WA9903-SP 991116'J,J~ c~9o3
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Product Overview
Badger 4500
Ultrasonic Flow Meters
For
Water Applications
Prepared for
The City of Coppell, Texas
Presented 11-16-1999
PLAN VIEW
Z-SHOT
r'-3
II
V-SHOT
II ['1
SENSOR MOUNTING METHODS
Pan-Tech Controls
BY: dbs } DATE: 8-18-99
100
90
80
70
60
50
40
30
20
10
0
/
/
10 20
30 40 50 60 70 80
PERCENTFLOW
90 100
% FLOW % DP
100 100
90 81
80 64
70 49
60 36
50 25
40 16
30 9
20 4
10 1
FLOW VS. DIFFERENTIAL
Pan-Tech Controls
BY: DBS D~T~ 8-18-99
Prior to installing the sensors into the
holders, apply a bead of the grease, fur-
nished with the meter, across the center of
the face of the sensor. The grease does not
have to cover the entire face but only
across the center as pictured to the right.
VIEW FROH FACE OF SENSOR
}
APPLY GREASE ACROSS
CENTER OF SENSOR FACE
After determining the
position to locate each
sensor to get the sensor
offset distance and having
put the grease on the face
of the sensor, install each
sensor with the two bolts,
springs and washers as
pictured to the right.
~ If four threaded holes
are visible through the
slots in the top plate of
the sensor, install the
bolts at opposite corners.
Tighten the bolts until
the spring comes in con-
tact with the holder and
the bolt head. Tighten the
bolts two and one-half
more turns. This should
be done one-half turn at a
time, alternating between
the two bolts.
Once the installation is
complete, it should look
like one of the pictures on
the next pages depending
on the mounting configu-
ration for your applica-
tion.
SENSOR HOUNTINO
BOLTS
SPRING -
rASHER -
UPSTREAM
SENSOR
~' FLOV
HORIZONTAL RUN
OF PIPE TOP VIE'w'
DOVNSTREAM
SENSOR
3A-12
FLOW
UPSTREAM~
SENSOR USE INSIDE END TO
, S~,ET SENSOR OFFSET
' ~ _ ' _ w ALIGN CENTER LINE MARK
I TO FOLD OR ENDS OF TEMPLATE
7'
ALIGN END OF HOLDER ,.:.:.:.:-:.:-:.:.:.:.:.:.:.:.:
TO EDGE OF TEMPLATE :::::::::::::::::::::::::::::::
\ ...............
hi~ALIGN CENTER LINE MARK
TO FOLO OR ENDS OF TEMPLATE
DOWNSTREAM
SENSOR
SENSOR MOUNTING CONFIGURATION
CASEA
USE OUTSIDE END TO
SET SENSOR OFF~.,~T UPSTREAM
. SENSOR
FLOW
I
ALlON CENTER LINE MARK
TO FOLD OR ENDS OF TEMPLATE
ALIGN END OF HOLDER v. : ::::: ALIGN ENd Of HOLDER
TO LINE ::::::.:.:
~ ......
ALlON CENTER LINE MARK
TO FOLD OR ENDS OF TEMPLATE
h~ " '
:U
USE OUTSIDE END TO
SET SENSOR OFFSET
SENSOR MOUNTING CONFIGURATION
CASEB
3A-13
WINDOW SPOOL INSTALLATION
125# FF
L= LAYING LENGTH IN INCHES
ANSI 150# RF PLAIN END
REFER TO CUSTOMER DATA SHEET
LIFTING LUGS TO TOP OF PIPE
__
FLOW ) . . (~
'/ '
INSTALL WITH ARROW POINTING WITH FLOW
SPOOL PIECES MAY BE INSTALLED EITHER IN THE HORIZONTAL PLANE OR
IN THE VERTICAL PLANE (WITH FLOW IN THE UP DIRECTION)
3B-1
WINDOW SPOOL INSTALLATION
1. SPOOL
2. ROLL PIN (USED AS A GUIDE FOR # 4)
3. O RING
4. SENSOR WINDOW
5. SENSOR HOLDER
6. WASHER (4 PLACES)
7. SCREW (4 PLACES)
8. SILlCONE GREASE
9. SENSOR & CABLE (25 FT STANDARD}
10. SPRING
11. CAUTION TAG
12. SENSOR RETAINER
· i::!!::i:: iiiiiiiii::iiiii::iiiii i ':A.'iil i B !iiii::!iiiii::ilili!i.
