Calibron Systems, Inc.

OPERATION AND INSTALLATION

MANUAL
MODEL D625L
Dated : JUNE 1999
P/N 17172324
Rev: F

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MODEL D625L DENSITY METER
OPERATION AND INSTALLATION
MANUAL

DENSITRAK® MODEL D625L LIQUID DENSITY METER

REV. F
June, 1999

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 MODEL D625L DENSITY METER
OPERATING MANUAL
TABLE OF CONTENTS

SECTION I DESCRIPTION Page

1. Introduction 3
2. Theory of Operation 3
3. Specification 5
4. Design Features 6
5. Electronics 7

SECTION II INSTALLATION

1. Unpacking 8
2. Piping Installation 8
3. Wiring Installation 9

SECTION III CALIBRATION

1. Factory Calibration 10
a. Density Linearization 10
b. Pressure and Temperature Compensation 10
2. Field Calibration 10
2.1. Pycnometer measurement 10
2.2. Hydrometer measurement 11

SECTION IV MAINTENANCE 12

SECTION V TROUBLESHOOTING GUIDE 13

SECTION VI CONVERSION TABLES 14

SECTION VII FIGURES 15

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 Model D625L Operating Manual

Section I
DESCRIPTION

1. INTRODUCTION

The DENSITRAK® Model D625L is designed to provide continuous measurement of fluid density
under operating conditions. It produces a square wave frequency output signal that can be processed by
microprocessor-based signal converters or flow computers. Model D625L is widely used but not
limited to many of the following density monitoring applications:
■ Petroleum Pipeline & Refinery
■ Chemical & Petrochemical
■ Products Blending & Interface
■ Pulp & Paper Industries
■ Automotive
■ Food processing
■ Chemical

2. THEORY OF OPERATION

Calibron’s “DENSITRAK®” Model D625L Density meter consists of a spring-mass system containing
a vibrating tube flooded with the measured fluid. The change in natural resonant frequency of the
vibrating tube due to the effect of fluid mass represents the fluid density.
The driving force unit maintains the tube’s natural vibration frequency through an electrical feedback
circuit, as well as supplies an output signal of the frequency as the tube vibrates.
Figure 1 illustrates the cutout view of the Model D625L and its operating principle. In normal
operation, the fluid flows through the vibrating tubes changing the oscillation periodic time
proportionally with the density of the fluid. The heavier fluids will cause an increase in the periodic
time (a decrease in frequency). This change in the Density meter periodic time is defined by the
following relationship:
Du = K0 + (K1 x T) + (K2 x T2)
Where:
Du = Density in gr/cc, uncorrected for the temperature and pressure effects of the vibrating tubes.
T = Periodic time of oscillation of the Density meter in microseconds

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 Model D625L Operating Manual

K0, K1, K2 = Factory Calibration coefficients for each instrument. The K0 coefficients may be
adjusted in the field to optimize the actual performance of the Density meter.

To allow for thermal effects compensation of the basic signal output frequency, a platinum RTD is
bonded to one of the vibrating tube elements. The RTD’s output is conditioned and linearized by the
built-in electronics for 4-20 mA output. The 4-20mA output for temperature and the frequency from
the Density meter can be processed by Calibron SPUD 604 or SPUD 620 Signal Processor for Density.
A pressure transmitter is required externally for pressure compensation.
The temperature and pressure compensation for the vibrating tubes are defined by the following
relationship:
Dt = Du + [(KTv x Du + KT0) x (tm-tc)] + [KT1 x (tm-tc)2]
Where:
Dt = Density, compensated for temperature

KTv, KT0, KT1 = Temperature calibration coefficients

tm = Live temperature in degree Fahrenheit
tc = Calibration temperature in degree Fahrenheit
Dpt - Dt x (Dt*KPv*P) + (KP0*P + KP1*P2)
Where:
Dpt = Density, compensated for temperature and pressure

KPv, KP0, KP1 = Pressure calibration coefficients

P = Live pressure in psig

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 Model D625L Operating Manual

3. SPECIFICATION

DENSITY RANGE:
0.3 to 2.0 gr/cm3 or 300 to 2000 Kg/m3
Maximum Range 0.7 gr/cc
ACCURACY / LINEARITY:
<0.0001 gr/cm3 OR 0.5 Kg/M3
REPEATABILITY:
Better than 0.01%
OPERATING TEMPERATURE:
Standard: 50oF to 140oF
Optional: 32oF to 240oF

OPERATING PRESSURE:
Line Pressure . . . . . . . . . . . . . . . . 2500psi (ANSI 1500) / 24821 KPa
Hydrostatic test . . . . . . . . . . . . . .3250psi / 37231 Kpa
MATERIAL:
Wetted part. . . . . . . . .Hastelloy C-276, stainless steel type 316, viton O-ring
Cover. . . . . . . . . . . . . .Stainless steel type 304

