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

CONTENTS
Scope of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Terminology and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Meter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shuto Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dierential Pressure Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Meter Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Straight Pipe Run Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Installation Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation Checkpoints for the Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
User Manual
Page iiiJune 2018 DPM-UM-00206-EN-03

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
Dierential Pressure Flow Meter, Gemini Cone
Page iv June 2018DPM-UM-00206-EN-03

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.
Scope of This Manual
Page 5June 2018 DPM-UM-00206-EN-03

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.
∆P
High Pressure
Port (P1)
Low Pressure
Port (P2)
Support and Cone
Assembly
Meter Body
Flow
Figure 1: Principles of operation
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.
Introduction
Page 6 June 2018DPM-UM-00206-EN-03

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
Introduction
Page 7June 2018 DPM-UM-00206-EN-03

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
Flow
BA
Single Elbow
A00011
B00011
Flow
BA
Two Elbows In-Plane
A00011
B00011
Flow
BA
Two Plane
Changes
Two Elbows Out of Plane
A00011
B00011
1½ - 3 D
Flow
AB
≤ 2D
Pipe Reduction
A11122
B1 1 1 2 2
1 - 2 D
Flow
AB
≥ ½ D
Pipe Enlargement
A11122
B11122
D A B
Flow
Pipe With Tee
A00011
B00011
A B
Flow
Gate/Globe Valve Fully Open/Partially Open
A33344
B00011
A33344
B33344
Straight Pipe Run Requirements
Page 8 June 2018DPM-UM-00206-EN-03

INSTALLATION
Installation Basics
Here are the basic steps for installing a Gemini Cone meter system:
1. Install the meter in the meter run in accordance with the ow run requirements. See “Straight Pipe Run Requirements” on
page8.
2. Secure the manifold to the meter taps.
3. Connect the differential pressure transmitter to the manifold, following the guidelines in “Mounting Location” on
page10.
4. Connect the transmitter to the flow computer according to instructions in the transmitter user manual.
5. Zero the transmitter.
NEVER USE EXCESSIVE PRESSURE OR FORCE WHEN CONNECTING TUBING TO A DIFFERENTIAL PRESSURE
TRANSMITTER.
IF HIGH-TEMPERATURE FLUIDS ARE LIKELY TO BE ENCOUNTERED, MAKE SURE THE CONNECTION TUBING IS RATED FOR
THE ANTICIPATED TEMPERATURE RANGE.
Installation Checkpoints for the Transmitter
Before putting the Gemini Cone meter into service, verify that the transmitter is installed properly by reviewing the
following checkpoints:
• Is the transmitter full scale correct?
• Has the transmitter zero been checked and/or adjusted?
• Are the transmitter and flow computer set to the appropriate modes—linear or square root?
• Have the transmission lines to the transmitter been purged?
• Are there any leaks in the transmission lines?
• Is the manifold bypass valve closed?
• Is the Gemini Cone meter's high pressure port located upstream of the low pressure port?
Installation
Page 9June 2018 DPM-UM-00206-EN-03

Mounting Location
The Gemini Cone meter should be installed with zero to five pipe diameters of straight run upstream of the meter and zero
to three pipe diameters downstream (see “Straight Pipe Run Requirements” on page8). The meter can be used in pipelines
that are slightly larger than the meter tube; however, if the meter tube is larger than the pipeline, operators should contact
Badger Meter or installation requirements. This is usually determined before supply according to application and the degree
of accuracy and performance required.
Meter Orientation and Transmitter Position
The location of the transmitter with respect to the meter should be based on the properties of the fluid being measured and
the direction of flow through the pipeline. The direction of flow is clearly labeled on the body of every Gemini Cone meter.
The meter must be installed so that the high pressure tap (labeled P1 in Figure 1 on page 6) is always upstream of the low
pressure tap labeled P2.
Vertical installations measuring liquids may introduce a slight hydrostatic head effect, which must be considered when
zeroing a transmitter. With liquid applications, the meter should be installed so flow is moving UP to ensure a full pipe. Use
of a 3-valve manifold for zeroing a transmitter. Before installation of any Gemini Cone meter, inspect the meter for damage,
particularly at the sealing surfaces. Any damage should be reported to Badger Meter as soon as possible. Each flow element
has an arrow indicating the required direction of flow. Failure to properly orient the meter according to the direction of flow
will cause improper results and potentially damage the meter.
For vertical installations, the location of differential pressure taps is unrestricted, as long as the static pressure tap is upstream
of the lower-pressure tap.
WARNING
NEVER EXCEED THE MAXIMUM PRESSURE OR TEMPERATURE RECOMMENDED FOR THE MEASURED PROCESS.
EXCEEDING PROPER PRESSURE OR TEMPERATURE RATINGS CAN LEAD TO PERSONAL INJURY OR EQUIPMENT
DAMAGE. THE PROCESS PIPING FLANGES SHOULD BE IDENTICAL TO THOSE ON THE GEMINI CONE BOTH IN PRESSURE
CLASS AND INSIDE DIAMETER. THE PROCESS TEMPERATURE AND PRESSURE SHOULD NEVER EXCEED THOSE FOR
WHICH THE ELEMENT HAS BEEN DESIGNED.
IF HIGH-TEMPERATURE FLUIDS ARE LIKELY TO BE ENCOUNTERED, MAKE SURE THE CONNECTION FITTINGS VALVES
AND TUBING ARE RATED FOR THE ANTICIPATED TEMPERATURE RANGE.
Pressure Tap Location
Location of the pressure taps will vary with the product flowing through the pipeline (liquid, gas, or steam) and the
orientation of the meter (vertical or horizontal).
For horizontal installations, the following installation guidelines apply:
• For measuring liquid, differential pressure taps should be located in the bottom half of the pipeline, between 4 o’clock and
5 o’clock positions, or between 7 o’clock and 8 o’clock positions.
• For measuring gas, differential pressure taps should be located in the top half of the pipeline. For wet gas, taps should be
located between the 10 o’clock and 2 o’clock positions to allow proper drainage of condensate.
• For steam, differential pressure taps should be located in the side of the pipeline at 3 o’clock or 9 o’clock.
Liquid
120…150° or −120…−150°
Wet Gases
60… −60°
Dry Gases
90… −90°
Steam
90…−90° Only
0° 0° 0° 0°
Figure 3: Typical piping configurations for liquid, gas, and steam
Straight Pipe Run Requirements
Page 10 June 2018DPM-UM-00206-EN-03