,SENSOR REffiOVAL PROCEDURE:
1. Remove condu~ from the sensor retainer (12).
2. Unscrew the sensor retainer {12).
3. Gently pull on the sensor cable, The sensor spring (10)
and the sensor (9), should "~p" out of the sensor
holder (5).
4. Before reinstailing the sensor, carefully clean
the sensor grease from the sensor window lens (4).
NOTE: a long 6" cotton swab available at ms/electronic or audio Melallic conduit or Seal-tile (by others)
stores wo~s well for cleaning the window.
5. Wipe the end and sides ol the sensor clean, relying any grease and gdt.
6. Spread a thin 1/32" layer of sensor grease (Dow Coming 111 valve' lubr~ant & sealant)
on the end sunace of the sensor.
7. Carefully reinsea the sen~r into the sen~r holder and gently push the sensor all the
way in.
NOTE: ~ the sensor will not ~sh in, t~ to loosen the holder ~rews (7) slightly (without re~ving
the safety wire seal) and shift the holder until the sensor will slide all the way in. retighten the holder screws.
8. Screw the sen~r retainer down firm (hand tight) and reconnea the condu~. *Type
p 29 silicone heat sink com~und may be used. (available at most electronic stores)
3B-2
HS3 SENSOR INSTALLATION
FIG,
UPSTREAM SENSOR
FLOW
4
SCRIBE MARK
SCRIBE MARK
DOWNSTREAM SENSOR
JUNCTION BOX
(CUSTOMER SUPPLIED)
METALLIC CONDUIT
(CUSTOMER SUPPLIED)
SYSTEM DIAGRAM
OUTPUTS
FLEX CONDUIT
(CUSTOMER SUPPLIED)
3C -4
I
HS3 SENSOR INSTALLATION
TAPPING PROCEDURE:
FLOW
PREPARATION TO INSTALL SENSORS:
1. Install template and nipples per 3-1.
2. Use teflon tape, wrap the end of
male nipple (item 10) and screw into
female nipple of tapping saddle,
3. Slide safety plate (item 12) over
outer end of nipple.
4. Screw ball valve (item 9) onto
nipple. adjust valve to the "open"
position.
5. Connect tapping machine into end
of ball valve, 1-1/2".
6. Use 1.38" minimum tapping bit and
tap through pipe wall.
7. Back the tapping bit out past the
valve assembly and move the valve
handle to the "off" position.
TAIL PIECE ASSEMBLY
(ASSEMBLED AT FACTORY)
o f
(
FIG. 2
SENSOR & COLLAR ASSEMBLY
- SEE NOTE 1 PG. 3-3 '
NOTE SCRIBE
MARK
3C-2
HS3 SENSOR INSTALLATION
8.15"
"T" MEASURED BY INSTALLER
FIG.
"?+0.82" OR 8.97"+"S"+WALL THICKNESS
"S"= Length of saddle or threadolet nipple
"'1"'= Length from i.d. of pipe to outside edge of item 8
NOTE 1: USE ABOVE FORMULAS TO DETERMINE THE PLACEMENT OF ITEM 2,
ONCE COLLAR IS PLACED AT CORRECT DIMENSION TIGHTEN
BOTH SOCKET HEAD SCREWS.
1. Screw tail piece assembly fig.1 (items 5, 6, 7 and 8) into ballvalve (item 9).
2. Slide items 12 and 1 onto sensor (item 11) use fig.2, pg. 3C-2.
3. Position collar (item 2) onto sensor and use above formula to calculate
correct dimension. Please note that the collar should already be
installed by the factory on new orders, the collar dimension will have to
be changed only ff pipe dimensions are other than given.
4. Slide brass collar and o-ring assembly (items 3 and 4) onto end of sensor and
butt up against the split collar (item 2).
NOTE: USE SOAPY WATER. PETROLEUM JELLY OR SOME TYPE OF LUBRICANT TO SLIDE
BRASS COLLAR AND O-RING ONTO SENSOR.
5. Note scribe mark running near the end of the sensor. This scribe mark, when the
sensOr is installed, should be facing toward the opposite sensor. (fig. 4)
6. Place tip of sensor through bearing seal (item 7) and carefully push until the
sensor stops at the ball valve. Fasten safety cable clip (long length) to opposite safety plate.
