GPI GSCP, GSCPS Operating Manual

G SERIES TURBINES

5252 East 36th Street North
Wichita, KS USA 672 20- 320 5
TEL: [phone]
FAX: [phone]

“A Gr ea t P la ins Ve nt ure s Sub si dia ry ”

www.gpi.net

1-888-996-3837

Owner’s Manual

Sanitary Type

Industrial Type

Rev. B 921977-0206/08

To the owner…

Congratulations on receiving your GPI
G Series Turbine. We are pleased to provide
you with a product designed to give you

maximum reliability and efciency.

Our business is the design, manu­facture, and marketing of liquid handling,
agricultural, and recreational products. We
succeed because we provide customers
with innovative, reliable, safe, timely, and
competitively-priced products. We pride
ourselves in conducting our business with
integrity and professionalism.
We are proud to provide you with a
quality product and the support you need to
obtain years of safe, dependable service.

President
Great Plains Industries, Inc.

TABLE OF CONTENTS

General Information ...................................2

Installation
Maintenance
Troubleshooting

Specications

Service

..................................................3

...............................................4

.......................................11

...........................................12

......................................................14

GENERAL INFORMATION

This manual will assist you in installing and
maintaining your GPI G Series Turbine. For
best results, take the time to fully acquaint
yourself with all information about all com­ponents of your G Series Turbine. If you need
assistance, contact the distributor from whom
you purchased your turbine.

Product Description

GPI G Series Turbine owmeters are volu-

metric flow measurement devices. The

moving uid is used to turn a rotor, which is
suspended in the ow stream. The rotating
speed of the rotor is proportional to the uid
velocity or owrate. As the blades from a

spinning rotor pass by a magnetic sensor, an
AC voltage pulse is generated and transmit­ted to the readout instrument. Each pulse is
equal to a given volume of liquid, therefore
“x” number of pulses are equal to a gallon,
litre, pound, barrel, etc.

2

Turbine Sizing

GPI G Series Turbines are identied by the

internal diameter of the inlet and outlet.
Model 050 1/2 inch (0.6-6.0 GPM)

Model 051 1/2 inch (0.8-6.0 GPM)
Model 075 3/4 inch (1.6-16 GPM)
Model 075E 3/4 inch (2.3-23 GPM)
Model 100 1 inch (6.7-67 GPM)
Model 150 1-1/2 inch (17.7-177 GPM)
Model 200 2 inch (33-330 GPM)
Model 300 3 inch (60-600 GPM)

Turbine owmeters should be sized in ac-

cordance to the actual owrate and not the
process pipe size. For example: a process
having a owrate of 10-20 GPM in a 1-1/2"

process line requires either a Model 075E or

Model 100 turbine owmeter.

Another important factor to take into con-

sideration when sizing a turbine owmeter
is instantaneous owrate. This is extremely
important when sizing a turbine owmeter

where the volume is measured per hour or per
day. For example, an application where the
total output is 500 barrels per day, occurring

in a 5 hour period; the recommended turbine

owmeter should be sized according to the
instantaneous owrate:

.
.

(500 – 5) x 24 or 2,400 barrels per day
Thus, requiring an 1-1/2 inch turbine ow-

meter.

1. Install magnetic pickup (See Figure 1).

2. Make sure that the new or correct K­factor is entered into the readout device.

NOTE: The K-factor is printed on the turbine

body. The calibration report included
with the product provides several points

along the ow curve.

INSTALLATION

Turbine flowmeters are affected by both

upstream and downstream process congu-

rations. Turbine owmeters should always

be installed with a minimum of 10 pipe
diameters upstream and 5 pipe diameters
downstream. The only exception is the
placement of the pumps, valves, etc., on the
upstream end. When this occurs, 20 diameters
of straight pipe should be used. The direc-

tion of ow is indicated by the arrow on the
turbine. All turbine owmeters are designed
to measure ow in only one direction.

Check the items that follow once the turbine

owmeter is installed in the process line. This

will ensure a successful start-up.

Figure 1

Initial Start-Up

Turbine owmeters can be installed in the

horizontal or vertical position. When install­ing a turbine owmeter in the vertical posi-

tion, it is important that the direction of ow
be up through the turbine owmeter.

A spool should be installed in place of the
turbine owmeter during initial start-up of a

new process line. The process line should be
purged, thus eliminating any solids contained
in the line. Once this is completed, the spool

can be removed and the turbine owmeter

installed.

NOTE: Control valves should always be

installed downstream of the turbine

owmeter.

MAGNETIC PICKUP
(HAND TIGHTEN ONLY)

RETAINING
RING

END VIEW

ROTOR
SUPPORT

F L O W

➞

ROTOR BODY ROTOR

SUPPORT

Industrial version is illustrated.

Service procedures are identical for Sanitary versions.

RETAINING
RING

3

The turbine owmeter should be installed in

a location where the process line will remain
full of liquid at all times. Otherwise, when
the process line becomes empty and a valve

is opened, the high velocity uid hitting the
turbine owmeter rotor can cause severe

damage.
When there is trapped air in the process line,

an air eliminator should be used. This trapped
air causes air pockets and these air pockets
will cause the rotor to spin at a faster rate than
liquid, thus resulting in incorrect readings,
which results in an overstatement of actual
flowrate and volume. This condition can

damage the owmeter.

