User Manual - Controls Warehouse
Contents
1. Mechanical vibration causes rotor to oscillate without turning Isolate meter No flow indication Full or partial open position Fluid shock full flow into dry meter or impact caused bearing separation or broken rotor shaft Rebuild meter with repair kit and recalibrate monitor Move to location where meter is full on startup or add downstream flow control valve Erratic indication at low flow good indication at high flow Rotor has foreign material wrapped around it Clean meter and add filter No flow indication Faulty pickup Replace pickup System works perfect except indicates lower flow over entire range By pass flow leak Repair or replace bypass valves or faulty solenoid valves Meter indicating high flow upstream piping at meter smaller than meter bore Fluid jet impingement on rotor Change piping Meter indicating low flow upstream piping at meter smaller than meter bore Viscosity lower than calibrated Change temperature change fluid or recalibrate meter July 2014 TUR UM 00014 EN 03 Page 11 Control Manage Optimize Blancett is a registered trademarks 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 t2. Valve Figure 3 Meter installation with a bypass line Control Valve Page 6 10 Pipe Turbine 5 Pipe Diameters Flow Meter Diameters Figure 4 Meter installation without a bypass line July 2014 Pressure drop charts PRESSURE DROP CHARTS Pressure Drop vs Flow Rate Pressure Drop vs Flow Rate 30 2 1 o 10 E 8 a F a 5 0 1 gV E 5 1 v a a g a 0 01 0 1 0 005 0 5 1 10 100 1000 8000 1 10 100 1000 10 000 17 34 343 3429 34 286 274 236 1 44 14 4 144 1440 14400 20 000 Flow Rate GPM BPD Flow Rate LPM m Day 57 600 Figure 5 English units pressure drops Figure 6 Metric units pressure drops OPERATIONAL STARTUP Follow these steps when installing and starting the meter MAKE SURE TO SHUT OFF FLUID FLOW AND RELEASE PRESSURE IN THE LINE BEFORE ATTEMPTING TO INSTALL THE METER IN AN EXISTING SYSTEM ASSUREZ VOUS QUE LE FLUX DE FLUIDE A ETE COUPE ET DE LA PRESSION DANS LA LIGNE A ETE LIBEREE AVANT D ESSAYER D INSTALLER LE METRE DANS UN SYSTEME ACTUEL 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 HIGH VELOCITY AIR OR GAS MAY DAMAGE THE INTERNAL COMPONENTS OF THE METER DES DOMMAGES PEUVENT ETRE PROVOQUES EN FRAPPANT UN METRE VIDE AVEC UN JET D COULEMENT DE VITESSE ELEVEE 5 Open t
3. on either side of the rotor that require removal before the rotor can be removed see Figure 9 6 Remove the retaining ring from the opposite side of the meter 7 Remove the second rotor support Magnetic Pick up A Retaining Ring Retaining Ring Groove Groove Rotor Flow Direction Assembly E MEEN Arrow der on rrow gt is gt vir ae Flow Direction Rotor Support Arrow Downstream Retaining Rotor Support Retaining Ring nr Flow Direction Arrow Figure 7 Component positions for B110 375 B111 115 and B111 121 Pick up Magnetic Flow Direction Retaining Ring Retaining Ring Arrow Groove Groove Upstream Downstream Rotor y del Support UN A m i Directi Flow Direction er Flow A Arrow Arrow ion Retaining Ring Rotor Flow Met Assembly Body Direction Retaining Ring rrow Figure 8 Component positions for B111 120 and B111 130 Flow Direction ne Magnetic Arrow Retaining Ring Pick up Retaining Ring Grooves Grooves Upstream Downstream Rotor Support Rotor Support EJ gt Flow Direction Rotor Flow ce Flow Direction Flow Direction Arrow Assembly Body Arrow Arrow Retaining Ring Retaining R
4. the second retaining ring in the opposite groove using the same procedure as in step 2 above EXCESS AIR PRESSURE MAY DAMAGE THE ROTOR AND BEARINGS BY OVER SPINNING LA PRESSION ATMOSPHERIQUE EXCESSIVE PEUT ENDOMMAGER LE ROTOR ET LES ROULEMENTS PRES AU DESSUS DE LA ROTATION 5 Check the meter by lightly puffing air through the assembly If the rotor does not turn freely disassemble the meter and remove anything that might obstruct movement of the rotor NOTE At this time electronics require recalibration Refer to the display s user manual If there are any questions on recalibration contact Badger Meter Inc or the manufacturer of the associated electronics 6 Install the magnetic pickup PART NUMBER INFORMATION End to End Length Flow Ranges Part Number Meter Size End Connection 3 inches mm gpm bpd m d B110 375 1 2 3 8 in 3 76 2 1 2 in Male NPT 0 6 3 0 20 100 35344616 B110 500 1 2 1 2 in 3 76 2 1 2 in Male NPT 0 756075 25 250 4 1 41 B110 750 1 2 3 4 in 3 76 2 1 2 in Male NPT A E 68 515 10 9 81 75 B110 375 3 8 in 4 101 6 1 in Male NPT 0 6 3 0 20 100 3 3 16 B110 500 1 2 in 4 101 6 1 in Male NPT 0750 75 25 250 4 1 41 B110 750 3 4 in 4 101 6 1 in Male NPT 2 13 68 515 10 9 81 75 B110 875 7 8 in 4 101 6 1 in Male NPT 3 30 100 1000 16 160 B111 110 Tin 4 101 6 1 in Male NPT 5 50 170 1700 2 25 2
