GE Sensing C-RS Operating Manual

Measurement & Control Solutions Flow

CModel C-RS

Ultrasonic Flow Transducer

Installation Guide

916-077 Rev. C

July 2010

Model C-RS

Ultrasonic Flow Transducer

Installation Guide

916-077 Rev. C July 2010

GESensingInspection.com

Technical content subject to change without notice.

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Contents

1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Transducer Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3. Couplants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

4. Preparing for Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

4.1 Choosing an Installation Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

4.2 Preparing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

4.3 Obtaining the Transducer Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

4.4 Determining the Number of Traverses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

5. Installing the Universal Clamping Fixture and Transducers - UCF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5.1 Verify Fixture Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5.2 Identifying the UCF Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5.3 The Double-Traverse Method -UCF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

5.4 The Single-Traverse Method - UCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5.5 Mounting Transducers into the UCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

6. Installing the General Clamping Fixture and Transducers - GCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

6.1 The Double-Traverse Method - GCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

6.2 The Single-Traverse Method - GCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

6.3 Mounting Transducers into the GCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

6.4 Installing the Magnetic Clamping Fixture and Transducers - MCF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

6.5 Identifying the MCF Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

6.6 The Double-Traverse Method - MCF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

6.7 The Double-Traverse Method - MCF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

6.8 The Single-Traverse Method - MCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

6.9 Mounting Transducers into the MCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

6.10 Maintaining the C-RS Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

6.11 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

C-RS Ultrasonic Flow Transducer Installation Guide iii

Contents

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iv C-RS Ultrasonic Flow Transducer Installation Guide

Preface

Information Paragraphs

Note paragraphs provide information that provides a deeper understanding of the situation, but is not essential to

•

the proper completion of the instructions.

• Important paragraphs provide information that emphasizes instructions that are essential to proper setup of the

equipment. Failure to follow these instructions carefully may cause unreliable performance.

• Caution! paragraphs provide information that alerts the operator to a hazardous situation that can cause damage to

property or equipment.

• Warning! paragraphs provide information that alerts the operator to a hazardous situation that can cause injury to

personnel. Cautionary information is also included, when applicable.

Safety Issues

WARNING! It is the responsibility of the user to make sure all local, county, state and national codes,

regulations, rules and laws related to safety and safe operating conditions are met for each installation.

Auxiliary Equipment

Local Safety Standards

The user must make sure that he operates all auxiliary equipment in accordance with local codes, standards, regulations, or laws applicable to safety.

Working Area

WARNING! Auxiliary equipment may have both manual and automatic modes of operation. As equipment

can move suddenly and without warning, do not enter the work cell of this equipment during automatic operation, and do not enter the work envelope of this equipment during manual operation. If you do, serious injury can result.

WARNING! Make sure that power to the auxiliary equipment is turned OFF and locked out before you

perform maintenance procedures on the equipment.

Qualification of Personnel

Make sure that all personnel have manufacturer-approved training applicable to the auxiliary equipment.

Personal Safety Equipment

Make sure that operators and maintenance personnel have all safety equipment applicable to the auxiliary equipment. Examples include safety glasses, protective headgear, safety shoes, etc.

Unauthorized Operation

Make sure that unauthorized personnel cannot gain access to the operation of the equipment.

C-RS Ultrasonic Flow Transducer Installation Guide v

Preface

Environmental Compliance

Waste Electrical and Electronic Equipment (WEEE) Directive

GE Measurement & Control Solutions is an active participant in Europe’s Waste Electrical and Electronic Equipment (WEEE) take-back initiative, directive 2002/96/EC.

The equipment that you bought has required the extraction and use of natural resources for its production. It may contain hazardous substances that could impact health and the environment.

In order to avoid the dissemination of those substances in our environment and to diminish the pressure on the natural resources, we encourage you to use the appropriate take-back systems. Those systems will reuse or recycle most of the materials of your end life equipment in a sound way.

The crossed-out wheeled bin symbol invites you to use those systems.

