Flow Meters for Large Pipes

Large Pipe Flow Measurement

Insertion Turbine Flow Meters: Installation Notes

flow meters for pipe flow measurement

Flow Meters For Large Pipe Flow Measurement: Insertion Turbine Meters

1 Insertion Turbine Specification and Overview
2 Insertion Turbine Installation
3 Insertion Turbine Electrical
4 Insertion Turbine Commissioning

Flowmeters: Insertion Turbine specification

Model No.: 400-003

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 1.5 metres ( 5 feet )

Protection class: IP68 submersible ( Nema 6X )

Conduit entry: 3/8″ NPT or PG9

Shipping Weight: 1.2 kg ( 2.7 lbs.)

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 linearizing 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

insertion turbine pipe flow meters

Insertion Turbine – Pipe Flow Meter 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

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.

setting up pipe flow meters

Pipe Flow Meter Setup: Insertion Turbines


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 400-003 ) = 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 )

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).

pipe flow meters - insertion turbines

Insertion Turbines by Titan Enterprises: Pipe Flow Meters Height Adjustment

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

connections for pipe flow meters - insertion turbines

Pipe Flowmeters: Insertion Turbine Connections: Standard Outputs

Titan Flowmeters: Insertion Turbine: 3.2 Optional Reed switch output

Pipe flow measurement

Electrical Diagram: Insertion Turbine Flow Meter

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.

insertion flow meter

Insertion Turbine Wiring: Voltage

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.

wiring for pipe flow meter (insertion turbine)

Insertion Turbine Flow Meter Wiring: Pulse


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: 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

insertion turbine for pipes

Insertion Turbine Flow Meter K Factors

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 )

Flow meters for Pipes: Titan Insertion Turbine Flow Meter

Flow meters for Pipes: Titan Insertion Turbine Flow Meter: Calculation K-Factors

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.

insertion turbine connections

Insertion Turbines: Voltage pulse connection to family instruments