Turbine Flow Meter. User Manual. Top Load 1 in. and 2 in. Meters. TRB-UM EN-01 (September 2018)

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Turbine Flow Meter Top Load 1 in. and 2 in. Meters TRB-UM-02597-EN-01 () User Manual

Turbine Flow Meter, Top Load 1 in. and 2 in. Meters CONTENTS Unpacking and Inspection......................................... 3 Introduction................................................... 3 Operating Principle.............................................. 3 Preinstallation Considerations....................................... 4 Installation.................................................... 5 Pressure Drop Chart.............................................. 7 Operational Startup.............................................. 7 Turbine Assembly Replacement...................................... 8 Turbine Assembly Repair Kit Part Number............................. 8 Turbine Assembly Replacement Procedure............................ 8 Specifications................................................. 10 Part Number Information......................................... 10 Troubleshooting Guide........................................... 11 Page ii TRB-UM-02597-EN-01

Unpacking and Inspection UNPACKING AND INSPECTION Upon opening the shipping container, visually inspect the product and applicable accessories for any physical damage such as scratches, loose or broken parts, or any other sign of damage that may have occurred during shipment. NNOTE: If damage is found, request an inspection by the carrier s agent within 48 hours of delivery and file a claim with the carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser. INTRODUCTION Designed to withstand the demands of the most rigorous flow measurement applications, the Top Load Turbine Flow Meter is reliable, rugged and cost effective. Originally developed for the secondary oil recovery market, the Top Load Turbine Flow Meter is an ideal meter for liquid flow measurement on or off the oil field. The meter features a rugged 316 stainless steel housing, rotor shaft, and rotor support assemblies, a Buna-N O-ring, C17-4PH stainless steel rotor, and hybrid ceramic ball bearings with AMS 5898 duplex stainless steel race and stainless steel retainer. OPERATING PRINCIPLE Fluid entering the meter passes through the inlet flow straightener which reduces its turbulent flow pattern and improves the fluid s velocity profile. Fluid then passes through the turbine, causing it to rotate at a speed proportional to the fluid velocity. As each turbine blade passes through the magnetic field, the blade generates an AC voltage pulse in the pickup coil at the base of the magnetic pickup (see Figure 1). These pulses produce an output frequency proportional to the volumetric flow through the meter. The output frequency represents flow rate and/or totalization of fluid passing through the meter. Magnetic Pickup or Other Frequency Output Device Turbine Rotor Output Signal Figure 1: Schematic illustration of electric signal generated by rotor movement TRB-UM-02597-EN-01 Page 3

Preinstallation Considerations PREINSTALLATION CONSIDERATIONS All Badger Meter Top Load Turbine Flow Meters use stainless steel construction materials. Make sure the operating fluid is compatible with these materials. Incompatible fluids can cause deterioration of internal components and cause a reduction in meter accuracy. The measured liquid should be free of any large particles that may inhibit rotation of the turbine blades. If particles are present, install a mesh strainer upstream before operating the meter. See Table 1 for strainer recommendations. Part Number Strainer Mesh Clearance Filter Size B411-110 60 0.0092 in. 260 μm B411-120 10 0.0650 in. 1.6 mm Table 1: Strainer mesh installation details The preferred plumbing setup is one containing a bypass line (see Figure 2 on page 6) that allows meter inspection and repair without interrupting flow. If a bypass line is not used, it is important that all control valves be located downstream of the flow meter (see Figure 3 on page 6). STRIKING AN EMPTY METER WITH HIGH VELOCITY FLOW STREAM CAN CAUSE DAMAGE. ATTENTION DES DOMMAGES PEUVENT ÊTRE PROVOQUÉS EN FRAPPANT UN MÈTRE VIDE AVEC UN JET D ÉCOULEMENT DE VITESSE ÉLEVÉE. Remove any restriction in the flow line that may cause the liquid to flash. If necessary, install air eliminators so the meter is not incorrectly measuring entrained air or gas. Badger Meter recommends installation of a minimum length, equal to ten (10) pipe diameters of straight pipe on the upstream side and five (5) diameters on the downstream side of the flow meter. Otherwise meter accuracy may be affected. Piping should be the same size as the meter bore or threaded port size. Severe pulsation and mechanical vibration affect accuracy and shorten the life of the meter. If this condition is present, consider using a meter possessing superior resistance to pulsation and vibration like the Badger Meter QuikSert Inline Flow Meter. Do not locate the meter or connection cable close to electric motors, transformers, sparking devices, high voltage lines, or place connecting cable in conduit with wires furnishing power for such devices. These devices can induce false signals in the meter coil or cable, causing the meter to read inaccurately. If problems arise with the meter, consult the "Troubleshooting Guide" on page 11. If further problems arise, consult the factory. If the internal components of the meter are damaged, replace them with a turbine meter repair kit available from Badger Meter. For information pertaining to the repair kits, see "Turbine Assembly Replacement" on page 8. Page 4 TRB-UM-02597-EN-01