If you need more information on the collection, reuse and recycling systems, please contact your local or regional waste administration.

Visit http://www.gesensing.com/environment/weee.htm this initiative.

for take-back instructions and more information about

vi C-RS Ultrasonic Flow Transducer Installation Guide

1. Introduction

BNC Connector

Transducer Body

Adapter

The Model C-RS clamp-on ultrasonic flow transducer for liquids is used exclusively with the GE line of ultrasonic flowmeters. These transducers measure the flow rate of sonically-conductive liquids through pipes having diameters from 2 in. (5 cm) to over 300 in. (7.6 m). Such measurements are typically independent of the pipe material.

2. Transducer Construction

C-RS transducers may be used at process temperatures from -40 to 302oF (-40 to 150oC). Each C-RS transducer assembly consists of the following components (see Figure 1):

• A stainless steel adapter with 3/4” NPT male thread for attaching a junction box

• A transducer that consists of a peizoelectric element mounted on a wedge and wired to the BNC connector

• A BNC style connector for use in connecting the transducer to the flowmeter.

Note: The process temperature range specified above is for ATEX certified designs. Consult the factory for higher

temperatures.

Figure 1: General C-RS Transducer Assembly

C-RS Ultrasonic Flow Transducer Installation Guide 1

3. Couplants

An ultrasonic couplant is supplied for your C-RS installation. The purpose of the couplant is to provide reliable transmission of ultrasound between two adjacent solid surfaces. Generally speaking, couplants perform this task by excluding air from between the adjacent surfaces. Accordingly, the C-RS transducers should be pressed tightly against the pipe, using hand pressure on the set screw to squeeze the couplant to as thin a film as practical for the given pipe surface.

The most commonly used couplants in ultrasonic testing are ordinarily satisfactory for any short-term clamp-on flowmeter application. These couplants include, in general order of preference: gels, grease, propylene glycol, oil, glycerine, and water. Long-term couplants include grease, epoxy adhesive, and solid rubber-like sheet couplant.

The factory provides couplants for both permanent and temporary use as well as for high- and low-temperature applications. For long-term installations, make sure the couplant does not dry or run out.

Standard couplants supplied by GE are listed in Table 1.

Table 1: Couplants

PART NO. TYPE TEMP. RANGE USE

CPL-1 Standard

CPL-2 High/Low Temperature

CPL-3 For Portable

CPL-4 Special As Required *Difficult Applications CPL-7 Epoxy

CPL-8 Solid Sheet

* Installations involving hotter or colder temperatures than listed above, may require special couplants. Consult the factory for such applications.

-40 to 149

-256 to 500

-4 to 140

14 to 122

-40 to 446

F (-40 to +65oC)

F (-160 to +260oC)

F (-20 to +60oC)

F (-10 to +50oC)

F (-40 to +230oC)

Semi-Permanent

Temporary

Permanent

4. Preparing for Installation

Before the clamping fixture and transducers can be properly installed, you must do the following:

• Choose an installation location

• Prepare the pipe

• Obtain the transducer spacing

• Determine the number of traverses

CAUTION! A flowmeter’s accuracy and performance depends on the location, spacing, and alignment of

the transducers. The transducer spacing is unique to your installation.

2 C-RS Ultrasonic Flow Transducer Installation Guide

4.1 Choosing an Installation Location

Transducer

Pipe

Signal Path

End View

To select a suitable transducer location, complete the following steps:

1. Locate the transducer measurement point at least 3 ft (1 m) from any butt welds or flanges. Ideally the location

would be in the center of a 20 ft (6 m) section of straight pipe. Make sure there is sufficient clearance on both sides of the pipe for easy transducer installation:

• 6 in. (15 cm) if you are not using a junction box, or

• 9 in. (22.5 cm) if you are using a junction box.

Note: To guarantee the specified accuracy of the flowmeter, a straight section of pipe and a fully-developed flow

profile are highly recommended. If such conditions are not possible, the transducer location should be such that the acoustic signal travels through the full distribution of the under-developed flow profile for best repeatability.