POWER REQUIREMENTS:
Voltage. . . . . . . . . .18 - 30 VDC
Current . . . . . . . . . .30 mA nominal
SIGNAL CHARACTERISTICS:
300 Hz to 2000 Hz frequency output. Open collector square wave @ 24 VDC pp
TEMPERATURE SENSOR : (built in)
RTD Output, 100 Ω Platinum (α = 0.00385) and 4-20 mA Output (0oC to 100oC)
PHYSICAL SIZE : (See figure 2)
Height - 14 inch (355.6 mm) Diameter - 3 inch (76.2 mm)
Shipping Weight (approx.) 8 pounds (3.63 Kg)
Process pipe connection -!” Female NPT (U.S.)
Electrical conduit connection -"” Male NPT (U.S.)

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 Model D625L Operating Manual

ELECTRICAL CLASSIFICATION: Design to meet

Standard . . . . . . . . . . . . .Explosion-Proof Class I, Division 1, group D
Optional . . . . . . . . . . . . . Intrinsic Safety Barriers

FLOW RATE:
Model D625L will operate when it is filled completely with measuring fluids in static condition. When
it is used on line in a continuous measurement, the minimum flow rate should be between 2 to 3 gpm or
sufficient to maintain the same temperature between the Density meter and the line. In the case that a
pycnometer is installed in series with the Density meter, a higher flow rate may be required. The
maximum flow rate is 30gpm.

Note: The measuring liquid must be free of air or gas bubbles

since they will alter or disrupt the operating frequency of the
Density meter.

4. DESIGN FEATURES
High Accuracy and Repeatability - High accuracy, stability and repeatability of Model D625L is assured
because its operation is dependent solely upon the mechanical stability of the vibrating tubes.
Small Size - The DENSITRAK’s small size allows the instrument to be mounted on line in short inlet
runs assuring the DENSITRAK is measuring at line temperature.
Safety Feature - A heavy, walled, welded cover completely protects the sensitive measuring elements
from inadvertent mechanical and environmental damage.
Temperature Sensor - A two-wire Platinum RTD sensor is permanently affixed to one of the vibrating
tube elements. An RTD amplifier transmitter provides complete RTD current excitation, instrument
amplifier, linearization and 4-20mA current output. The transmitter operates on loop power supply
voltages down to 9 VDC.
Low Maintenance - The DENSITRAK’s smooth bore tubes are self-flushing and require cleaning only
under the most adverse condition. The electronic modules are simply encapsulated and easily field
replaceable.

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 Model D625L Operating Manual

5. ELECTRONICS
The Frequency Amplifier module and the Temperature module are all solid state and mounted within
the explosion-proof condulet mounted on the DENSITRAK®. They are easily accessible for service
and replacement.
The amplifier circuitry produces a frequency square wave signal suitable to drive external
microprocessor-based circuitry for density readout. The frequency amplifier and the Temp module
circuitry must be powered by an external power supply of 18 to 32 VDC.

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 Model D625L Operating Manual

Section II
INSTALLATION

WARNING
The accuracy performance depends largely on how well the Density meter is
installed. The Density meter installation should be carefully arranged to be free
from, but not limited to the following:
■ Gas or air bubbles
■ Severe vibration
■ Contaminants
■ Turbulence from pumps
■ Temperature effect from ambient due to insufficient insulation

The cost of designing an accurate density measurement installation is insignificant

in comparison to the potential loss resulting from an error in density measurement.

1. UNPACKING
Carefully unscrew and remove the cover of the electrical condulet. Visually inspect the electronic
modules and their wiring connection for any visible breaks, damage and loose hardware due to
shipment. Reinstall the condulet cover.

2. PIPING INSTALLATION
Normally the DENSITRAK is mounted on the pipeline, either up stream or down stream of the
metering point and as close to the metering point as good measurement practices permit. Some method
must be used to cause flow through the instrument (Figure 4-6d). The pressure drop across an orifice
plate, valve or scoop is all that will be necessary. Flow rate through the DENSITRAK should be high
enough to maintain temperature stability, but not so great as to cause cavitation or undue pressure drop.
The DENISTRAK will operate in any position, but the preferred orientation is on its side so as to aid in
the purging of all the entrained gas from the sensing tubes.
If mounting other than in Figure 4, always keep the inlet run as short as possible. Insulate both the inlet
runs and the DENSITRAK to maintain temperature unity.

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 Model D625L Operating Manual

For Natural Gas Liquids use, refer to API Chapter 14, Section 6, for more information on density meter
installation and on Pycnometer tap installation. Also refer to Figure 5 for the API’s recommended
installation.