WARNING

If liquid being measured contains large

solids, install a lter or strainer. Without
the use of a lter or strainer, damage can

occur to the internal components.

In process lines where particulates are pres-

ent, a lter/strainer should be used. Refer

to the table below for the recommended

mesh size.

Turbine
Flowmeter Size Mesh Size

1/2 inch 40
3/4 inch 40
1 inch 40
1-1/2 inch 18
2 inch 14
3 inch 14

MAINTENANCE

Cleaning Procedures

G Series Sanitary Turbines are designed to
be compatible with commercially accepted
methods of both CIP (Cleaned-In-Place)
mechanical cleaning as well as intermittent
SIP (Steam-In-Place) cleaning methods.

If CIP or SIP cleaning methods are not avail­able, manual COP (Cleaning-Out-of-Place)
methods can be used.

Care must be taken during system start-up,
chemical cleaning, air purge or steam clean­ing processes to ensure that the turbine rotor
does not over speed as damage can result to
the rotor and/or bearing. Maximum allowable
over range for G Series Turbines is 125%

of maximum rated owrate for intermittent

periods.

A minimum uid velocity of 5 foot per sec-

ond (1.5 meter per second) must be main­tained during the CIP process to ensure
adequate cleaning.

Reference: 3-A Accepted Practices for

Permanently Installed Product and Solu­tion Pipelines and Cleaning Systems Used
in Milk and Milk Product Processing
Plants, Number 605-XX as amended for

procedures and recommended owrates.

The following owrates are recommended by
the 3-A Recommended Practices 605-XX to

achieve 5 FPS or 1.5 MPS in the respective

Sanitary Tube size:

Sanitary Tube Size

O.D. I.D. Flowrate

N

I N C H E S

1.0 .875 9.4 GPM

1.5 1.375 24 GPM

2.0 1.875 43 GPM

C E N T I M E T E R S

2.5 2.22 35.6 LPM

3.8 3.50 90.8 LPM

5.1 4.75 163 LPM

4

Temperature limit for SIP cleaning is primar­ily limited by the temperature rating on the
magnetic pickup. If the pickup temperature
rating will be exceeded during SIP cleaning,
remove it during the cleaning process or
a higher temperature rated pickup should

be specied. Internal components of the G

Series Sanitary Turbine must be limited to
less than 285°F (140°C). The temperature
and pressure rating of gaskets and clamps
used in the installation must also be taken
into consideration when determining clean­ing parameters.

Minimum requirements for effective ster-

ilization with SIP cleaning are to maintain

250°F (121°C) at the coldest point in the
system for a minimum of 30 minutes. This
requires a minimum of 15.3 psig (106 kPa)
saturated steam pressure. Normal recom­mended maximums for SIP cleaning on G
Series meters is 285°F (140°C) and 39 psig
(269 kPa) saturated steam pressure.

Disassembling the Turbine

1. Disconnect the turbine owmeter cable

from the magnetic pickup. Refer to
Figure 1.

2. Remove the magnetic pickup.

3. Ensure that the process line is depressur-

ized and empty prior to removal of the
turbine owmeter. Remove the turbine
owmeter from the process line.

4. Using a small screwdriver or similar
tool, insert it into the radius notch of the
retaining ring, pull away from the groove
and up, removing the retaining ring

from one end of the turbine owmeter.

This will allow the support to slide out

of the turbine owmeter body. Remove

the rotor before proceeding to the other
support.

NOTE: To remove the other support, simply

repeat this operation.

5. Once the turbine flowmeter is taken
apart, inspect the turbine flowmeter
body for signs of wear or defects. The
body bore should be smooth and show
no evidence of wear.

NOTE: Do not install a new replacement kit

into a turbine owmeter body that shows
signicant signs of wear.

6. Examine the rotor for broken and/or bent
blades. Remove any foreign matter.

7. Examine the supports for signs of de­terioration, such as wear marks and/or
burrs along the outer edge of the support
vanes.

8. When the rotor or the supports show any
sign of deterioration, a new replacement
kit should be installed. Do not install
a new replacement kit into a defective

turbine owmeter body.

Replacement Kits

A replacement kit is comprised of all the

internal component parts within the turbine

owmeter. A replacement kit consists of the
following:

Parts
Description Quantity

Rotor Assembly 1

Support Assembly* 2

Retaining Ring 2

* The support assemblies come complete with

bushings and thrust balls, which are factory
installed. Proper selection of bearing material is
critical when ordering a new replacement kit.

GPI supports are identical in design, thus
eliminating assembly error. Each support
incorporates a thrust bearing, which allows

for bidirectional ow and prevents damage

to the rotor and/or supports in the event the

turbine owmeter is installed backwards with
respect to the direction of ow.

Notice that the direction of ow is displayed
on the body of the turbine owmeter. This is

important when installing the rotor and also
denotes the direction in which the turbine

owmeter was calibrated.

NOTE: GPI rotors are tapered on one end

(except 1/2" and 3/4"). The tapered end

should be installed on the inlet side.

See Figure 1. The 1/2" and 3/4" rotors

are marked with a point on the hub and
should be installed with the marked side
of the rotor hub on the inlet side.

5