7. Turn valve handle to the "on" position and insed the sensor until the brass
collar (item 3)seats on the o-ring on the tail piece (items 5 & 8).
8. Tighten retainer (item 1 ) onto the tail piece (item 8) using a 1/16" square screw
driver shaft in the notch on the end of the retainer.
9. Fasten shod length of safety cable to opposite safety plate,
3C-3
Simple to Install, Simple to Operate, Highly Reliable
Installation
Operation
Majntellallce
· Snhfil FjEMA ,l X pn, h ,, .jrp
Badger Meter
System Description
General
The Series 4500 Compu-Sonic is a transit-time
ultrasonic flowmeter designed for accurate and
reliable.measurement of process water,
influent/effluent, and industrial flows in full pipe
applications.
The Series 4500 can be supplied for measuring flow
rates in 3-inch and larger pipes. Three styles of
transducer configurations are available to suit the
application: strap*on transducers for metal and plastic
pipes which can support ultresonic transmission;
insertion transducers, which penetrate pipe walls; and
internally mounted transducers for large pipes. It is also
capable of measuring both forward and reverse flow.
The microprocessor-based meter is supplied with a
24-character, 2-line alphanumeric LCD display for rate
of flow and totalized flow information. Front panel
switches activate commands which allow functions
such as zero/span, self-test and rescaling to be
selected.
PIping Requirements
Model 4500 flowmeters may be either horizontally or
vertically mounted. A well-developed velocity profile is
needed. General practice requires the pipe to be full
and the upstream piping run to be sufficient to assure
predictable fluid velocity distribution.
Operation
The Model 4500 Compu-Sonic flowmeter operates as a
transit-time flowmeter using Badger Meter's phase
shift time detection system. This technique, exclusive
to Badger Meter, improves time difference detectability
to enhance accuracy and stable operation while
substantially reducing noise effects,
SYSTEM
DIAGRAM
""'
CABLES ~ [[I, RELAYS
Ultrasonic energy "bursts" are transmitted and
received via well-defined paths across the flow stream~
The velocity of the flow is accuralely measured by the
difference in the arrival times of signals from the
upstream and downslream transducers. The overall
"time of flight" is measured Io accurately compensate
for changes in the sonic velocity of the fluid. Sonic
velocity variations in the fluid may result from changes
in the amount of suspended and dissolved solids as
well as temperature variations. The Model 4500
flowmeter also accounts for acoustic beam changes
due to refraction and diffraction.
The electronics are microprocessor-controlled, and
signals are digitized for processing before any analog
modifications are able to distort data or cause drift
which can contaminate the signals. This technique
allows more precise and accurate measurement of the
flow, improves meter reliability and minimizes meter
drift normally associated with component instabilities.
Early digitization also enhances interchangeability
during maintenance. Digitized data is confirmed,
stored and filtered by sophisticated mathematical
algorithms to correct for signal distortions.
System Features
NO HEAD LOSS
The Series 4500 flowmeter, with its externally
mounted sensors, has no moving parts in the
flow stream to create an energy loss.
EASILY INSTALLED
Simple, yet reliable, sensor technology allows
customer start-up with minimal mechanical
effort. New or retrofit applications have the
same high degree of accuracy.
HIGH ACCURACY
Transit-time operation assures dependable
operation and system accuracy. Accuracies of
+ / - 1% over the flow range are common for
calibrated units.
BI-DIRECTIONAL
Standard with each unit is the ability to
measure fluid velocity in either direction with
the same degree of exactness.
ZERO STABILITY
The microprocessor-based electronics provide
zero stablilly, reducing low end drift.
REPEATABILITY
The ultrasonlc flowmeter provides exceptional
repeatability results of + / - 0.25% over the flow
range within the predictable profile and
Reynolds' regime.
REMOTE MOUNTING OF THE ELECTRONICS
The sophisticated signal processing technique
allows locating the electronics up to 1000 feet
from the sensors.
Application Guide
Design Consideration
The Badger Compu-Sonic flowmeters are precisely set
up and calibrated to the conditions set forth by the
customer. ,.These meters are assigned a meter factor
based on known transducer spacing to yield an absolute
accuracy to within + / - 1 o/o on calibrated spool sections
and to +/- 2-4% for field installed meters. As with many
other types of flowmeters, the uitrasonic must be installed
in a piping run of sufficient length to establish a
predictable velocity profile. Table 1 presents this data.
