Article 5 of 10: Installing Clamp-On Transducers for OUF-W Flowmeters

Why Proper Clamp-On Installation Matters
Clamp-on transducers offer non-invasive flow measurement for the OUF-W Series, but installation accuracy directly impacts performance. Misalignment or poor surface preparation can degrade signal strength (Q value) and skew readings. This guide details the V-method (DN15–200) and Z-method (DN200–6000), with step-by-step instructions to ensure optimal accuracy.

Tools and Materials Required

• Pipe Polishing Machine: Remove rust, paint, or scaling.
• Couplant Gel: High-viscosity, temperature-resistant (included in Kaifeng Oasis kits).
• Steel Belts/Ropes: Secure transducers (DN25–6000).
• Ultrasonic Thickness Gauge: Verify pipe wall thickness (Menu M12).
• Tape Measure & Angle Protractor: For precise positioning.

Step 1: Surface Preparation

1. Clean Installation Points:

o Use a polishing machine to remove paint, rust, or insulation until bare metal is exposed.
o For plastic/PVC pipes, clean with alcohol wipes to eliminate grease.

2. Verify Pipe Roundness:

o Measure circumference at multiple points. Deviation >3% requires insertion transducers.

Step 2: V-Method Installation (DN15–200)

Positioning Transducers

1. Horizontal Alignment:

o Place transducers parallel to the flow axis on opposite sides of the pipe.
o Ensure the distance between transducers matches Menu M25 (calculated by the OUF-W converter).

2. Angle Adjustment:
o Tilt transducers at ±45° relative to the pipe centerline (see diagram below).

Top View: Transducers parallel to flow. Side View: 45° angle alignment.

Securing Transducers

1. Apply a 2–3mm layer of couplant to transducer faces.
2. Fix transducers using steel belts (DN25–100) or wire ropes (DN100+).
3. Tighten belts until couplant oozes slightly (prevents air gaps).

Step 3: Z-Method Installation (DN200–6000)

Positioning Transducers

1. Vertical Alignment:

o Install one transducer upstream and the other downstream on the same pipe side.
o Ensure vertical spacing matches Menu M25 (typically 1x pipe diameter).

2. Axis Alignment:

o Transducers must lie on the same axial plane (use a laser level for large pipes).

Top View: Transducers on the same axial plane. Side View: Vertical spacing.

Securing Transducers

1. Use wire ropes for DN300+ pipes to distribute tension evenly.
2. For uneven surfaces (e.g., concrete pipes), add rubber pads between transducers and pipe.

Step 4: Signal Verification & Troubleshooting

1. Check Signal Strength (M90):

o Ensure upstream/downstream signals >75.0 (excellent) or >60.0 (minimum).

2. Validate Transmission Time Ratio (M91):

o A ratio of 97–103% confirms correct installation.

3. Adjustments for Poor Signals:

o Low Q Value (<60): Reapply couplant, tighten belts, or reposition transducers.
o Ratio Out of Range: Verify pipe parameters (M11–M14) and transducer distance (M25).

Common Pitfalls

• Ignoring Pipe Vibrations: Secure loose pipes with clamps to prevent signal drift.
• Mismatched Transducers: Ensure UP (red) and DN (blue) labels match converter terminals.
• Temperature Extremes: Use HT-rated couplant for fluids >90°C to prevent drying.

Optimize your installation! Get in touch with us to learn more about the installation techniques!

Next in the Series

In Article 6: Installing Insertion Transducers for OUF-W Flowmeters, we’ll cover drilling under pressure, ball valve installation, and alignment for high-accuracy measurement.