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Turbine Flow Meter Model 1100

Installation, Operation & Maintenance Manual

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Kimray is an ISO 9001- certified manufacturer. Kimray quality assurance process maintains strict controls of materialsand the certification of parts used in Kimray electronic level switch.

Kimray.comIM:0022Nov 2017

Operational Start-UpFluid 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 blades causing it to rotate at a speed proportional to the fluid velocity.As each blade passes through the magnetic field, created at the base of the pickoff trans-ducer, AC voltage (pulse) is generated in the pickup coil (see Figure 1). These impulses produce an output frequency proportional to the volumetric flow through the meter. The output frequency is used to represent flow rate and/or totalization of fluid passing through the turbine flow meter.

Turbine MeterThe Model 1100 turbine flow meter is de-signed withstand the rigorous demands of the most remote flow measurement applica-tions. The Model 1100 Flow meter maintains measurement accuracy and mechanical integrity in the corrosive and abrasive fluids commonly found in oil field waterflood projects pipelines, in-situ mining operations, offshore facilities and plant locations. Simple to install and service, it can operate in any orientation (horizontal to vertical) as long as the “flow direction” arrow is aligned in the same direction as the actual line flow. For optimum performance, the flow meter should be installed with a minimum of 10 diameters upstream pipe length and 5 diameters down stream pipe length.

Operational Start-Up 1Turbine Meter 1Specifications 2Installation Instructions 3Installing Start-Up 4Repair 6Turbine Meter Removal 6Disassembly 6Installation of New Kit 7Repair Kit Information 7Trouble Shooting Guide 8

Figure 1 Schematic illustration of electric signal generated by rotor movement.

Figure 2 Typical cross-section of B110-375 through B111-121 turbine flow meter

Contents


Turbine Flow Meter Model 1100Installation, Operation & Maintenance Manual

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Material of Construction:Body: 316 Stainless SteelRotor: CD4MCU Stainless SteelRotor Support & Bearings: 316 Stainless SteelRotor Shaft: Tungsten Carbide

Accuracy: +/- 1.0% of reading.

Repeatability: +/- 0.1%

Calibration: Water (NIST Traceable Calibration)

Corrosion: All Kimray Model 1100 turbine meters are con-structed of stainless steel and tungsten carbide. The operator must ensure that the operating fluid is compatible with these materials. Incompatible fluids can cause deterioration of internal components and cause a reduction in meter accuracy.

Pulsation & Vibration: Severe pulsation and mechanical vibra-tion will affect accuracy, and shorten the life of the meter.

Filtration: If small particles are present in the fluid Kimray rec-ommends that a strainer be installed upstream of the meter (see Table 1 for filtration recommendations).

Operating Limitations:Temperature: -150 °F to +350 °F (-101 °C to +177 °C) The meter should not be subjected to tem-peratures above +350° F (177° C), or below -150° F (-101° C) or the freezing point of the metered liquid. High temperatures will damage the mag-netic pick-up while lower temperatures will limit the rotation of the rotor.

Repair Kit:The Model 1100 Turbine Meter Repair Kit is designed for easy field service of a damaged flow meter, rather than replacing the entire flow meter (see Appendix B for repair kit information). Repair parts are constructed of stainless steel alloy and tungsten carbide and is factory calibrated to ensure accuracy throughout the entire flow range. Each kit is complete and includes the calibrated K-factor which used to recalibrate the flow monitor or, other electronics, to provide accurate output data.

Pressure:The following meters have a maximum pressure rating of:

SpecificationsWARNING

Pressure in excess of allowable rating may cause the housing to burst and cause serious

personal injury.

NoteConsult factory for pressure ratings for

flanged meters.

5,000 psi 800 psiKSB100-375 KSB111-130KSB110-500 KSB111-140KSB110-750KSB110-875KSB111-110KSB111-115KSB111-121KSB111-120



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Prior to installation, the flow meter should be checked internallyfor foreign material and to ensure the turbine rotor spins freely.Fluid lines should also be checked and cleared of all debris.

The flow meter must be installed with the flow arrow, etched onthe exterior of the meter body, pointing in the direction of fluidflow. Though the meter is designed to function in any position itis recommended, where possible, to install horizontally with themagnetic pick-up facing upward.