5. 125 B111 115 1 1 2 in 6 152 4 1 1 2 in Male NPT 15 180 515 6000 82 981 B111 121 2 in Low 6 152 4 2 in Male NPT 15 180 515 6000 82 981 B111 120 2in 10 254 2 in Female NPT 40 400 1300 13 000 218 2180 B111 130 3 in 12 1 2 317 5 3 in Grooved End 60 600 2100 21 000 327 3270 B111 140 4 in 12 304 8 4 in Grooved End 100 1200 3400 41 000 545 6540 B111 160 6 in 12 304 8 6 in Grooved End 200 2500 6800 86 000 1090 13 626 B111 180 8in 12 304 8 8 in Grooved End 350 3500 12 000 120 000 1363 19 076 B111 200 10 in 12 304 8 10 in Grooved End 500 5000 17 000 171 000 2725 27 252 Page 10 July 2014 TROUBLESHOOTING GUIDE Part number information Trouble Possible Cause Meter indicates higher than actual flow rate Cavitation Debris on rotor support Build up of foreign material on meter bore Gas in liquid Remedy Increase back pressure Clean meter Clean meter Install gas eliminator ahead of meter Meter indicates lower than actual flow rate Debris on rotor Worn bearing Viscosity higher than calibrated Clean meter and add filter Clean meter and add filter Recalibrate monitor Erratic system indication meter alone works well remote monitor application only Ground loop in shielding Ground shield one place only Look for internal electronic instrument ground Reroute cables away from electrical noise Indicator shows flow when shut off
6. CESS OF ALLOWABLE RATING MAY CAUSE THE HOUSING TO BURST AND CAUSE SERIOUS PERSONAL INJURY LA PRESSION AU DESSUS DE L ESTIMATION PERMISE PEUT FAIRE ECLATER ET CAUSER LE LOGEMENT LE DOMMAGE CORPOREL SERIEUX Check the internals 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 on 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 Badger Meter model B111109 or equivalent into the conduit adapter completely finger tight without forcing Secure with a lock nut if supplied 4 Install conduit or other fittings suitable for the installation area onto the conduit adapter hub on the flow meter Page 4 July 2014 Installation All Badger Meter Model 1100 turbine meters use stainless steel and tungsten carbide 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 flow mete
7. TE Indicates parts supplied in repair kits Figure 2 Typical cross section of B110 375 B111 121 turbine flow meter July 2014 TUR UM 00014 EN 03 Page 3 Turbine Flow Meter 1100 Series SPECIFICATIONS Materials of Construction Body 316 Stainless Steel Rotor CD4MCU Stainless Steel Rotor Support 316 Stainless Steel oe and Tungsten Carbide Operating Parameters 150 350 F 101 177 C Temperature The meter should not be subjected to temperatures above 350 F 177 C or below 150 F 101 C or the freezing point of the metered liquid Maximum pressure ratings as follows 5000 psi for all NPT meters up to 2 in Pressure 3000 psi for 3 in and 4 in Grayloc meters 800 psi for 3 10 in grooved end meters 1 of reading for 7 8 in and larger meters Accuracy A 1 of reading over the upper 70 of the measuring range for 3 8 in 1 2 in and 3 4 in meters Repeatability 0 1 Calibration Water NIST traceable calibration Single Seal ANSI ISA 12 27 01 2003 MWP 5 000 PSI 34 5 MPa 350 F Approvals L S Entity Parameters with Badger Meter B111109 standard magnetic pickup installed Vmax 10V Imax 7mA Ci OuF Li 0 9H End Connections NPT BSP Victaulic Flange and Hose Barbed Contact the factory for ordering options NOTE Consult factory for pressure ratings for flanged meters INSTALLATION PRESSURE IN EX