These numbers apply Only to Newtonian fluids at flow
rates generally above one foot a second and Reynolds'
numbers over 75,000.
Table 2 suggests an acceptable level of solids carried in
suspension for transit-time operation. The data is based
on the assumption that the attenuation loss of the fluid is
equal to that of water. The magnitude of acoustic losses
is dependent upon the viscous forces between
neighboring particles, thermal conduction, and the
physical nature of the solids. Consultation with the factory
is suggested when applications deal with viscous fluids
and solids.
The effect of aeration on uitrasonic measurements must
be considered for any application. The problem can be
classified into two regimes, large and small bubbles,
Large bubbles (classified by size in relation to the
transmitted wave length) normally block the signal for a
brief period; this is taken care of electronically. Small
bubbles, on the other hand, exhibit the phenomenon
called "Rayleigh scattering" in which the medium tends
to behave like a diffuse reflector which gives rise to weak
waves scattered in many directions. This upper limit
varies depending upon the application, but is direally
related to the square of the transmitted frequency and is
propodional to the volume of the scattering object. Air
bubbles are easily compressed, thus the reflected
intensity ratio is very large.
Transit-time ultrasonic flowmeters require acceptable
levels of acoustic energy to operate. Known areas of
concern generally center around small hubhie air
entralnment. This can be avoided by not locating the
meter near the following:
-Cascading water - fall in excess of pipe IDxl .5
-Pump cavitation and/or leaking seals
-Air-entrained fluids such as
Nitrifled sludge
Aerebically digested sludge
Anaembically digested sludge
DAF sludge
TABLE 1
Suggested straight run of pipe diameters
required upstream of the meter
REQUIRED
ITEM
1, Pumps
centrifugal
positive
2, Vah/es
throttling
globe
check
3. Reducer
4. Increaser
PIPE DIAMETERS
IN A SINGLE PLANE
40
30
20-40
10-20
10-20
10
25
5. Long Radius Ells
6. Tees
7. Straightening Vanes
8. Downstream
Clearance
15
10-20
5
2-5
TABLE 2
SOLIDS CONCENTRATION
Pep3ent by Volume
Line Size % Sofids
3 inches 12.0
4 8.0
6 7.0
8 4.5
10 3.7
12 3,0
14 2.75
16 2.5
18 2.25
20 2,0
36 1.0
Sonlc Velocity
The accuracy of the Badger Meter transit-time ultrasonic
meter depends upon knowing the sonic velocity in a
relative manner. Exact knowledge is not required but an
estimate within 10-20% should be made. The following
table illustrates the differance with several common
fluids.
SONIC
FLUID VELOCITY A'I'rENUATION
Water 1488 m/s 0.22 dBlum.
Alcohol 1200 0.302
Gasoline
R grade 1208 0.18
Ethylene
glycol 1658 1.20
Application Guide
Hydraulic Considerations
Transit-time single chord ultrasonic flowmeters do not
measure the average velocity of the flow in the pipe but
rather the average velocity of flow in the chord of the flow
stream traversed by the acoustic beam. The relation
between this measured chordal velocity and the true
average flow velocity is a correction factor that is
dependent upon Reynolds' numbe~ For single chord
transit-time ultrasonics, the correction factor K, (the ratio
of chordal to average velocity), is expressed as:
K = I + .01/V6.25 + 435Re -0.23
This relationship is valid when the Reynolds' numbers
indicate that the flow regime is in the turbulent zone. For
those applications that operate in the laminar regime but
with well-established and predictable profiles, the unit
must be programmed for a different correction factor.
CALIBRATION DATA
,~, ' , _L I I ~k Ff'T~I '1""~ I I r ~Le
PIPE SIZE
Calibration run showing the rangeability.
Cost-effective nature of the ultra-
sonic as compared to alternate
technologies.
CAPACITY CHART
The following flow rates are based on nominal pipe sizes and are approximate due to variations in pipe diameter and
wall thickness as well as the type of pipe material. The maximum flow rates are for single direction flow. For bi-
directional flow, the maximum flow will be half this value. The minimum detectable values represent the lowest velocity
the meter will sense. This value is below the predictable accuracy range of the meter. For flows over this rate, please
consult the factory.
