GPI (Great Plains Industries) GNP-075S2-5 User manual

G SERIES TURBINES

Owner’s Manual

Sanitary Type

Industrial Type

Rev. D 921977-0203/13

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TABLE OF CONTENTS

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

Installation ...........................................3

Maintenance ........................................4

Troubleshooting .................................11

Specications ....................................12

Service...............................................14

To the owner…

Congratulations on receiving your GPI
G Series Turbine. W e 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.

Victor Lukic, President

Great Plains Industries, Inc.

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 volumetric ow 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.

Turbine Sizing

GPI G Series Turbines are identied

by the internal diameter of the inlet
and outlet.

Model 050 ½ inch (0.6-6.0 GPM)

Model 051 ½ inch (0.8-6.0 GPM)
Model 075 ¾ inch (1.6-16 GPM)
Model 075E ¾ inch (2.3-23 GPM)
Model 100 1 inch (6.7-67 GPM)
Model 150 1 ½ 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 accordance to the actual owrate
and not the process pipe size. For
example: a process having a owrate

of 10-20 GPM in a 1-½" process line
requires either a Model 075E or Model

100 turbine owmeter.

Another important factor to take into
consideration 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 ve 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 ½ inch turbine

owmeter.

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INSTALLATION

Turbine owmeters are affected by

both upstream and downstream
process configurations. 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 direction 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.

1. Install magnetic pickup (Figure 1).

2. Make sure that the new or correct
K-factor 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.

Initial Start-Up

Turbine owmeters can be installed
in the horizontal or vertical position.
When installing a turbine owmeter

in the vertical position, 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.

Figure 1

END VIEW

F L O W

➞

RETAINING
RING

ROTOR
SUPPORT

Industrial version is illustrated. Service procedures are identical for Sanitary versions.

ROTOR BODY ROTOR

MAGNETIC PICKUP
(HAND TIGHTEN ONLY)

SUPPORT

RETAINING
RING

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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 owrate 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 filter or
strainer, damage can occur to the
internal components.

In process lines where particulates

are present, a lter/strainer should

be used. Refer to the table below for

the recommended mesh size.

Turbine

Flowmeter Size Mesh Size

½ inch 40
¾ inch 40

1 inch 40

1 ½ 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 (Cleaning­Out-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

second (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 recom-

mended 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

FlowrateO.D. I.D.

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

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,

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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

sterilization 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

depressurized 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: T o remove the other support,

simply repeat this operation.

5. Once the turbine owmeter is

taken apart, inspect the turbine

owmeter 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 replace-

ment 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.

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NOTE: GPI rotors are tapered on

one end (except ½" and ¾"). The
tapered end should be installed

on the inlet side. See Figure 1.

The ½" and ¾" 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.

1. Install a support on the inlet side

(where the ow starts), placing a

vane between the notches in the

turbine owmeter body. Install a

retaining ring – this will keep the
support in place.

2. Place the rotor with the shaft in
the support that has not been in-

stalled. Hold the turbine owmeter

body with the open end down and
slide the rotor and support into the

turbine owmeter body. Make sure

the vane is placed between the
notches.

Figure 2

Standard Design Replacement Kit

(Industrial & Chemical)

3. Once the support is in place, install
the retaining ring.

4. Blow into the turbine owmeter

to ensure the rotor spins freely.
Installation of the replacement
kit is complete and the turbine

owmeter can be reinstalled into

the process line.

5. Install the magnetic pickup. HAND

TIGHTEN ONL Y.

NOTE: Be sure to use the proper

magnetic pickup, cable and con­nector for the application.

6. Enter the new K-factor supplied
with the replacement kit into the
electronic readout device. (Refer
to the calibration report.)

NOTE: All internal replacement kits

are factory calibrated and are
supplied with a ve point calibra­tion report.

F L O W

➞

F L O W

➞

6

RETAINING
RING

RETAINING
RING

ROTOR ASSEMBLY

FLUSH
HOLE

Single Post Design Replacement Kit

FRONT
SUPPORT

ROTOR SUPPORT

ASSEMBLIES

Figure 3

(Sanitary Series)

ROTOR
ASSEMBLY

FLUSH
HOLE

REAR
SUPPORT

RETAINING
RING

RETAINING
RING

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Replacement Kits for Industrial Turbine Flowmeters

Size

½ in. 2.2-22 LPM

½ in. 3.0-22 LPM

¾ in. 6-60 LPM

¾ in. E 8.7-87 LPM

1 in.

1 ½ in.