Installation INSTALLATION PRESSURE IN EXCESS OF ALLOWABLE RATING MAY CAUSE THE HOUSING TO BURST AND CAUSE SERIOUS PERSONAL INJURY. AVERTISSEMENT LA PRESSION AU-DESSUS DE L ESTIMATION PERMISE PEUT FAIRE ÉCLATER ET CAUSER LE LOGEMENT LE DOMMAGE CORPOREL SÉRIEUX. 1. Check the inside of the flow meter for any foreign material. Make sure the turbine rotor spins freely prior to installation. Also, check fluid lines and remove any debris found. 2. Install the flow meter with the flow arrow, etched onto the exterior of the meter body, pointing in the direction of fluid flow. Though the meter is designed to function in any position, where possible, install it horizontally with the conduit adapter facing upward. 3. Thread a magnetic pickup into the conduit adapter completely, finger tight without forcing it. 4. Install conduit or other fittings suitable for the installation area onto the conduit adapter hub on the flow meter. TRB-UM-02597-EN-01 Page 5

Installation Isolation Valve Electronic Flow Monitor Isolation and Flow Rate Control Valve 10 Pipe Diameters Turbine Flow Meter 5 Pipe Diameters Bypass Valve Figure 2: Meter installation with a bypass line Electronic Flow Monitor Control Valve 10 Pipe Diameters Turbine Flow Meter 5 Pipe Diameters Figure 3: Meter installation without a bypass line Page 6 TRB-UM-02597-EN-01

Pressure Drop Chart PRESSURE DROP CHART 7 6 Pressure Drop (psi) 5 4 3 2 1 QCM0200 B411-120 QCM0100 B411-110 0 0 50 100 150 200 250 Flow Rate (gpm) OPERATIONAL STARTUP Figure 4: Pressure drop Follow these steps when installing and starting the meter. After meter installation, close the isolation valves and open the bypass valve. Allow liquid to flow through the bypass valve for sufficient time to eliminate any air or gas in the flow line. MAKE SURE TO SHUT OFF FLUID FLOW AND RELEASE PRESSURE IN THE LINE BEFORE ATTEMPTING TO INSTALL THE METER IN AN EXISTING SYSTEM. AVERTISSEMENT ASSUREZ-VOUS QUE LE FLUX DE FLUIDE A ÉTÉ COUPÉ ET DE LA PRESSION DANS LA LIGNE A ÉTÉ LIBÉRÉE AVANT D ESSAYER D INSTALLER LE MÈTRE DANS UN SYSTÈME ACTUEL. HIGH VELOCITY AIR OR GAS MAY DAMAGE THE INTERNAL COMPONENTS OF THE METER. ATTENTION DES DOMMAGES PEUVENT ÊTRE PROVOQUÉS EN FRAPPANT UN MÈTRE VIDE AVEC UN JET D ÉCOULEMENT DE VITESSE ÉLEVÉE. 1. Open the upstream isolating valve slowly to eliminate hydraulic shock while charging the meter with the liquid. Open the valve to full open. 2. Open the downstream isolating valve to permit the meter to operate. 3. Close the bypass valve to a fully closed position. 4. Adjust the downstream valve to provide the required flow rate through the meter. NNOTE: If necessary, use the downstream valve as a control valve. TRB-UM-02597-EN-01 Page 7

