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Preso Gemini Cone
User Manual
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Badger Meter Preso Gemini Cone User Manual

Dierential Pressure Flow Meter
Gemini Cone
DPM-UM-00206-EN-03 (June 2018)
User Manual
Dierential Pressure Flow Meter, Gemini Cone
Page ii June 2018DPM-UM-00206-EN-03
User Manual
CONTENTS
Scope of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Valve Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shuto Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dierential Pressure Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Straight Pipe Run Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Meter Orientation and Transmitter Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Tap Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Line Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Dierential Pressure Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transmitter Connection Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Full Port Block Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Impulse Tubing Size Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Impulse Tubing Length and Conguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Meter Installation for Liquid Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Installation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Horizontal Meter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bubble Pot Installation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Vertical Meter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Page iii June 2018 DPM-UM-00206-EN-03
Dierential Pressure Flow Meter, Gemini Cone
Transmitter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Meter Installation for Gas Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Horizontal Meter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Condensate Chamber (Drip Pot) (Optional for Wet Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Vertical Meter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transmitter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Meter Installation for Steam Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Horizontal Meter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Vertical Meter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transmitter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Modications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Square Root Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Gauge Line Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Elevation and Temperature Eects in Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Part Number Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Wafer Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Threaded and Socket Weld Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Flanged Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Butt Weld Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Page iv June 2018DPM-UM-00206-EN-03

Scope of This Manual

SCOPE OF THIS MANUAL
This manual contains instructions for installing and operating the Preso® Gemini Cone Differential Pressure Flow Meter.
MPORTANTI
Read this manual carefully before attempting any installation or operation. Keep the manual accessible for future reference.

SAFETY

Terminology and Symbols

Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing death or serious personal injury.
Indicates a hazardous situation, which, if not avoided, could result in severe personal injury or death.
Indicates a hazardous situation, which, if not avoided, is estimated to be capable of causing minor or moderate personal injury or damage to property.

Considerations

WARNING
NEVER OPEN A MANIFOLD VALVE OR FLANGE UNLESS YOU HAVE FIRST VERIFIED THAT THE SYSTEM IS COMPLETELY DEPRESSURIZED. DURING LIQUID OR WET GAS SERVICE, OPEN VALVES VERY SLOWLY TO AVOID SLUGGING IN THE METER RUN.
WARNING
SECURE ALL CONNECTIONS PROPERLY BEFORE STARTING UP A SYSTEM. KEEP A SAFE DISTANCE AWAY FROM THE PROCESS UPON STARTUP.
WARNING
BE MINDFUL OF STATIC ELECTRICITY GENERATED BY INSULATED FOOTWEAR ETC., AND ALWAYS GROUND YOURSELF BEFORE TOUCHING PIPES IN THE HAZARDOUS AREA WHERE FLAMMABLE GAS IS BEING METERED OR MAY BE PRESENT.

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.
OTE:N 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.
WARNING
ALWAYS USE PROPER PROCEDURES AND EQUIPMENT FOR LIFTING AND MOVING THE GEMINI CONE METER TO AVOID RISK OF INJURY.
Page 5 June 2018 DPM-UM-00206-EN-03

Introduction

INTRODUCTION
The Preso Gemini Cone meter is a differential pressure device that combines excellent performance with many benefits including low maintenance, low head loss and a unique ability to have none/minimum straight pipe runs in front of the meter. The Gemini Cone meter produces a pressure differential across a pair of pressure measurement ports. The movement of a fluid around the cone-shaped element creates a pressure differential between an upstream and a downstream pressure port, which is processed by a differential pressure transmitter to provide the flow rate. The conical shape of the element also causes the flow meter to act as a flow straightener, pre-conditioning the flow and making the Gemini Cone meter a versatile measuring instrument for many applications. Badger Meter takes pride in designing an optimized differential pressure metering solution for your system.

Theory of Operation

The Preso Gemini Cone meter creates a differential pressure that is proportional to the rate fluid flow. A transmitter measures the differential pressure and outputs an integrated electronic signal, typically via Modbus or a 4…20 mA output, to a flow computer or other process controller for interpretation and readout. For compressible fluids, line pressure and temperature measurements are required for accurate flow rate calculations as well as compensation for the adiabatic change in the expansion factor. As fluid flowing through the pipe flows around the cone, a pressure drop occurs. The static line pressure (P1) is measured via a wall tap located just upstream of the cone. Pressure is also measured via a sensing tap that is connected to the cone and measures pressure at a point immediately downstream of the cone (P2). The fluid flow rate is calculated from the difference between the two pressures using variations of the Bernoulli flow principles and equations.
High Pressure
Port (P1)
∆P
Low Pressure
Port (P2)
Flow
Support and Cone
Assembly
Figure 1: Principles of operation
Meter Body