The liquid being measured should be free of any large particlesthat may obstruct rotation of the rotor. If particles are present, amesh strainer should be installed upstream before operation of the flow meter. (See Table 1)

PART NUMBER STRAINERMESH

CLEARANCE FILTER SIZE

KSB110-375 60 x 60 .0092 260 MicronKSB110-375-1/2 60 x 60 .0092 260 Micron



KSB110-875 60 x 60 .0092 260 MicronKSB111-110 60 x 60 .0092 260 MicronKSB111-115 20 x 20 .0340 .86mmKSB111-120 10 x 10 .0650 1.6mmKSB111-121 20 x 20 .0340 .86mmKSB111-130 8 x 8 .0900 2.3mmKSB111-140 10 x 10 .0650 1.6mm

Table 1Strainer Mesh Installation Details

Installation Instructions


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The preferred plumbing setup is one containing a by-pass line (Figure 3) that allows meter inspection and repair without interrupting flow. If a by-pass line is not utilized, it is important that all control valves be located down-stream of the flow meter (Figure 4).

This is true with any restriction in the flow line that may cause the liquid to flash. If necessary, air elimina-tors should be installed to ensure that the meter is not incorrectly measuring entrained air or gas.

It is recommended that a minimum length, equal to ten (10) pipe diameters of straight pipe, be installed on the up-stream side and five (5) diameters on the down-stream 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.

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 and monitor consult Appendix B (Trouble Shooting Guide). If further problems arise, consult the factory. Turbine Meter Repair Kits are also available, see Appendix A. If the internal components of the turbine flow meter are damaged beyond repair, these repair kits are available. Information pertaining the turbine meter repair kits are referenced in Appendix A

The following steps should be followed when installing and starting the meter.

1) After meter installation, close the isolation valves, and open the by-pass valve. Flow liquid through the by-pass valve for sufficient time to eliminate any air or gas in the flow line.

2) Open up-stream isolating valve slowly to eliminate hydraulic shock while charging the meter with the liquid. Open the valve to full open.

3) Open down-stream isolating valve to permit meterto operate.

4) Close the bypass valve to a full closed position.

5) Adjust the downstream valve to provide the required flow rate through the meter. Note: The downstream valve may be used as a control valve.

Installing Start-UpCAUTIONDamage can be caused by striking an empty

meter with a high velocity flow stream.

CAUTIONHigh velocity air or gas may damage the

internal components of the meter

WARNINGMake syre that fluid flow has been shut off and

pressure in the line released before attempting to install the meter in an existing system



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Figure 3 Meter installation utilizing a bypass line

Figure 4 Meter installation without utilizing a bypass line

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Bypass Valve

Isolation Valve

ElectronicFlow Monitor

Isolation andFlow Rate

Control Valve

5 PipeDiameters

TurbineFlow Meter

10 PipeDiameters

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ElectronicFlow Monitor

Control Valve

5 PipeDiameters

TurbineFlow Meter

10 PipeDiameters


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Repair

General DescriptionThe Kimray Model 1100 turbine flow meter is designed with wear resistant moving parts to provide trouble free operation and long service life. The kit allows easy field repair of a damaged flow meter, rather than replacing the entire flow meter. Repair parts are constructed of stainless steel alloy and tungsten carbide. Fluid moving through the turbine flow meter causes the rotor to turn at a speed proportional to the flow rate. The rotor blade cuts the magnetic field of the magnetic pick-up, which in turn generates a frequency output signal that is directly proportional to the speed. The signal is used to represent flow rate and/or totalization of fluid passing through the turbine flow meter. See Figure 1 for typical turbine meter assembly.

Each turbine meter repair kit is factory calibrated to ensure accu-racy throughout the entire flow range. Each kit is complete andincludes a new K-Factor, which is the calibrated number of pulses generated by each gallon of liquid. This K-factor will be used torecalibrate the monitor, or other electronics, to provide accurate output data.

Refer to Figures 5, 6, and 7 for relative positions of repair kitcomponents.

1. Remove the magnetic pick-up from the meter body to avoid damage during repair.

2. Remove the retaining ring from one end of the meter.3. Remove the rotor support from the body. If the rotor support is

jammed in the body, use a pair of pliers or vice-grips to break the rotor support free.

4. The rotor may also be removed at this time. Note: 4 inch and larger meters have two retaining rings (one on either side of the rotor) that need to be removed before the rotor can be removed (Figure 7).

5. Remove the retaining ring from the opposite side of the meter.6. Remove the second rotor support.

Turbine Meter Removal

Dissassembly

WARNINGHigh-pressure leaks are dangerous and cause

personal injury. Make sure that fluid flow has been shut off and pressure in the line released before attempting to remove

the meter.