Turbine Assembly Replacement TURBINE ASSEMBLY REPLACEMENT The meter uses wear-resistant moving parts to provide trouble-free operation and long service life. Designed for easy field service of a damaged turbine assembly, the repair kits replace only the internal parts, rather than replacing the entire meter. The turbine assembly uses stainless steel alloy construction materials. Each repair kit assembly is factory calibrated to provide accuracy throughout the entire flow range. Each kit is complete and includes a new K-factor, which is the calibrated number of pulses generated by each gallon of liquid. Recalibration of the monitor or other electronics use the K-factor to provide accurate output data. Turbine Assembly Repair Kit Part Number For 1 in. Meter B411-110 Meter Size Repair Part Number Repair Kit Fits Meter Part Number Repair Kit Part Number 1 in. B411-110 B411005 2 in. B411-120 B411006 Table 2: Repair kits For 2 in. Meter B411-120 Description B251-610 B251-620 Complete turbine assembly replacement kit, with magnetic pickup B251-611 B251-621 Turbine assembly replacement kit, without pickup B411005 B411006 Insert, with pickup B411026 B411027 Insert, without pickup B411007 B411008 External retainer ring B411003 B411004 Retainer nut B251-610 TI B251-620 TI Turbine assembly replacement kit for TI meters Table 3: Turbine assembly repair kit components Turbine Assembly Replacement Procedure HIGH-PRESSURE LEAKS ARE DANGEROUS AND MAY CAUSE PERSONAL INJURY. MAKE SURE TO SHUT OFF FLUID FLOW AND RELEASE RESIDUAL PRESSURE IN THE LINE BEFORE ATTEMPTING TO REMOVE THE METER. AVERTISSEMENT LES FUITES À HAUTE PRESSION SONT DANGEREUSES ET PEUVENT CAUSER LE DOMMAGE CORPOREL. ASSUREZ-VOUS QUE LE FLUX DE FLUIDE A ÉTÉ COUPÉ ET DE LA PRESSION DANS LA LIGNE A ÉTÉ LIBÉRÉE AVANT D ESSAYER D ENLEVER LE MÈTRE. Page 8 TRB-UM-02597-EN-01

Turbine Assembly Replacement IIMPORTAN Before installing the new turbine assembly, note that an arrow is cast or engraved on each component. The arrow indicates the primary flow direction. When reassembled, the arrowheads must point in the direction of the fluid flow. The arrows must also be oriented in the UP position on both rotor supports. The magnetic pickup side of the body signifies the UP position. Performance of repair kit calibration is in the UP position. Reinstalling the repair kit in the UP position provides continuation of accurate measurements. 1. Shut off the fluid flow and release any residual pressure in the line. 2. Remove the wiring from the magnetic pickup. 3. Remove the external retainer ring from the meter. Set it aside for re-use. 4. Unscrew and remove the large retainer nut. Set it aside for re-use. 5. Remove and discard the turbine assembly. 6. Insert the replacement turbine assembly into the meter housing, aligning the cutout in the assembly with the key in the housing. 7. Screw on the large retainer nut you set aside in step 4. Tighten it enough to clear the lip in the meter body. 8. Insert the external retainer ring you set aside in step 3. It fits just below the lip in the meter body. 9. Reconnect the monitor to the magnetic pickup. Figure 5: Typical cross-section of B411-110 and B411-120 meters TRB-UM-02597-EN-01 Page 9

Specifications SPECIFICATIONS Materials of Construction Body Rotor Bearing Rotor Shaft Rotor Support O-Ring 316 stainless steel C17-4PH stainless steel Hybrid ceramic ball bearing with AMS 5898 duplex stainless steel race and stainless steel retainer 316 stainless steel 316 stainless steel Buna-N Operating Temperature 150 350 F ( 101 177 C) Pressure Rating End Connections 1500 psi max. NPT Turndown Ratio 15:1 Flow Accuracy Repeatability ±0.1% Calibration Pickup Certifications ±1% of reading Water (NIST traceable calibration) B111129 PART NUMBER INFORMATION 1 Part Number Bore Size End Connections Max. PSI Flow Ranges Strainer Mesh Approx. K-factor Pulse/Gal Meter Weight (lb) 1 in. B411-110 1 in. male NPT 1500 40 870 2 (25.4 mm) See Flow Ranges 2 in. B411-120 2 in. male NPT 1500 20 52 14 (50.8 mm) 1 Includes Standard Mag Pickup, p/n B111129, -150 330 F (-101 165 C), suitable for all mounting styles Flow Ranges Part Number Flow Ranges gpm (lpm) bpd m3/d B411-110 5 75 (18.9 283.91) 171.43 2571.43 27.26 408.82 B411-120 15 225 (56.78 851.72) 514.29 7714.29 81.76 1226.47 End to End Length 6 in. (152.4 mm) 6 in. (152.4 mm) Page 10 TRB-UM-02597-EN-01

