 for NPT connections or applicable
torque requirements for pipe connections.
Upper housing installation procedure
The threaded seal is supplied with carbon steel, bolts, and nuts. 304 SST or
316 SST bolts and nuts can be ordered as options. The torque specifications
for the RTW seal can be found in the table below.
Gasket installation
Threaded seals with flushing connection rings come with a sealing gasket. When
connecting the remote seal, gasket, and flushing connection ring make sure the
gasket is properly aligned on the gasket sealing surface.
Torque Specifications
PSIG rating | Bolt material | Torque specification |
---|---|---|
800 | CS | 20 ft-lbs |
500 | SST | 15 ft-lbs |
2500 | CS | 53 ft-lbs |
2500 | SST | 50 ft-lbs |
5000 | CS | 105 ft-lbs |
5000 | SST | 120 ft-lbs |
10000 | CS (SST N/A) | 180 ft-lbs |
Alternative system installation procedure
An alternative to threading the entire seal system assembly to the process
piping is to unbolt the seal upper and lower housing and thread the lower
housing to the hard piping separately. Bolt the upper and lower housings
together to the required torque specification. Note that gaskets need to be
replaced once they have been torqued. Thus this alternative system
installation procedure requires gasket replacement.
Hygienic type seals
Hygienic approvals
Supplied 3-A approved hygienic seals are marked with a 3-A symbol. Supplied
EHEDG approved hygienic seals are marked with a EHEDG symbol.
Clamp style tank spud
For clamp style tank spud seals the procedures for welding the tank spud to
the tank vessel are shipped with the tank spud. For the welding procedure
refer to Rosemount DP Level Transmitters and Diaphragm Seal Systems Reference
Manual for proper welding tank spud guidelines. The clamp and gasket are
furnished by the user. Maximum pressure rating of the system is dependent upon
the clamp device. The clamp and O-ring are provided with the tank spud seal.
Attach the clamp and hand-tighten the connection.
Flange style tank spud
When connecting the process and mating flange, the bolts should be torqued to
the specifications outlined by ANSI B16.5 or applicable flange requirements.
Saddle type seals
Lower housing installation procedure
For 4-in. line size, the lower housing is welded directly into the process
pipe. For 2- and 3-in. line sizes, the lower housing is welded onto the
process pipe. The upper housing must be removed from the system when welding
the lower housing into the process pipe. Allow the pipe connection to cool
before installing the seal upper housing.
Upper housing installation procedure
The torque specifications for the saddle seal upper housings is 180 in-lb. (20
N-m) for all bolting material. As it is necessary for the customer to torque
the upper housing bolts during installation, each saddle seal includes a
torque label with the specified torque.
Gasket installation
The saddle type seal comes standard with a sealing gasket. When connecting the
upper and lower housings make sure the gasket is aligned properly on the
gasket sealing surface.
TFS wafer style in-line seal
Connection styles
The in-line flow-through seal is attached to the process piping by flange,
clamp, or male threaded connections.
Flanged type connection
The flow-through seal comes between the two process flanges due to the flanged
process connection. The bolts should be torqued to the specifications outlined
by ANSI B16.5 or EN 1092-1, JIS B 2210 flange torque requirements. Required
torque is a function of the gasket material and surface treatment of the bolts
and nuts, which are customer supplied.
Ranging the transmitter
Rosemount DP Level Transmitters and Diaphragm Seal Systems Reference Manual for proper ranging guidelines for open tank-single seal and pressurized tank- two seals.
Rosemount 1199 seal types
Flanged seal assemblies
- FFW Flush Flanged Seal
- RFW Flanged Seal
- EFW Extended Flanged Seal
- PFW Pancake Seal
- FCW Flush Flanged Seal – Ring Type Joint (RTJ) Gasket Surface
- RCW Ring Type Joint (RTJ) Flanged Seal
- FUW and FVW Flush Flanged Type Seals
Threaded seal assemblies
- RTW Threaded Seal
- HTS Male Threaded Seal
Hygienic seal assemblies
- SCW Hygienic Tri-Clover Style Tri Clamp Seal
- SSW Hygienic Tank Spud Seal
- STW Hygienic Thin Wall Tank Spud Seal
- EES Hygienic Flanged Tank Spud Extension Seal
- VCS Tri Clamp In-Line Seal
- SVS VARIVENT®
- Compatible Hygienic Connection Seal
- SHP Hygienic Cherry-Burrell “I” Line Seal
- SLS Dairy Process Connection – Female Thread Seal per DIN 11851
Specialty seal assemblies
- WSP Saddle Seal
- UCP Male Threaded Pipe Mount Seals and PMW Paper Mill Sleeve Seals
- CTW Chemical Tee Seal
- TFS Wafer Style In-Line Seal
- WFW Flow-Thru Flanged Seal
Rosemount 1299 Seal Types
Flanged seal assemblies
- Offline Flanged Seal
- Flush Flanged Seal
- Pancake Seal
- Extended Flange Seal
- Flush Flanged with RTJ Surface Seal
Threaded Seal
- Offline Threaded Seal