8. ber Meter Part Number 3 8 in B110 375 B110 375 1 2 B251 102 1 2 in B110 500 B110 500 1 2 B251 105 3 4 in B110 750 B110 750 1 2 B251 108 7 8 in B110 875 B251 109 Tin B111 110 B251 112 1 1 2 in B111 115 B251 116 2 in Low B111 121 B251 116 2in B111 120 B251 120 3in B111 130 B251 131 4in B111 140 B251 141 6in B111 160 B251 161 8in B111 180 B251 181 10 in B111 200 B251 200 Standard Magnetic Pick up All Meter Sizes B111109 Table 2 Repair kit part numbers Turbine Assembly Removal 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 LES FUITES HAUTE PRESSION SONT DANGEREUSES ET PEUVENT CAUSER LE DOMMAGE CORPOREL ASSUREZ VOUS QUE LE FLUX DE FLUIDE A T COUP ET DE LA PRESSION DANS LA LIGNE A T LIB R E AVANT D ESSAYER D ENLEVER LE METRE Page 8 July 2014 Disassembly 1 Refer to Figure 7 Figure 8 and Figure 9 for relative positions of repair kit components Remove the magnetic pickup from the meter body to avoid damage during repair Remove the retaining ring from one end of the meter AWN break the rotor support free 5 The rotor may also be removed at this time Turbine replacement Remove the rotor support from the body If the rotor support is jammed in the body use a pair of pliers or vise grips to NOTE 4in and larger meters have two retaining rings one
9. d journal bearings The Model 1100 maintains measurement accuracy and mechanical integrity in the corrosive and abrasive fluids commonly found in oil field water flood project and many industrial applications 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 turbine flow meter Magnetic Pickup or Other Frequency ig Output Device AD 0 POPE 3 Output Turbine Rotor Siqnal Figure 1 Schematic illustration of electric signal generated by rotor movement Magnetic Pick up Rotor and Rotor Shaft Conduit Adaptor 1 IS E E I 1 I 1 a Wan Upstream Rotor Support I l Meter Body I ILN LT l So Retaining Ring NZ Retaining Ring Groove Retaining Pins Downstream Rotor Support Thrust Ball Bearing NO
10. f Blancett Blancett Turbine Flow Meter Turbine Flow Meters SS Flow Meters 1100 Series Turbine Meter 3 Badger Meter TUR UM 00014 EN 03 July 2014 User Ma n ual Turbine Flow Meters 1100 Series CONTENTS INEFODUCHON EEE EE NE EE a wae haa Fae 3 Operating Principle ss sat aar aia a a bak adr ce Shed Fa aker bad ele waka ado Rd Aa 3 SPECINICALIONS arab de be Sk Se ek ae Se lad ae A eda ie 4 Materials of Construction ass cias ass ads ceeded A da heave sofa Fe ai do an 4 Operating Parameters danesa peak Grand ae Ga ed Ohad G ad 454 Leem fee SEERE KG Goa d 4 Installations xa a RA ARA A E ARA AE ads dekade ad 4 Pressure Drop Charts au coco a a a a awe bald 7 Oper tionalStantupsasssaskassressas C8 Ra Aaa CRORE GEE SSR EE FEIL GE EGG e a AEE ST 7 Turbine Replacement css curras a A Sa Ve Gea SEA ke La KG GDS Abe dad 8 Part Number Informations sos 2 sa dea Pes A ae alet ser aka ted Bae et saa RA e s 10 Page ii July 2014 Introduction INTRODUCTION Designed to withstand the demands of the most rigorous flow measurement applications the Model 1100 turbine flow meter is reliable rugged and cost effective Originally developed for the secondary oil recovery market the Model 1100 is an ideal meter for liquid flow measurement on or off the oil field The meter features a rugged 316 stainless steel housing and rotor support assemblies CD4MCU stainless steel rotor and abrasive resistant tungsten carbide rotor shaft an
11. he extent an outstanding contractual obligation exists O 2014 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 M xico Badger Meter de las Americas S A de C V Pedro Luis Ogaz n N 32 Esq Angelina N 24 Colonia Guadalupe Inn CP 01050 M xico DF M xico 52 55 5662 0882 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 Czech Republic Badger Meter Czech Republic s r o Mafikova 2082 26 621 00 Brno Czech Republic 420 5 41420411 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 China Badger Meter 7 1202 99 Hangzhong Road Minhang District Shanghai China 201101 86 21 5763 5412 Legacy Document Number 02 TUR UM 00103 EN