Flow Range

(Litres Per Minute)

25.2-252 LPM

67-670 LPM

Tungsten Carbide* High Density Plastic*

Model Part No. Model Part No.

GNT-051

GFT-051

GNT-051H

GFT-051H

GNT-075

GFT-075

GNT-075H

GFT-075H

GNT-075E

GFT-075E

GNT-75EH

GFT-75EH

GNT-100

GFT-100

GNT-100H

GFT-100H

GNT-150

GFT-150

GNT-150H

GFT-150H

80518031

80518081

80758031

80758081

80768031

80768081

81008031

81008081

81508031

81508081

GNP-050

GSCP-050

GNP-051

GSCP-051

GNP-075

GSCP-075

GNP-075E

GSCP-075E

GNP-100

GSCP-100

GNP-150

GSCP-150

80508032

80518032

80758032

80768032

81008032

81508032

GNT-200

2 in.

3 in.

* Sleeve Bearing

125-1,250 LPM

227-2,270 LPM

Replacement Kits for Sanitary Turbine Flowmeters (GSCPS)

GFT-200

GNT-200H

GFT-200H

GNT-300

GFT-300

Flow Range

Size

1 in. 6.7 - 67 GPM GSCPS 81008074

1 ½ in. 17.7 - 177 GPM GSCPS 81508074

2 in. 33 - 330 GSCPS 82008074

(Gallons Per Minute)

82008031

GNP-200

GSCP-200

82008081

83008031

Single Post

Model Part No.

82008032

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Magnetic Pickups

GPI offers two types of magnetic
pickups: Standard and Wire Lead.

See Figure 4.

Figure 4

STANDARD

WIRE
LEAD

Selection Guide for ½ in. Turbine Meters

Magnetic

Pickup Type Part No. Application

Wire Lead

Low Drag

Low Drag 81006000

High Temp,

Low Drag

RF Digital 81005002

Wire Lead

Standard
Standard 81001000

Herm/High

Temp.

High Temp.

Standard

81006001

81007001

Selection Guide for ¾ in. to 3 in. Turbine Meters

81003000

81002000

81007000

Use with Model 051. Meter mount electronics.

Temperature range: -100° F to +250° F. Sine

wave output.
Use with Model 051. Remote mount electronics.

Temperature range: -450° F to +450° F. Sine

wave output.
Use with Model 051. Remote mount electronics.

Temperature range: -450° F to +800° F. Sine

wave output.
Use with Models 050 or 051. Temperature range:

-40° F to +248° F. Square wave, open collector

output. 7-30 VDC required.

Meter mount electronics. Temperature range:

-100° F to +250° F. Sine wave output.

Remote mount electronics. Temperature

range: -100° F to +250° F. Sine wave output.

Remote mount electronics. Temperature range:

-450° F to +450° F. Sine wave output.

Remote mount electronics. Temperature

range: -450° F to +800° F. Sine wave output.

Remote mount electronics. Temperature range:

Active Digital 81004000

-40° F to +248° F. Square wave, open collector

output, 5-32 VDC required. Signal Output: 0-10
V, NPN.

When choosing a magnetic pickup,
the turbine meter and electronics are
generally already known. Electron­ics can be either Local or Remote.
Remote electronics include GPI Re­mote Displays or output to customer

supplied equipment. Follow the next

three steps when choosing a magnetic
pickup.

1. Select your size: ½ in. or ¾ to 3 in.

2. Choose Local or Remote/Output.

Local uses a wire lead pickup. Re-

mote/Output requires a connector.

3. Choose either Sine Wave or
Square Wave as your signal type.
Sine Wave does not require ex­ternal power for sensor and can
be used with battery powered
displays. Square Wave means
sensor power is required.

Cable

Type

None

S

None

D

None

S

H or T

H or T

D

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Magnetic Pickup Enclosures

Pickup Enclosures are optional on G
Series Turbine Meters. Choose from

three pickup enclosures: Model N4A

Figure 5

is the weatherproof enclosure. For

explosion-proof enclosures, choose

N7A for the enclosure without the
terminal strip or the N7AT with the
terminal strip. See Figure 5.

CABLE CLAMP
1" NPT

MODEL N4A

Weatherproof Enclosure

Part No. 80001101

Cable Assemblies

Cable Assemblies include the connector.