Applications

The Gemini Cone meter is designed to work in unprocessed and processed applications, and is ideal for applications that present a wide range of measurement challenges. The Gemini Cone meter is a great solution for steam and boilers, coke oven gas, multiphase (non-homogeneous) fluids, biogas and industrial gas management.
Page 6 June 2018DPM-UM-00206-EN-03
Introduction

Meter Components

The meter comprises three primary elements, as shown in Figure 1 on page 6:
• A meter body or tube with various available end connections.
• A cone assembly, either fabricated or machined from a solid piece of metal, positioned in the center of the meter tube.
• A pair of pressure taps—a wall tap upstream and an integral sensing tap downstream—for reading the differential pressure across the center of the meter tube. (Alternately a downstream tap may be used under certain process measurement conditions.)
The meter can be manufactured from various materials (carbon and stainless steels are standard, but more exotic materials such as duplex stainless steel or nickel-based alloys are also available upon request) to meet the specific requirements for metering steam, air, natural gas, digester gas, nitrogen, ethanol, and a host of media from crude oil to industrial gases.
Preso Gemini Cone meters are differential pressure flow devices providing highly accurate and repeatable measurements of liquids, gases and steam. The meter design provides longer lasting accuracy and lower permanent pressure loss than orifice type meters, reducing maintenance and operating costs. The Gemini Cone can be built to meet the highest pressure and temperature specifications often limited in other flow meter technologies. All models can also be supplied with RTD's and transmitters to provide an economical mass flow measurement solution.

System Components

Valve Manifolds

A 3-way or 5-way valve manifold isolates the transmitter from the process lines. A manifold allows the operator to calibrate the transmitter without removing it from the impulse tubing, draining the transmitter and impulse tubing or venting it to atmosphere. Valve manifolds must be oriented according to the manufacturer’s instructions to prevent trapping air or liquid.

Shutoff Valves

Choose a blocking valve that is rated for the operating pressure of the pipe in which it will be installed. Where dangerous or corrosive fluids or gases like oxygen are likely, the blocking valve and packing must provide ample protection. The valves must not affect the transmission of the differential pressure signal.
Install blocking valves next to the Gemini Cone meter pressure taps.

Differential Pressure Transmitter

A differential pressure transmitter interprets the differential pressures generated by the cone within the meter body and provides an analog or serial output to a flow computer or data control system. Select a transmitter that is rated for accuracy and safety for your particular operating conditions.
Differential pressure devices must be zeroed following installation. The procedure varies somewhat for liquid, gas, and steam applications and by manufacturer. See the manufacturer’s literature for complete procedures on zeroing the transmitter.

Meter Nameplate

This name plate identifies the proper specifications associated with the meter designed for the defined application. The direction of the flow is also indicated on each tag.
Figure 2: Nameplate
Page 7 June 2018 DPM-UM-00206-EN-03

Straight Pipe Run Requirements

STRAIGHT PIPE RUN REQUIREMENTS
With most flow elements, proper operation and performance is dependent on the required lengths of unrestricted upstream and downstream piping. One of the advantages of the Gemini Cone meter is that a fully developed symmetrical flow profile is achieved with relatively short upstream and downstream lengths, so it needs minimal if any upstream and downstream straight pipe runs. We recommend that the Gemini Cone meter be installed with zero to five pipe diameters and zero to three pipe diameters downstream.
0.4 0.5 0.6 0.7 0.8
BA
A
Flow
0 0 0 1 1
1½ - 3 D
≤ 2D
1 - 2 D
≥ ½ D
Two Plane
Changes
Flow
Single Elbow
Flow
Two Elbows In-Plane
Flow
Two Elbows Out of Plane
A
Flow
Pipe Reduction
A
B
BA
A
B
BA
A
B
B
A
B
B
A
0 0 0 1 1
0 0 0 1 1
0 0 0 1 1
0 0 0 1 1
0 0 0 1 1
1 1 1 2 2
1 1 1 2 2
1 1 1 2 2
Pipe Enlargement
D A B
B
A
Flow
Pipe With Tee
A B
Flow
B
A
B
A
Gate/Globe Valve Fully Open/Partially Open
Page 8 June 2018DPM-UM-00206-EN-03
B
1 1 1 2 2
0 0 0 1 1
0 0 0 1 1
3 3 3 4 4
0 0 0 1 1
3 3 3 4 4
3 3 3 4 4
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