2. Place the transducers as close as possible to the horizontal plane of the pipe (see Figure 2). Locate the transducers

on opposite sides of the pipe 180

IMPORTANT: Do not place transducers on the top or bottom of the pipe.

apart, ideally at the 3 and 9 o’clock positions.

Note: For the best flow profile identification in limited straight section of pipe, place the transducers at 1 and 7

o’clock.

C-RS Ultrasonic Flow Transducer Installation Guide 3

Figure 2: Transducer Placement

4.2 Preparing the Pipe

To prepare the pipe for transducer installation, complete the following steps:

1. Remove any rust and paint from an area 2 in. (5 cm) wid e by 4 in. (10 cm) long on one side of the pipe.

2. Polish the cleaned area, taking care to preserve the original curvature of the pipe.

3. With an ultrasonic thickness gage, measure the pipe thickness at a minimum of six spots on the cleared area. Take

at least three measurements at each spot to ensure accuracy. The thickness readings should not vary by more than 5% at each spot. If you encounter more than a 5% variation at each spot, try a different section of the pipe. Verify that the wall thickness at both transducer locations has less than the 5% variation.

4. Measure the outside diameter (OD) of the pipe using a tape measure or the supplied pipe wrap.

4.3 Obtaining the Transducer Spacing

Before installing the clamping fixture, you must obtain the calculated transducer spacing from the flowmeter. You will need to know the transducer spacing to complete this procedure.

To obtain the transducer spacing, you must enter the measured pipe OD and the pipe wall thickness into the Pipe Parameters menu of the flowmeter User Program The flowmeter will then calculate the correct transducer spacing for the installation. Refer to your flowmeter User’s Manual for more details.

4.4 Determining the Number of Traverses

The next step in the installation is to determine the number of traverses that you will use. The transducers can be mounted using one of two methods (see Figure 3 on the next page):

Note: The “number of traverses” refers to the number of times the ultrasonic signal transmitted from one transducer

passes through the fluid from one side of the pipe to the other before it reac hes the second transducer.

• Double-traverse method (“V” method) - transducers are mounted on the same side of the pipe. The ultrasonic

signal is sent from one transducer to the other by bouncing it off the opposite pipe wall.

• Single-traverse method (“Z” method) - transducers are mounted diagonally across from each other. The ultrasonic

signal is transmitted directly from one transducer to the other by traveling across the pipe.

If the pipe diameter is 4 to 20 in. (10 to 50 cm), you should always try the double-traverse method first, because it easier to install and provides greater accuracy. The single-traverse method is preferred in the following situations:

• pipe diameters greater than 20 in. (50 cm)

• pipes with poor inside surface conditions

• applications with a highly attenuating fluid

Note: For all installations, it may be useful to try both methods to determine which one yields more accurate results.

Proceed to the appropriate section to properly install your clamping fixture and transducers.

4 C-RS Ultrasonic Flow Transducer Installation Guide

4.4 Determining the Number of Traverses (cont.)

Double Traverse (“V” Method)

Single Traverse (“Z” Method)

Ultrasonic Signal Path

Transducer

Transducers

TOP VIEW

Figure 3: Double- and Single-Traverse Installations

C-RS Ultrasonic Flow Transducer Installation Guide 5

5. Installing the Universal Clamping Fixture and Transducers - UCF

The Universal Clamping Fixture (UCF) acts as a spacing device and a transducer holder. The UCF is available in two lengths and includes several components. Before you begin the installation, you should verify that your fixture is the correct length and familiarize yourself with the fixture components.

IMPORTANT: To maintain ATEX certification the transducer face must be protected against impact. Protection is

provided by properly installing the transducer into the clamping fixture. Care must be taken during installation to ensure that protection is provided.