PIPE SIZE MIN. DET. FLOW MAX, FLOW RATE
(inches) (gpm) (gpm) GALLONS PER MINUTE
3 12 2000
48 226 127916
60 246 15~8 ~ Meter Size
72 3~ m~s76 ]~ ~
" 345 22~6 li Illl HIItll lllll
3
Technical Specifications
Display Function
The front panel of the Series 4500 contains a
24-character alphanumeric LCD display and five
individual s.witches for selection of operating modes.
The function switches are:
Menu- This key allows the user to select meter statt~s
or calibration modes. The status screens
check the meter's operating status. The
calibration screens allow adjustments and
calibration of various parameters such as;
rescaling of full scale, 4-20 zero and span
calibration, etc. Each depression advances
the menu and prompts the user. Among the
menu items are span, zero, scale and
self-test.
Enter- This key steps through the various screens in
the status and calibration modes.
1' ,I. -4 These switches are used to raise or lower
display items such as full scale flow rate, 4-20
mA signal levels, etc.
External Communications
The Series 4500 is equipped with a bi-directional serial
port which supports interactive communication with
hand-held microcomputers as well as mainframe
machines. The port is accessed by a plug mounted on
the electronics unit. Versatile communication protocols
have been established to ensure reliability. Serial port
communications can be used to change the meter
applications, to change the engineering units used for
flow calculations, to ascertain signaling and operation
quality of the meter, and to transmit data such as flow
rate and flow totals.
Mechanical Description
Electronics Unit: The standard unit is housed in a
foam-molded polycarbonate enclosure suitable for wall
or panel mounting. The enclosure is rated NEMA 4X
for complete corrosion resistance and watertight
integrity. Optional enclosure with heater and
thermostat available for environments below 32° E
Transducers: The transducers are constructed of
corrosion-resistant material and sealed to provide
sufficient protection from the environmental elements.
Triax cable is used to provide shielding from external
signal interference. The mounting hardware is
designed to make the installation simple and easy.
Three styles of transducers and mounting
arrangements are available to meet the needs of the
application.
PROGRAMMABLE RELAY OUTPUTS
The Series 4500 is supplied with 4 relay outputs.
These relays are programmable for functions such as;
High and Low alarms, Loss of Signal, Flow Direction,
etc. These relays are SPDT,.5 A at 120 VAC or 1.0 A at
12 VDC.
General Specifications
Electronics
Microprocessor-based: Advanced single-chip
microcomputer with 8K bytes of ROM, 512 bytes of
EEROM and 256 bytes of RAM.
Linearity: +1- 0.5%
Repeatability: 0.250/~
Sensitivity: +1- 0.0(~5 ft./sac.
Accuracy: +/- 1 to 3% above 1 fps
velocity
Output signals: LCD display,
4-20 mADC isolated
RS-232 serial port
4 programmable relays
Operating temperature: 32° to 140° F
Operating humidity: 5 to 950/~ Relative
Power requirements: 117/230 VAC 50~60 Hz
maximum 5 watts
12 VDC
Transducers
Operating temperature: -30° to 150° F
(Optional strap-on to 300° F.)
Encapsulation: Able to withstand prolonged
submergence or direct burial.
Interchangeability: Replacement without affecting
meter accuracy.
Three mounting styles:
Strap-on for metal or plastic pipes which can
support ultrasonic transmission.
Insertion for pipe walls that will not support
ultrasonic transmission.
Internal for large pipes to eliminate costly
meter vaults.
4
Technical Specifications
Ultrasonic Velocity Sensors
General
The transit-time flowmeters from Badger utilize
acous/,ic signals transmitted from pipe-mounted
sensors to accurately measure fluid velocities in both
open channel and closed pipe conduits. Because of
the diverse applications in fluid monitoring, as well as
different pipe materials available, several versions of
the acoustic velocity sensor can be provided. Shown
below are the most common.
Description
Each sensor manufactured by Badger can both
remotely transmit and receive acoustic pulses. These
sensors can be mounted externally, ciamp-on or
welded; with "hot shot" wetted insert probes; mounted
on the inside of the conduit, fully submerged; or
premounted on a factory made spool, windowed or
external. This flexibility in sensor design provides
custom tailoring to fit the user's application. Also,
these sensors can be isolated from the electronic
processor up to 1000 feet (250 ft. windowed sensors),
requiring only signal cable to be run from the power
source to the meter site.
Mounting Hardware
The acoustic sensors and the associated mounting
hardware manufactured by Badger Meter, Inc., are
constructed from materials that are resistant to
corrosive environments.