Figure 4 and 5 illustrates a typical bypass installation. If the densitometer is to be installed in an

area of severe vibration, it may be necessary to install the instrument with flexible hose.

3. WIRING INSTALLATION
Four conductor 18 AWG shielded cable is recommended for field wiring installation between Model
D625L and the signal processors or flow computers. Refer to Figure 7,8 and 9 for field wiring
details. The wiring between the DENSITRAK and its signal processor units should be within 1500
feet.

Note: For intrinsically safe wiring and hazardous installation, refer to

National Electrical Code Article 500 and ISA-RP12.1, ISA-S12.4 &
ANSI/ISA-RP12.6.

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 Model D625L Operating Manual

Section III
CALIBRATION

1. FACTORY CALIBRATION
a. Density Linearization: Three calibration coefficients K0, K1 & K2 are determined by measuring
the periodic time (in microseconds) of oscillation of three fluids with known density at same
temperature and pressure. These time periods and the three known densities are then used to solve
three simultaneous equations for K0, K1 & K2.
b. Temperature and Pressure Compensation: The periodic time of oscillation of the vibrating tube
changes due to the change in temperature and pressure of the measuring fluids that differ from the
factory calibration condition
The temperature coefficients KTv, KT0 & KT1 and pressure coefficients KPv, KP0 & KP1
as described in Section 1.2 are generated at the factory from the temperature and
pressure effects in mass and volume change of Model D625L Density meter.

All above calibration coefficients are supplied with the DENSITRAK for use with other
microprocessor based signal processors and flow computers.

2. FIELD CALIBRATION
The following methods can be used for measuring density:
2.1-Pycnometer measurement:
The equipment should include a precision electronic scale with 0.01gram accuracy, a set of certified
test weights and a certified glass thermometer with 0.2oF resolution. The Pycnometer should be
certified every two years in accordance with API Chapter 14.6.
For On Line Calibration: A Pycnometer with certified volume and tare weight is used for the
routine calibration. This routine may be set for monthly or quarterly as required by the users. Install
the pycnometer on line with the Density meter in either series or parallel for proving (calibration).
Proceed with the Density meter calibration procedure in accordance with API Chapter 14, Section 6
on “Continuous Density Measurement” to obtain two repeatable proving runs to within 0.05% and
perform the following steps:
a. Take the average of the two- Pycnometer test densities and subtract the average of the two indicated
densities from the Density meter.
b. Add the deviation from step “a” above to the coefficient “K0” as a zero offset adjustment. Replace
the old K0 with the new K0 in the microprocessor.

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 Model D625L Operating Manual

The following calculation sample illustrates the procedure for computing the new K0 as described in
steps “a” and “b”.
Example: Run No. 1 Run No. 2

(1) Indicated Density (gr/cc): 0.56791 0.56825

(from Density meter)
(2) Pycnometer Test Density (gr/cc): 0.56762 0.56794

(3) Deviation [ (2) - (1) ]: -0.00029 -0.00031

(4) Average Deviation[(-0.00029) + (-0.00031)] / 2: -0.00030

If the existing K0 = -1.34923, then the new K0 = (-1.34923) + (-.00030) = -1.34953

2.2 Hydrometer measurement: A Hydrometer or a glass beaker with certified volume can be used to
verify the density of fluid at atmospheric pressure that is measured by the Density meter.
The temperature between the Density meter and the beaker must be the same or within 0.2oF of
each other for accurate density measurement. Use the same procedure as in steps “2.1a” and “2.1b”
above to adjust the K0 coefficient.

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 Model D625L Operating Manual

Section IV
MAINTENANCE

The DENSITRAK has essentially no moving parts. The vibrating tubes flex at their centers only
a few thousands of an inch when in operation. Long-term stability can be effected by corrosion
or deposits on the tube. A high rate of flow through the instrument will normally flush the walls
of the tubes. However, should material collect on the walls of the tubes, the construction of the
DENSITRAK is such that the sensor housing can be detached for cleaning without removing the
complete instrument from the line.
To clean the tubes, close the valves to the instrument, reduce the pressure in the instrument and
carefully remove the four 5/16 cap screws at the bottom of the instrument base, detaching the
sensor housing from the base. Remove the wiring from the sensor to the condulet housing
containing the amplifier and 4-20mA temperature modules. Slowly lift the sensor housing from
its base and carefully pull the sensor wiring from the condulet housing.
After the sensor housing is removed from its base, clean the tubes with alcohol or any residue-
removing agent, using a long brush or a rod with a cloth attached. Use caution not to damage
the tubes.
Prior to re-installation, inspect the o-rings for visible damage.
Verify that the 5/16” cap screws are tightened properly.
As corrosion could weaken the vibrating tubes, a periodic pressure test of the DENSITRAK
should be conducted.
CAUTION - Be sure pressure is down before removing the four 5/16 cap screws.