5.1 Verify Fixture Length

The UCF is available in 12 in. (30 cm) and 24-in. (60 cm) lengths. Each size fixture can be used for either the single- or double-traverse method. However, the pipe size ranges listed in Table 2 below must be followed for each method.

Table 2: UCF Pipe Size Ranges

Clamping Fixture

Length

12-in.

(30 cm)

24-in.

(60 cm)

Single-Traverse

Pipe Diameter

2 to 24 in.

(5 to 60 cm)

2 to 48 in.

(5 to 120 cm)

Double-Traverse

Pipe Diameter

2 to 12 in.

(5 to 30 cm)

2 to 24 in.

(5 to 60 cm)

Note: The mounting chain or strap provided by GE with your UCF is the one best suited for your application.

5.2 Identifying the UCF Components

The UCF includes the following components (see Figure 4 on page 7):

• Two adjustable short blocks for use in the double-traverse method

• Two slide tracks that connect the two blocks

• A ruler attached to one of the slide tracks to help set the transducer spacing

• A long block for use in the single-traverse method

The UCF is chained or strapped to the pipe. Two blocks, which are positioned using the transducer spacing calculated by the flowmeter, are used to hold the transducers in the proper location on the pipe.

6 C-RS Ultrasonic Flow Transducer Installation Guide

5.2 Identifying the UCF Components (cont.)

End View

Side View

Locking Nut

Short Block

1 Screw Hook

Long Block

2 Screw Hooks

Thumbscrew

Chain

Example with Short Blocks

Slide Track

(fixed and adjustable)

Pressure Bolt

Figure 4: Components of the UCF

C-RS Ultrasonic Flow Transducer Installation Guide 7

5.3 The Double-Traverse Method -UCF

Note: The instructions in this section can also be used for a multiple-traverse method. However, you must use an

EVEN number of traverses. Consult the factory for details.

There are three advantages to using the double-traverse method:

• Accuracy is improved because the signal is in contact with the fluid longer than with a single-traverse method

• This configuration can reduce some effect of an underdeveloped flow profile.

• If there is enough pipe length available, the double-traverse fixture is easier to install.

Note: You will only need the short block assembly for a double-traverse installa tion. The long block is not used.

To install a double-traverse UCF, complete the following steps:

1. Obtain the transducer spacing dimension, as described in your flowmeter User’s Manual.

2. Be sure the location you have chosen for the installation has a straight pipe and undisturbed flow for at least 10

pipe diameters upstream and 5 pipe diameters downstream from the flow measurement point.

3. Prepare the pipe where you intend to pla ce the clamping fixture by making sure it is clean and free of loose

material. Sanding, though usually not required, may be necessary to remove any high spots on the pipe. When sanding, be careful to preserve the original curvature of the pipe.

8 C-RS Ultrasonic Flow Transducer Installation Guide

5.3 The Double-Traverse Method -UCF (cont.)

S = Spacing

Select one method to set the spacing

Centerline

Side View

4. Using the attached ruler, move the blocks so they are a distance S from each other. As shown below, use either the

pressure bolts or the ends of the blocks as reference points.

5. Position the clamping fixture along the horizontal plane of the pipe - not on the top or bottom. Make sure the

chains are both on the opposite side of the pipe from the slide track with the ruler.

C-RS Ultrasonic Flow Transducer Installation Guide 9

Top View

Side View

Top View

5.3 The Double-Traverse Method -UCF (cont.)

6. Wrap the chain around the pipe and fasten the chain on the “J” screw hook on the opposite side of the block. Do

this for both blocks.

7. Using the screw hook on the blocks, tighten the chains until the fixture is secured snugly to the side of the pipe.

Note: Make sure the chains are perpendicular to the clamping fixture and are not twisted. If the chains are slanted,

the fixture may move and this could change the final transducer spacing.

Figure 5 shows a completed double-traverse installation without transducers.

Figure 5: Double-Traverse Clamping Fixture w/o Transducers

10 C-RS Ultrasonic Flow Transducer Installation Guide

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