The hardware can be welded on for those applications
where factory spool fabrication is
required or can be strapped on using stainless steel
cables for the field-installed unit.
Standard Externally Mounted Velocity Sensor The
externally mounted sensor is the preferred design
when acoustic signals can be transmitted through the
pipe or conduit material. These sensors are fully
potted, incorporating an intrinsic safety design
concept; they can be directly buried and operate under
water. The sensor holders are stainless steel. These
sensors can operate over a temperature range from
-30° to 150° F (-30° to 300° F optional) They can be
placed on all metallic and plastic piping, with the
exception of pit cast iron and fiberglass pipe, and
maintain pipe or conduit integrity.
Instream Velocity Sensor
In open conduits over 24 inches in width or in large
concrete pipes where the outside of the pipe is not
accessible, the instream sensor is recommended for
accurate fluid velocity measurement.
The unique design of the sensor facilitates simple
installation. This sensor configuration allows flush
mounting against the sidewall. After mechanical
installation, the housing may be grouted to the
sidewall, producing a streamlined profile in the conduit.
The sensor construction is of a hydraulic efficient
design, watertight, and is intended for continuous
submergence.
ASSY., SENSOR HOLDER
UNDERWATER SENSOR HOUSING
Technical Specifications
Also available is a unique internal hoop design that
comes with the in-stream sensor accurately positioned
and mounted. This mounting arrangement makes
installation fast and precise,
These sensors are constructed of PVC, are fully
potted, and incorporate the same unique technology
associated with the standard externally mounted
sensor.
"Hot Shot" Wetted Sensor
Badger's "Hot Shot" sensors are used where the pipe
or conduit material will not allow transmission of
acoustic energy. A standard concrete saddle tap is
utilized for penetration through the pipe wall.
HOT SHOT WETrED SENSOR
NOTE: VALVE PROVIDED ]O ASSURE WATERTIGHT CONNECTION
DURING PROBE REMOVAL.
The sensor design allows for flush mounting with the
conduit inside diameter, thereby eliminating solids
buildup or turbulence around the measuring point. The
sensors are used with an integral valve to allow sensor
removal without process shutdown. Hot shot wetted
sensors are recommended for concrete, asbestos
cement, wood stave, fiberglass, and heavy
mottar-lined pipe. They are constructed of PVC, fully
potted, and incorporate the same unique technology
associated with the standard externally mounted
sensor. Maximum pressure rating is 150 PSI.
WINDOWED SPOOL
Fabricated Spool
Fabricated spool pieces are available in windowed
sensor designs, with a choice of end
connections and materials of construction. Spool
pieces come with the sensors mounted and calibrated
with the electronics.
Windowed sensors transmit and receive the ultrasonic
pulse through an acoustic window which is in contact
with the flow stream. The design allows sensor removal
without de-watering the fine. The sensors and
windows are constructed of Ultem® (a registered
trademark of General Electric) thermoplastic and have
temperature ratings of 150°F, with a pressure rating to
150 psi.
The windowed spool pieces are available in sizes 3" to
48" with stainless or carbon steel construction, with
ANSI, AWWA and plain end connections being
standard.
DIMENSIONS
NominaiPipe NominaiPipe NominaiPipe
Size(Inches) L Si~(Inches) L Size(Inches) L
3" 12" 12" 18" 24" 30"
4" 12" 14" 21" 30" 30"
6" 12" 16" 24" 36" 36"
8" 14" 18" 27" 42" 42"
10" 15" 20" 30" 48" 48"
6
Mounting Configurations
Series 4500
Applied to existing piping systems with either externally mounted or wetted sensor design.