Figure 6

MATING CONNECTOR

RedWhite

PIN “A” BLACK

PIN “B” RED

OR CLEAR

PIN “A” RED

PIN “B” BLACK

Black

PIN “C” WHITE OR CLEAR

SHIELDED CABLE

SHIELD

SHIELD

TERMINAL

STRIP

1" NPT

MODEL N7A

Explosion-proof Enclosure

without terminal strip
Part No. 80001100

MODEL N7AT

Explosion-proof Enclosure

with terminal strip

Part No. 80001102

Type S, H and T
Cable Assemblies

Type D Cable Only

Cable Length Selection Guide

Type “S” Type “D” Type “H” Type “T”
Cable Standard Digital or RF Water Resistant Hi-Temperature
Length (2 Conductor) (3 Conductor) (2 Conductor) (2 Conductor)

8 inch 83001001 83002001 83003001 83004001
5 feet 83001005 83002005 83003005 83004005
10 feet 83001010 83002010 83003010 83004010
15 feet 83001015 83002015 83003015 83004015
20 feet 83001020 83002020 83003020 83004020
25 feet 83001025 83002025 83003025 83004025
30 feet 83001030 83002030 83003030 83004030
40 feet 83001040 83002040 83003040 83004040
50 feet 83001050 83002050 83003050 83004050
75 feet 83001075 83002075 83003075 83004075
100 feet 83001100
125 feet 83001125

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FLOW RANGES

Gallons Per Minute Litres Per Minute
Size Min. Max. Min. Max. Frequency Output

½ in. 0.6 6.0 2.2 22 100 - 1000 Hz
½ in. 0.8 6.0 3.0 22 125 - 1000 Hz
¾ in. 1.6 16 6.0 60 100 - 1000 Hz
¾ in. E 2.3 23 8.7 87 100 - 1000 Hz
1 in. 6.7 67 25.2 252 100 - 1000 Hz
1 ½ in. 17.7 177 67.0 670 100 - 1000 Hz
2 in. 33 330 124.9 1249 100 - 1000 Hz
3 in. 60 600 227.1 2271 50 - 500 Hz

DIMENSIONS

NPT & Flared Flanged Sanitary Clamp Tri-Clover Clamp
Size Height Length Height Length Height Length Height Length

½ in. 2.562 2.750 — — — — 2.562 2.750
½ in. 2.562 2.750 — — — — 2.562 2.750
¾ in. 2.625 3.250 2.00 5.50 — — 2.625 3.250
¾ in. E 2.625 3.250 2.00 5.50 — — 2.625 3.250
1 in. 2.75 3.562 2.125 5.50 2.75 3.562 2.75 3.562
1 ½ in. 3.00 4.594 2.50 6.00 3.00 4.594 3.00 4.594
2 in. 3.25 6.063 3.00 6.50 3.25 6.063 3.25 6.063
3 in. 3.50 10.00 3.75 10.00 — — — —

Dimensions are provided in inches.

➤

HEIGHT

➤

➤

(For optional low profile models, subtract 1 inch from height.)

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LENGTH

➤

TROUBLESHOOTING

Symptom Probable Cause Solution

A. MORE VOLUME/

OUTPUT THAN
DISPLAYED OR

REGISTERED

1. Rotor may drag due to
foreign matter obstruction.

2. Magnetic pickup not
screwed down all the way

into the turbine owmeter

body. This causes it not to
detect all the rotor blades
as they pass.

3. Turbine owmeter installed

backwards.

Check for debris inside the
meter. Clean and reassemble.

Screw the magnetic pickup all
the way down into the turbine

owmeter body. Hand-tighten

only.

Install the turbine owmeter in

accordance with the process

ow direction.

B. LESS VOLUME/

OUTPUT THAN
DISPLAYED OR

REGISTERED

4. Turbine owmeter rotor
installed backwards.

5. K-factor is too high in

electronic/readout device.

1. Caused by trapped air in
the process line.

2. K-factor is too low in

electronic/readout device.

Install the turbine owmeter

rotor in accordance with the

process ow direction.

Verify K-factor used. K-factor
should be decreased.

Install an air eliminator up-

stream of turbine owmeter.

Verify K-factor used. K-factor
should be increased.

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SPECIFICATIONS

Accuracy*: ±0.5% of the true ow at

any point within the linear range of

the turbine owmeter.

Linearity*: ±0.5% of the mean

K-factor throughout the linear range.

Repeatability*: ±0.1% of the indicated

ow throughout the linear range.

Response Time:
½ in. to 2 in: 2-5 milliseconds for

step change in owrate.

3 in: 10-25 milliseconds for step

change in owrate.