Troubleshooting Guide TROUBLESHOOTING GUIDE Meter indicates higher than actual flow rate. Issue Possible Cause Remedy Cavitation. Debris on rotor support. Increase back pressure. Clean meter. Meter indicates lower than actual flow rate. Build up of foreign material on meter bore. Gas in liquid. Debris on rotor. Worn bearing. Clean meter. Install gas eliminator ahead of meter. Clean meter and add filter. Clean meter and add filter. Erratic system indication, meter alone works well (remote monitor application only). Indicator shows flow when shut off. No flow indication. Full or partial open position. Erratic indication at low flow, good indication at high flow. Viscosity higher than calibrated. Ground loop in shielding. Mechanical vibration causes rotor to oscillate without turning. Fluid shock, full flow into dry meter or impact caused bearing separation or broken rotor shaft. Rotor has foreign material wrapped around it. Recalibrate monitor. Ground shield one place only. Look for internal electronic instrument ground. Reroute cables away from electrical noise. Isolate meter. Rebuild meter with repair kit and recalibrate monitor. Move to location where meter is full on startup or add downstream flow control valve. Clean meter and add filter. No flow indication. Faulty pickup. Replace pickup. System works perfect, except indicates lower flow over entire range. Meter indicating high flow, upstream piping at meter smaller than meter bore. Meter indicating low flow, upstream piping at meter smaller than meter bore. By-pass flow, leak. Fluid jet impingement on rotor. Viscosity lower than calibrated. Repair or replace bypass valves, or faulty solenoid valves. Change piping. Change temperature, change fluid or recalibrate meter. TRB-UM-02597-EN-01 Page 11

Turbine Flow Meter, Top Load 1 in. and 2 in. Meters Control. Manage. Optimize. BLANCETT is a registered trademark of Badger Meter, Inc. Other trademarks appearing in this document are the property of their respective entities. Due to continuous research, product improvements and enhancements, Badger Meter reserves the right to change product or system specifications without notice, except to the extent an outstanding contractual obligation exists. 2018 Badger Meter, Inc. All rights reserved. www.badgermeter.com The Americas Badger Meter 4545 West Brown Deer Rd PO Box 245036 Milwaukee, WI 53224-9536 800-876-3837 414-355-0400 México Badger Meter de las Americas, S.A. de C.V. Pedro Luis Ogazón N 32 Esq. Angelina N 24 Colonia Guadalupe Inn CP 01050 México, DF México +52-55-5662-0882 Europe, Eastern Europe Branch Office (for Poland, Latvia, Lithuania, Estonia, Ukraine, Belarus) Badger Meter Europe ul. Korfantego 6 44-193 Knurów Poland +48-32-236-8787 Europe, Middle East and Africa Badger Meter Europa GmbH Nurtinger Str 76 72639 Neuffen Germany +49-7025-9208-0 Europe, Middle East Branch Office Badger Meter Europe PO Box 341442 Dubai Silicon Oasis, Head Quarter Building, Wing C, Office #C209 Dubai / UAE +971-4-371 2503 Slovakia Badger Meter Slovakia s.r.o. Racianska 109/B 831 02 Bratislava, Slovakia +421-2-44 63 83 01 Asia Pacific Badger Meter 80 Marine Parade Rd 21-06 Parkway Parade Singapore 449269 +65-63464836 Switzerland Badger Meter Swiss AG Mittelholzerstrasse 8 3006 Bern Switzerland +41-31-932 01 11