Insertion Turbine
Sight Flow Indicators
Calibration
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Flowmeters: Insertion Turbine Instruction Sheet
1 Insertion Turbine Overview
2 Insertion Turbine Installation
3 Insertion Turbine Electrical
4 Insertion Turbine Commissioning
Flowmeters: Insertion Turbine specification
Model No.: DP490SS
Suits pipe sizes: 40mm - 900mm ( 1.5 – 36 inches )
Flow range: 0.25 - 6300 litres/sec ( 4-99600 USGPM )
Process connections: 1.5" NPT or BSPT (G1.5)
Velocity range: 0.3 - 10 metres/sec. ( 1 - 33 feet/sec.)
Linearity: typically ± 1.5%
Repeatability: typically ± 0.5%
Pressure (max): 80 Bar ( 1200PSI )
Temperature range: -40°C to 100°C (-40°F to 212°F ) - Optional 204°C (400°F)
Body material: 316L stainless steel (1.4404)
Rotor materials: PEEK rotor with graphite-PTFE impregnated PEEK bearing
O-Ring material: VITON - options available
(a) Voltage output (to 100°C): 1.5volt x 10m sec pulse width, self -generated (2 wire)
(b) Square wave ( Hall Effect ): 5-24vdc, 3wire NPN open collector (20mA max. current sink)
(c) Reed Switch (to 100°C): 30vdc max. x 20mA max. (output freq. is 1/3 std. K-factor)
Output freq. @ max. velocity: ( a & b ) outputs 220~240 hz ( c ) output 73~80 hz
Output options: I.S. or Ultra high temp. coil 204°C (400°F) or non magnetic
Transmission distance: 1000 metres ( 3300 feet ) maximum
Wiring: 5 core, screened cable, length 3 metres ( 10 feet )
Protection class: IP68 submersible ( Nema 6X )
Conduit entry: 3/8" NPT or PG9
Shipping Weight: 1.2 kg ( 2.7 lbs.)
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Titan Flowmeters: Insertion Turbine
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Titan Flowmeters: Insertion Turbine: 1.0 Overview
These insertion flow transducers provide a cost effective and
simple means of measuring the flow of a wide range of low
viscosity liquids. Installation is quick and inexpensive in pipe
sizes ranging from 40mm to 900mm (1.5-36") and up to
2500mm (100") nominal bore for the Hot tap model DP525SS.
It has a linear measuring range of 0.3~10.0 metres/sec. (1~33
ft/sec.). Minimum detectable flow velocity is 0.15 m/sec. (0.5
ft/sec.). When used in conjunction with a linearising flow rate
totaliser NLC feature the linear flow range is extended down to
0.15 m/sec. (0.5 ft/sec.) with an improved linearity.
The meter is constructed from 316 L (1.4404) stainless steel
enabling use in many applications for metering water and low
viscosity chemicals.
Two independent pulse outputs are provided suitable for direct
input to a wide range of ancillary instruments, PLC’s and computers.
Both pulse outputs display a high level of immunity to
electrical interference. Options include a reed switch.
Flow passes through a pipe causing the rotor to
spin. Magnets installed in the rotor pass by pulse
sensors within the transducer body & inturn this
produces frequency outputs proportional to flow
rate.
Titan Flowmeters: Insertion Turbine: 2.0 Installation
Install a female threaded weld on
fitting (threadolet) or service saddle.
Wrap the threads of the insertion
turbine with Teflon tape or sealing
compound & screw the unit into the
installed fitting.
Other locations around the pipe are
acceptable.
Titan Flowmeters: Insertion Turbine: 2.1 Meter Location
Choose an appropriate section of horizontal or vertical pipe as per the guidelines below. With vertical pipe installations the
media should be pumped up through the pipe past the flow sensor so that any entrained air will pass freely.
The flow sensor requires a fully developed turbulent flow profile to ensure maximum measurement accuracy and repeatability.
This is achieved by installing the flow transducer in a straight run of pipe. We recommend at least 10 straight pipe
diameters upstream & 5 pipe diameters downstream of the meter.
Major obstructions such as pumps, valves or strainers will require longer straight runs before and after the device.
Titan Flowmeters: Insertion Turbine: 2.2 Meter installation & orientation
Cut a 40mm diameter hole (1.6") on either the
2, 10 or 12 o’clock positions of the pipe. If there
is any likelihood of air entrainment in a horizontal
pipe do not locate the flow transducer in the
12 o’clock position.
Titan Flowmeters: Insertion Turbine: 2.3 Height adjustment calculation
Calculate the adjustment height A (or AA for the Hot Tap
version) as follows:
A ( model DP490 ) = 175mm ( 6.9") - ( B + C + D )
Where :
B = Distance between the top of the pipe & the top of the hex adaptor.