Figure 5Relative Positions of Internal Components for Turbine MeterSizes KSB110-375 through KSB111-115 and KSB111-121

Figure 6Relative Positions of Internal Components for Turbine Meter

Sizes KSB110-120 through KSB111-130

Figure 7Relative Positions of Internal Components for Turbine Meter

Size KSB110-140



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IMPORTANT: Before reassembly, note that an arrow is cast orengraved on each component *. The arrow indicates the directionof flow. The meter must be reassembled with arrowheads pointedin the direction, and must agree with the direction of fluid flow.The arrows are to be oriented in the up position on both rotor supports. The magnetic pick-up side of the body signifies the up position. This is the position that the repair kit was calibrated, andthis is the position it is to be used to ensure meter accuracy.

Figures 5, 6 and 7 shows the proper alignment and orientation of the repair kit.

* Fractional sizes (3/8”, 1/2”, 3/4”& 7/8”) rotors do not contain a cast or engraved arrow, however Kimray provides a colored cap on the down stream side of the rotor shaft to indicate flow direction. Remove this cap before assembly, noting flow direction.

1. Install one of the rotor support into the body bore, noting the orientation of the arrow.

2. Secure a retaining ring in the groove provided. Be sure that re-taining rings are completely installed in each groove. Note: 4 inch and larger meters have a retaining ring at both ends of the rotor (Figure 7).

3. Insert the rotor and second rotor support in the opposite side of the body, noting the orientation of the arrow.

4. Secure the second retaining ring(s) in the opposite groove, as noted in Step 2 above.

5. Check the meter by blowing air through the assembly. If the rotor does not turn freely, the meter should be dissembled and checked for anything that would obstruct movement of the rotor. CAU-TION: Excess air pressure may damage the rotor and bearings by overspinning.

6. Install the magnet pick-up.

Installation of New Kit

NOTEAt this time electronics will need recalibration. Refer to

the proper installation and operation manual. If there are any questions on recalibration, contact Kimray factory

toll free number 1.800.235.1638, or the manufacturer of the associated electronics.

FLOW METER SIZE REPAIR KIT FITS METER PART NUMBER

REPAIR KIT PART NUMBER

3/8” KSB110-375 KSB251-1021/2” KSB110-500 KSB251-1053/4” KSB110-750 KSB251-1087/8” KSB110-875 KSB251-1091” KSB111-110 KSB251-112

1-1/2” KSB111-115 KSB251-1162” KSB111-120 KSB251-1203” KSB111-130 KSB251-1314” KSB111-140 KSB251-141

Standard MagneticPick-up

All Meter Sizes KSB111109

APPENDIX A: Repair Kit Information


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TROUBLE POSSIBLE CAUSE REMEDY

Meter indicates higherthan actual flow rate

- Cavitation- Debris on rotor support- Build up of foreign materialon meter bore- Gas in liquid

- Increase back pressure- Clean meter- Clean meter- Install gas eliminatorahead of meter

Meter indicates lowerthan 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 workswell (remote monitorapplication only)

Ground loop in shielding

Ground shield one placeonly. Look for internalelectronic instrumentground. Reroute cablesaway from electrical noise

Indicator shows flowwhen shut off

Mechanical vibration causesrotor to oscillate without turning

Isolate meter

No flow indication. Fullor partial open position

Fluid shock, full flow into drymeter or impact caused bearing separation or bro-ken rotor shaft

Rebuild meter with repairkit and recalibrate monitor.Move to location wheremeter is full on start-up oradd downstream flow con-trol valve

Erratic indication at lowflow, good indication athigh flow

Rotor has foreign materialwrapped around it Clean meter and add filter

No flow indication Faulty pick-up Replace pick-upSystem works perfect,except indicates lowerflow over entire range

Bypass flow, leakRepair or replace bypassvalves, or faulty solenoidvalves

Meter indicating highflow, upstream piping atmeter smaller than meterbore

Fluid jet impingement on rotor

Change piping

Opposite effects ofabove

Viscosity lower than cali-brated

Change temperature,change fluid or recalibratemeter

APPENDIX B: Trouble Shooting Guide

All contents of this publication including illustrations are believed to be reliable. And while efforts have been made to ensure their accuracy, they are not to be construed as warranties for guarantees, express or implied, regarding Kimray products or services described herein or their use or application. All sales are governed by our terms and conditions, which are available on request. Kimray reserves the right to modify or improve the designs or specifications of such products at any time without prior notice.

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