12. he upstream isolating valve slowly to eliminate hydraulic shock while charging the meter with the liquid Open the valve to full open 6 Open downstream isolating valve to permit meter to operate 7 Close the bypass valve to a full closed position 8 Adjust the downstream valve to provide the required flow rate through the meter NOTE If necessary use the downstream valve as a control valve July 2014 TUR UM 00014 EN 03 Page7 Turbine Flow Meter 1100 Series TURBINE REPLACEMENT The Model 1100 turbine flow meter uses wear resistant moving parts to provide trouble free operation and long service life The Designed for easy field service of a damaged flow meter Model 1100 repair kits replace only the internal parts rather than replacing the entire flow meter Repair parts use stainless steel alloys and tungsten carbide construction materials Each repair kit is factory calibrated to ensure 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 uses the K factor to provide accurate output data NOTE If the meter repair kit part number ends in NCC no calibration it was not factory calibrated For these repair kits use the nominal K factor Turbine Replacement Kit Part Number Flow Meter Size Replacement MERE Repair Kit Part Num
13. ing Retaining Ring Retaining Ring Figure 9 Component positions for B111 140 and B111 200 July 2014 TUR UM 00014 EN 03 Turbine Flow Meter 1100 Series New Turbine Kit Installation IMPORTANT Before reassembly 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 Reinstallation of the repair kit in the up position ensures continuation of accurate measurements Figure 7 Figure 8 and Figure 9 show the proper alignment and orientation of the repair kits NOTE Fractional size 3 8 in 1 2 in and 3 4 in rotors do not contain a cast or engraved arrow However a colored cap on the downstream side of the rotor shaft indicates flow direction Remove this cap before assembly noting flow direction 1 Install one of the rotor supports into the body bore noting the orientation of the arrow 2 Secure a retaining ring in the groove provided Check for complete installation of retaining rings in each groove NOTE 4in and larger meters have a retaining ring at both ends of the rotor see Figure 9 3 Insert the rotor and second rotor support in the opposite side of the body noting the orientation of the arrow 4 Secure
14. nstream 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 flow meter possessing superior resistance to pulsation and vibration like the Badger Meter QuicSert Do not locate the flow 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 flow meter coil or cable causing the meter to read inaccurately If problems arise with the flow meter consult the Troubleshooting Guide on page 11 If further problems arise consult the factory If damaged replace the internal components of the turbine flow meter with a turbine meter repair kit available from Badger Meter For information pertaining to the repair kits see Turbine Replacement on page 8 July 2014 TUR UM 00014 EN 03 Page 5 Turbine Flow Meter 1100 Series Isolation Valve FL E Electronic Flow Monitor Isolation and Flow Rate Control Valve AE B E as 10 Pipe Turbine 5 Pipe Diameters Flow Meter Diameters Bae 3 Electronic gt Flow Monitor LE E Bypass
15. r See Table 1 for strainer recommendations Part Number Strainer Mesh Clearance Filter Size B110 375 60 x 60 0 0092 in 260 um B110 500 60 x 60 0 0092 in 260 um B110 750 60 x 60 0 0092 in 260 um B110 875 60 x 60 0 0092 in 260 um B111 110 60 x 60 0 0092 in 260 um B111 115 20 x 20 0 0340 in 0 86 mm B111 120 10x 10 0 0650 in 1 6mm B111 121 20 x 20 0 0340 in 0 86 mm B111 130 B117 130 8x8 0 0900 in 2 3mm B111 140 B117 140 10x 10 0 0650 in 1 6mm B111 160 4x4 0 1875 in 48mm B111 180 8x8 0 0900 in 2 3mm B111 200 4x4 0 1875 in 48mm Table 1 Strainer mesh installation details The preferred plumbing setup is one containing a bypass line see Figure 3 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 4 STRIKING AN EMPTY METER WITH HIGH VELOCITY FLOW STREAM CAN CAUSES DAMAGE DES DOMMAGES PEUVENT ETRE PROVOQUES EN FRAPPANT UN METRE VIDE AVEC UN JET D COULEMENT DE VITESSE ELEVEE This is true with any restriction in the flow line that may cause the liquid to flash If necessary install air eliminators to ensure that 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 dow
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