C = Pipe wall thickness
D = Insertion depth ( pipe ID ÷ 8 )
Examples:
For 40mm pipe ID ( D= 5.0 mm )
For 50mm pipe ID ( D= 6.25 mm )
For 100mm pipe ID ( D= 12.5 mm )
For 400mm pipe ID ( D= 50.0 mm )
Turn the height adjustment nuts (1) as required so that the distance between the top of the hex adaptor (2)
and the top of the positioning collar (3) equals your calculated distance A. Retighten the height adjustment nuts (1).
Titan Flowmeters: Insertion Turbine: 2.4 Flow direction orientation
The unit is bi-directional however
it is always good practice
to orientate the unit with the
flow directional arrow pointing
in the direction of flow.
Using a 2mm Hex key, unlock
the locking screw located on
the positioning collar (3). Using
the arrowed alignment recesses
at the top of the flow
transducer, turn the body until
the flow direction guides are
parallel with the pipe run and
pointing in the direction of the
flow (downstream). Retighten
the locking screw.
Titan Flowmeters: Insertion Turbine: 3.0 Eletrical connections
Titan Flowmeters: Insertion Turbine: 3.1 Standard outputs
Titan Flowmeters: Insertion Turbine: 3.2 Optional Reed switch output
HAZARDOUS AREAS
The REED SWITCH output is classed as a “simple
apparatus“ as defined in the CENELEC standard
EN50020. It can be connected to an approved I.S.
secondary instrument with both being located in the
hazardous area.
The Reed Switch may also be connected through an
approved I.S. barrier.
Note: The Reed switch produces 1/3 the normal
pulse output value
( eg. 1/3 the standard K-factor )
Titan Flowmeters: Insertion Turbine: 3.3 Instrument cable installation requirements
Use twisted multi-core low capacitance shielded instrument cable (22 AWG ~ 7x
0.3 stranded) for electrical connection between the flow meter and the remote instrumentation.
The screen should be earthed at the readout instrument end only to
protect the transmitted signal from mutual inductive interference.
The cable should not be run in a common conduit or parallel with power and high
inductive load carrying cables as power surges may induce erroneous noise transients
onto the transmitted pulse signal. Run the cable in separate conduit or with
other low energy instrument cables .
Titan Flowmeters: Insertion Turbine: 3.4 Pulse output selection
Each standard flowmeter has two independent pulse output signals that are linearly
proportional to volumetric flow rate. Pulse transmission can be up to 1000 metres
( 3300 ft ). An optional I.S. Reed Switch output is available (see page 7).
High Level Voltage Pulse
A self generating pulse output which produces a strong 1.5 volt voltage spike of
approximately 10 micro/second duration with no dependence on rotor speed.
Square Wave Pulse
( connections also apply to the non-magnetic output )
An NPN open collector transistor pulse output produced by a solid state Hall Effect
device. This three wire Hall Effect requires 5~24vdc and produces an NPN square
wave output (20mA max. sink), The Hall Effect output requires a pull up resistor,
pull up resistors are generally incorporated in most secondary instruments. Pulse
width is 2~75 mSec.
Titan Flowmeters: Insertion Turbine: 4.0 K - Factors
The K-factor (pulses / litre, gallon
etc.) will vary in relation to the
bore size of the pipe in which the
Dualpulse is installed.
The K-factors and formula shown
are a result of factory testing using
smooth bore piping under
ideal conditions. Variations to the
given K-factors may occur when
using rough bore piping or inadequate
flow conditioning on either
side of the flow transducer.
Titan Flowmeters: Insertion Turbine: 4.1 Flow transducer K- factors for common pipe sizes
Titan Flowmeters: Insertion Turbine: 4.2 K-factors for large pipes 460mm ID (18") and above use:
Pulses per litre = 28647 ÷ pipe ID² (mm)
Pulses per M³ = 28647000 ÷ pipe ID²
NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage pulse output.
Titan Flowmeters: Insertion Turbine: 4.3 Calculating K-factors ( litres or m³ )
Calculate K-factor ( pulses / litre ) using the above graph and the metric constant of 1273.2 as follows:
Pulses / litre = 1273.2 x (A) from graph ÷ pipe ID² (mm)
Example ‘a’:
K-factor for 100mm pipe: 1) from graph 100mm ID (A) = 24.0
2) pulses/litre. = 1273.2 x 24.0 ÷ 10000 = 3.056 p/litre
K-factor for m³ : multiply by 1000 eg. K = 3056 p/m³
K-factor for megalitres : multiply by 1000000 eg. K = 3056000 p/megalitre
NOTE : K-factors for Reed Switch output option are 1/3 the standard factors of voltage pulse output.
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