Model D625L Operating Manual

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 Section V
TROUBLESHOOTING CHECK LIST

1. NO SIGNAL
a) Verify that there is power to the amplifier module.
b) Verify that there is a square wave output from the amplifier module using an
oscilloscope. Replace the amplifier module if no output.

2. UNSTABLE OR WRONG DISPLAY DENSITY

a) Trapped air or gas bubbles may be present in the Density meter. Re-position the
instrument in the horizontal or up-side-down position.
b) Turbulent or pulsating flow from nearby pumps causing the erratic signal from the
Density meter. Relocate the instrument.
c) Severe vibration in the Density meter installation. Re-install the Density meter with
flexible hoses.
d) Verify that the signal processors or flow computers are in proper operation.

3. NON-LINEAR AND NON-REPEAT

a) Verify the accuracy of proving equipment as listed Section IV.
b) Verify the temperature difference between the pycnometer and the line to be within 0.2oF
and the temperature transmitter.
c) Recalibrate the density linearization coefficients K0, K1 & K2 by obtaining the time
periods of three different densities of measuring fluids. If not stable return to factory
(call for return material authorization number) for test and re-calibration.

4. CONTACT CALIBRON SYSTEMS INC.

a) PHONE: 480-991-3550
b) FAX: 480-998-5589
c) e-mail: ussales@calibron.com

Model D625L Operating Manual

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 SECTION VI
CONVERSION FORMULAS

Density = M / V where : M= mass, V= volume

Density of fluid at temp. t1

Relative Density or Specific Gravity = -------------------------------------
Density of pure water at t2

Units of density:

gr. / cc X 1000 = Kg / cm
kg / cm X 0.001 = gr. / cc
lb. / cft X 0.016018 = gr. / cc
lb. / gal X 0.11983 = gr. / cc

Degree C = (degree F –32) /1.8

Degree F = (degree C *1.8)+32

Convert from Into Multiply By

Millibars Atmospheres 0.000987
Bar 0.001
Newton/sq meter 100
Pascals 100
Pound-force/sq ft 2.0885
Pound-force/sq inch 0.0145
Pounds/cu foot Grams/cu cm 0.016018
Kg/cu meter 16.018
Lbs/cu inch 0.0005787
Lbs/ cu yard 27
Pounds/cu inch Grams/cu cm 27.6799
Grams/liter 27.6807
Kg/cu meter 27679.9
Lbs/cu foot 1728
Pounds/cu yard Lbs/ cu foot 0.037

Model D625L Operating Manual

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 SECTION VII
FIGURES

FIGURE DESCRIPTION DRAWING #

1 D625L PRINCIPLE OF OPERATION 44102661

2 D625L OUTLINE 44102662
3 ELECTRONIC ASSEMBLY D625L WITOUT SPUD 44102600
4 INSTALLATION KIT (275psi) WITHOUT PYCNOMETER 44102551
5 INSTALLATION KIT (275psi) WITH PYCNOMETER 12102127
6-6d OTHER INSTALLATION METHODS
7 ELECTRICAL CONNECTION D625L TO SPUD 604 25102245
8 ELECTRICAL CONNECTION D625L TO SPUD 620 25102281
9 ELECTRICAL CONN. D625L TO FLOW COMPUTER 25102322

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 FIGURE 1
Dwg.#44102661A
CALIBRON SYSTEMS INC.
Condulet contained amplifier module 3/4" NPT FEMALE THREAD
and temperature transmitter 2 PLACES

Subbase

End Cap
Base

9" ± .250

FIGURE 2
Cover Pipe

Ø 3"
Calibron Systems Inc.

14.53" ± .125 2.82"

1/2" NPT FEMALE THREAD

2 PLACES
Dwg#44102662A
Dwg#1212127A
 FIGURE 6

ORFICE PLATE METHOD

P = P1 - P2

CSI MODEL D625L

DENSIMETER
 FIGURE 6A

PITOT TUBE (SCOOP) METHOD

CSI MODEL D625L

DENSIMETER
 FIGURE 6B

INSTALLATION USING PUMP

PUMP

CSI MODEL D625L

DENSIMETER
 FIGURE 6C

PUMP FOR PROCESS TANK

INSTALLATION METHOD

CSI MODEL D625L

DENSIMETER

TANK

PUMP
 FIGURE 6D

INLINE INSTALLATION METHOD

CSI MODEL D625L

DENSIMETER
Dwg#2512281A