Externally Mounted Sensors
· Plastic pipe
· Metallic pipe
· Asbestos Cement pipe
· Ductile/Cast Iron pipe
Pressure vessel integrity
Non-Intrusive
Can be buried or completely submerged
Internally Mounted Sensors
· Large diameter pipe
· Pipe or conduit not
accessible from the
outside
Wetted Mounted Sensors
("Hot Shot" Construction)
· Concrete pipe
· Wood Stave pipe
· Fiberglass
PIPE CAST IRON DUCTILE IRON
MATERIAL Pit Cast CeelrRugalUnlioed Uned
Field Installed Velocity Sensors
METALLffi PLASTICS
Carbon Steel Stainless Exotic Metals; ANS PVC
CONCRETE OPEN K~N.FULL
RCP Asbestes CHANNEL PIPE
Cement CONDUIT CONDITIONS
> __> > > __>
No
3" 3" 3" 3" 3"
24" 24" 24" 24" 24" 24"
6" 6" 12" 12" 12" 12"
No
NO
Externally Mounted Sensors · Non-intrusive
· Stainless Steel Spools
· High Pressure Application
· Any Standard End Connections
WIndowed Sensors · Sizes 3" through 48"
· ANSIIAWWA/Plain End
Flanges Available
· CarbonlSS construction
Sample Specifications
General
A transit-time ultrasonic flowmeter shall be installed on
the piping system as shown in the plans and shall
be in accordance with the manufacturer's
recommendations. The meter shall consist of a set of
acoustic transducers, interconnecting cable, remote
microprocessor-based electronic transmitter and
accessories as required for the installation. The meter
shall be a Badger Meter Model 4500 Compu-Sonic.
Acoustic Sensors and Mounting Requirements
Two flow sensors shall be permanently mounted to the
pipe to ensure accurate and stable measurement of
flow. The sensors shall be positioned in accordance
with the manufacturer's specifications and factory
approved methods. Mounting tomplates and/or fixtures
for sensor attachments shall be provided by the
manufacturer.
The mounting hardware and transducere shall have
sufficient integrity to maintain accurate sensor
placement withstanding normal pipe vibration and
shall be capable of operating over a temperature range
of (-30° to 70° C) or (-30° to 150° F). In addition, the
sensors shall be so designed as to operate under
submerged conditions indefinitely.
The acoustic sensors shall alternately transmit and
receive acoustic energy pulses propagated along the
centerline of the fluid. Only transit-time method of
operation will be accepted.
Four designs are available depending upon the
application.
(1 .) For External Sensors (3" Dia. Meters and Larger):
The integrity of the pipe shall be maintained during
installation and operation. Cutting into the pipe to
install the sensors or holders shall not be allowed.
Stainless steel mounting bands shall be placed
about the pipe circumference to secure the sensor
brackets; the mounting bands shall have sufficient
strength to maintain accurate sensor position.
Positioning of the sensor mounting brackets shall
be in accordance with the manufacturer's
specifications.
The acoustic sensors shall be securely held in the
sensor brackets and shall transmit acoustic energy
through the (steel, cast iron, plastic) pipe wall for
measurement of flow.
These sensors shall be so designed as to be
operated directly buried (in accordance with the
manufacturer's recommendations) or underwater.
(2.) For "Hot Shot" Sensors (12" Dia. Meters and
Larger):
Two acoustic sensors of the "hot shot" style shall
be mounted on the piping at the positions shown
on plans. Valve assemblies shall be supplied to
allow the insertion or withdrawal of the sensors
without dawatering the conduit.
(3.) For Instream Wetted Sensors (24" Dia. Meters and
Larger):
The sensor design and mounting hardware shall
be such as to allow mounting against the inside of
the pipewall. Installation shall be in accordance
with the manufacturer's specifications.
(or)
The manufacturer shall supply an internal strap
design that will be installed on the inside diameter
of the conduit· This design will have the instream
sensors accurately positioned and mounted on the
field installed "hoop". The manufacturer shall
supply all the necessary hardware to ensure
proper installation.
(4.) For Fabricated Spool Design:
The meter body installed in the piping shall be
__" internal diameter with a laying length of
· It shall be constructed from
material with (ANSI, 150, or 300#), (AVVVVA, Class
D, 150#), carbon steel or plain end connections.
The design shall incorporate externally mounted
sensors that are field replaceable, factory mounted
on the meter body. This design will be in
accordance with ASME pressure vessel code
A windowed sensor design shall be supplied by the
manufacturer that allows sensor removal without
dewatering of the line, The sensors and windows
shall be constructed of Ultem' thermoplastic and
shall have a temperature rating of 150° F, The
sensor shall be replaceable without dewatering the
pipe,
8
Sample Specifications
Transmitter Requirements
The transmitter shall contain all the circuitry
necessary to produce a 4-20 mA DC signal linear
with the flow rate. The transmitter shall be capable
of measuring and totalizing forward and reverse
flow. It shall be microprocessor-controlled. The
microprocessor shall be of a single chip design
using at least 8K bytes of ROM, 512 bytes of
EEROM, and 512 bytes of RAM. The transmitter
shall be housed in a foam-moulded polycarbonate
enclosure suitable for wall/panel mounting, rated
NEMA 4X. The display on the enclosure will be a
24-character, 2-line alphanumeric LCD clearly
indicating instantaneous flow rate and totalized flow
information with the engineering units and multiplier
as specified. The transmitter shall utilize
menu-driven sequencing of the internal meter
functions via five front panel switches. The meter
shall be capable of performing the following
functions from the front panel switches without the
need or use of special external test equipment.