Frequency Output:

(over the linear range)

½ in. (051): 125 - 1000 Hz

½ in. to 2 in: 100 - 1000 Hz
3 in: 50 - 500 Hz

Voltage Output:
½ in. to 2 in: Approx. 100 mV

@ 100 Hz to 1.0-volt (r.m.s.)

@ 1000 Hz

3 in: Approx. 80 mV @ 50 Hz to

800 mV (r.m.s.) @ 500 Hz

Standard Materials of
Construction

GNT, GBT, GFT and GIT

Housing and Supports: 316 Stainless Steel
Rotor: CD4MCu Stainless Steel
Shaft: Tungsten Carbide
Sleeve Bearings: Tungsten Carbide
Thrust Bearings: Tungsten Carbide
Retaining Rings: 300 Series Stainless Steel

GNP, GBP, GFP, GIP and GSCP

Housing and Supports: 316 Stainless Steel
Rotor: CD4MCu Stainless Steel
Shaft: 316 Stainless Steel
Sleeve Bearings: PTFE Rulon®
Thrust Bearings: 440C Stainless Steel
Retaining Rings: 300 Series Stainless Steel

GSCPS

Housing and Supports: 316 Stainless Steel
Rotor: Nickel Plated CD4MCu Stainless Steel
Shaft: 316 Stainless Steel
Sleeve/Thrust Bearing: PEEK
Retaining Rings: 300 Series Stainless Steel

Maximum Overange: to 125% of

maximum owrate for intermittent

periods.

Operating Temperature:

GNP: -100° F to +185° F
(-74° C to +85° C)

GNT: -100° F to +225° F
(-74° C to +107° C)

GNT (High Temp):

-450° F to +800° F
(-268° C to +427° C)

GSCP: -100° F to +185° F
(-74° C to +85° C)

GSCPS: -100° F to +225° F
(-70° C to +107° C)

* Data based on water calibration

@ 77° F (25° C).

12

Figure 7

Materials of Construction

Industrial turbine flowmeter shown here.

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GPM = Hz x 60
K-factor

Hz = GPM x K-factor
60

K-factor = Hz x 60
GPM

Flow Related Formulas

Pulses Per Litre = K-factor

3.785

Pulses Per Barrel = K-factor x 42

Pulses Per Cubic Meter = K-factor
.003785

Pulses Per Pound = K-factor
Pounds Per Gallon

GPM = Pounds Per Hour
500 x S.G.

Pounds Per Hour = 500 x S.G. x GPM

Pounds Per Gallon = S.G. x 8.33 (Water)

BPH = GPM x 1.42857

BPD = GPM x 34.286

BPM = GPM x 0.238

GPS = GPM x .01666

GPD = GPM x 1440.0

GPM = BPD x .029167

GPM = BPH x 0.7

CFM = GPM x .13368

Pressure Drop vs. Flowrate

Pressure Drop PSI

BPH = Barrels Per Hour
BPD = Barrels Per Day
BPM = Barrels Per Minute
CFM = Cubic Feet Per

Minute
GPS = Gallons Per Second
GPD = Gallons Per Day
GPM = Gallons Per Minute

Flowrate Gallons Per Minute

For estimating pressure drops on liquids other than water, use the following formulas:

P = [ VISC (CPS) ] 1/4 x [ S.G. ] ¾ [ PH O ]

Where: CPS = Absolute Viscosity in Centipoise
SG = Specific Gravity
PH O = Pressure Drop at the Operating Flowrate from the Chart

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SERVICE

For warranty consideration, parts,

or other service information, please
contact your local distributor. If you
need further assistance, call the GPI
Customer Service Department in
Wichita, KS, during normal business
hours.

1-888-996-3837

To obtain prompt, efcient service,

always be prepared with the following
information:

1. The model number of your turbine.

2. The serial number of your turbine.

3. Specic information about part

numbers and descriptions.

For warranty work always be prepared

with your original sales slip or other
evidence of purchase date.

Returing Parts

Please contact the factory before re­turning any parts. It may be possible
to diagnose the trouble and identify
needed parts in a telephone call. GPI
can also inform you of any special
handling requirements you will need
to follow covering the transportation
and handling of equipment which has

been used to transfer hazardous or
ammable liquids.

CAUTION

Do not return turbines without

specic authority from the GPI

Customer Service Department.
Due to strict regulations gov­erning transportation, handling,
and disposal of hazardous or

ammable liquids, GPI will not

accept turbines for rework un­less they are completely free of
liquid residue.

14

CAUTION

Turbines not flushed before
shipment can be refused and
returned to the sender.

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