-RATE INDICATION
-TOTALIZATION
-ON-LINE METER STATUS
-SELF-TEST
-METER IDENTIFICATION AND TAG NUMBER
-SPAN ADJUSTMENT
-ZERO ADJUSTMENT
-FLOW DAMPING
-METER RESCALE
-METER RECALIBRATION
Meter output shall be an isolated 4-20mA DC signal
linearly proportional to flow rate operating into a
maximum of 1000 ohms. The power requirements
for the meter shall be a maximum of 5 watts
operating on 117 VAC 50~60 Hz. It shall be capable ·
of operating off 12 VDC continuous or battery back
up. The temperature range for the transmitter shall
be from (32° to 140° F) or (0° to 60° C).
The transmitter shall be equipped with a serial
communication port capable of interactive
communication with hand-held microcomputers or
mainframe machines.
Performance Specifications
The flowmeter shall measure, indicate and totalize
the flow to within the following parameters:
Accuracy equal to or better than +/- 3% of actual
flow above 1 fps velocity for field mounted
sensors.
Accuracy +/-10/O of actual flow above 1 fps
velocity for spool piece mounted sensors.
Linearity of the units shall be + / - 0.5%.
Repeatability to within + / - 0.250/O.
Sensitivity of + I - 0.005 ft./sec.
Flowmeter Maintenance
The flowmeter manufacturer shall incorporate
troubleshooting guides with the instruction
manuals. In addition, the meter shall be so
designed as to provide a continuous on-line
indication of meter status via the LCD display.
Through the front panel menu, a user operated,
self-test program can be activated that assesses
the health of the meter by checking the EEROM,
signal strength, transmission status, as well as
the electronic circuitry to assure reliable
operation of the meter.
BadgerMeter
Series 4500
Application Checklist
FLUID CHARACTERISTICS
Temperature
Viscosity
Specific Gravity
Line Pressure
Percent Solids
Gas and/or Air Bubbles
Acoustic Velocity
HYDRAULIC CHARACTERISTICS
Flow Rate
Actual Minimum
Actual Maximum
Desired Flow Range
Flow Conditions
Reynolds' Numbers for the operating range
Steady/Turbulent/Pulsating
Uni/Bi-Directional
Approach Conditions
Straight pipe diameters ahead of the meter
Pipe Orientation
Vertical/inclined/Horizontal
Distance downstream from
Valves/pumps/elbows
Is the pipe permanently full?
Does a free fall exist?
PIPE CHARACTERISTICS
Pipe Material
Inside Diameter
Outer Diameter
Pipe Wall Thickness
Pipe Class Rating
Flange Type/Rating (if applicable)
Liner - Type and Thickness
Outer Liner - Type and Thickness
FLOWMETER CHARACTERISTICS
Sensor Mounting Style
Standard External
High Temperature
Spool Design
Material
Laying Length
Flange - Style/rating
Liner - Type/thickness
Electronics
Distance from the Sensors
· Environment Conditions
Temperature
Humidity
Enclosure Rating
Power Supply Requirements
Indicator Units
Totalizer Units
Output Signal Format
All rights reserved. Date subject to change without notice,
The Representative In your area Is:
Badger Meter
RO. BOx 5813901 Tulsa, Oklahoma 74158-1390 / (918) 83S-8411
Telex: RCA 203605 I FAX: (918) 832-9962
Pan-Tech Controls Co.
2401 AVE. J, SUITE 200 METRO 817-640-3232
ARLINGTON, TX 76006-6118 FAX 817-649-7933
www.oantechcontrols.com
-REPRESENTING-
AMETEK THERMOX coMsusT~oN OXYGEN & CO ARALYZERS
www. thermox. com
BADGER METER
CONTROL MICROSYSTEMS
DIETERICH STANDARD
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RECORDERS - VIDEO GRAPHIC DISPLAYS
TURBINE FLOWMETERS-INDICATORS-
TOTALIZERSAND FLOWCOMPUTERS
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