TURBINE

GAS METERS
COMMON S.A.
ul. Aleksandrowska 67/93
91-205 Łódź, Poland
Phone no.: +48 42 253 66 00
CGT-02
Fax: +48 42 253 66 99

OPERATION MANUAL
(Technical manual)

CGT / IO12 / MID

July 2012

PLEASE READ THE OPERATION MANUAL BEFORE INSTALLING

AND OPERATING THE GAS METER
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Table of Contents

Page
I. INTENDED USE AND CONDITIONS OF USE 3
II. DESIGN AND FUNCTION 7
III. READOUT DEVICE AND MEASUREMENT OUTPUTS 9
IV. LABELING AND PROTECTION 15
V. PACKAGING, TRANSPORT AND STORAGE 19
VI. INSTALLATION AND OPERATION 24
VII. OPERATION MONITORING, MAINTENANCE, FAILURES,
REPAIRS 31
VIII. ADDITIONAL EQUIPMENT 33
IX. LIST OF STANDARDS AND TECHNICAL SPECIFICATIONS 35

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I. INTENDED USE AND CONDITIONS OF USE

Intended use
Turbine gas meters CGT-02 are electromechanical pressure devices designed to measure the
volume of gas flowing through a system. In standard embodiment, the gas meters may be
used at sites with probable occurrence of explosive atmospheres formed as mixtures of gases
classified as explosion groups IIA and IIB (and group IIC for the special purpose
embodiment) with air.
Table 1 lists the physical properties of the most common gases and gas mixtures that may be
measured with CGT-02 gas meters. The gas meters are produced with the following
connection types: PN10, PN16, PN20 (ANSI150), PN25, PN40, PN50 (ANSI300),
PN63/PN64, PN100, PN110 (ANSI600).

The turbine gas meters can be used both indoors in stabilized temperature conditions and
outdoors (open location); however, in the latter case, it is recommended that the gas meter is
shielded from direct exposure to atmospheric factors (metal containers, casings, roofs, shields
etc.)
Conditions for use
1. Directive 2004/22/WE (MID) compliance:
- Certificate PL-MI002-1450CM0003
- CE marking Mxx 1450, Oil and Gas Institute
- working pressure range p  0.4 MPa
- ambient temperature range –25°C  t  +70°C
- gas temperature range –25°C  tg  +55°C
- storage temperature range –30°C  ts  +70°C
- mechanical environment class M2
- electromagnetic environment class E2
- metrological parameters Table 1.
- metrological accuracy class 1.0
- operational position H, VU, VD
- harmonized standards: PN-EN 12261:2005 (EN 12261:2002+AC:2003),
PN-EN 12261:2005/A1:2008 (EN 12261:2002/A1:2006)
2. Directive 94/9/WE (ATEX) compliance:
- certificate KDB 04ATEX036, Central Mining Institute, Experimental Mine
”Barbara”
- CE marking 1453,
- operation conditions standard embodiment II 2G Ex ia IIB T5 Gb
special-purpose embodiment II 2G Ex ia IIC T5 Gb
- meter case index of protection IP66/IP67,
- harmonized standards: PN-EN 13463-1:2010 (EN 13463-1:2009),
PN-EN 60079-0:2009 (EN 60079-0:2009),
PN-EN 60079-11:2010 (EN 60079-11:2007).

3. Directive 97/23/WE (PED) compliance:

- certificate 67/JN/2004-003/3,
- CE marking 1433, Office of Technical Inspection

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- Maximum calculated pressure for gas meter bodies:

connection PN10 PS = 1.0 MPa,
connection PN16 PS = 1.6 MPa,
connection PN20 PS = 2 MPa,
connection PN25 PS = 2.5 MPa,
connection PN40 PS = 4 MPa,
connection PN50 PS = 5 MPa,
connection PN63/64 PS = 6.4 MPa,
connection PN100 PS = 10 MPa,
connection PN110 PS = 11 MPa,
- ambient temperature range –25°C  t  +70°C
- compliance with technical specification WUDT/UC/2003.
4. Directive 2004/108/WE (EMC) compliance:
Requirements met by the use of LF and HF pulse emitters (NAMUR) compliant with the
following harmonized standards: PN-EN 60947-5-2:2011 (EN 60947-5-2:2007), PN-EN
60947-5-6:2002 (EN 60947-5-6:2000).
Table 1. Physical properties of the most common gases and gas mixtures that may be
measured with CGT-02 gas meters. Densities are specified under pressure of
101.325 kPa at 20o C
Gas Chemical Density Density Gas meter
or symbol  relative embodiment
gas mixture (formula) [kg/m3] to air
argon Ar 1.66 1.38 standard IIB
nitrogen N2 1.16 0.97 standard IIB
butane C4H10 2.53 2.1 standard IIB
carbon dioxide CO2 1.84 1.53 standard IIB
ethane C2H6 1.27 1.06 standard IIB
ethylene C2H4 1.17 0.98 standard IIB
natural gas CH4 ca. 0.75 ca. 0.63 standard IIB
helium He 0.17 0.14 standard IIB
methane CH4 0.67 0.55 standard IIB
propane C3H8 1.87 1.56 standard IIB
carbon monoxide CO 1.16 0.97 standard IIB
acetylene C2H2 1.09 0.91 special IIC
hydrogen H2 0.084 0.07 special IIC
air – 1.20 1 standard IIB
The basic metrological parameters of CGT-02 turbine gas meters are listed in Table 2. The
table should not be taken as current sales offer; relevant information may be obtained at the
Marketing Department.
The gas meter causes a gas pressure drop in the system. The numerical value of the pressure
drop typical for the CGT-02 gas meter at gas density of 0 1.2 kg/m3 may be found in the
graph in Figure 1.

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In actual conditions, pressure loss pr [Pa] is calculated from the formula:
 pa  p
p rz  p
o pa
where:  – gas density from Table 1 [kg/m3],
pa – atmospheric pressure (pa  101 [kPa] ),
p – gauge gas pressure upstream of the gas meter [kPa],
p – pressure drop in reference conditions (as per Fig. 1) [Pa]..

Fig. 1. Pressure loss of CGT-02 gas meters

at the reference density of o = 1.2 kg/m3

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Table 2. Basic metrological parameters of CGT-02 meter in the DN50DN400 range at

maximum operating pressure p  0.4 MPa

DN G Qmin LF HF1, HF2 HF3 ÷ HF6

Qmax
minimum flow at scale:
nominal Gas meter emitter emitter constant emitter constant
Maximum flow constant (approximate) (approximate)
diameter size
1:20 1:30
3 3
– – m /h [m /h] [m3/h] [pulses / m3] [pulses / m3] [pulses / m3]

DN 50 G 65 100 5 – 10 2610 94829

G 100 160 8 – 1 742 26974
DN 80 G 160 250 13 8 1 742 26974
G 250 400 20 13 1 470 17059
G 160 250 13 – 1 692 16782
DN 100 G 250 400 20 13 1 692 16782
G 400 650 32 20 1 401 9719
G 400 650 32 20 1 227 6873
DN 150 G 650 1000 50 32 1 227 6873
G 1000 1600 80 50 0.1 129 3910
G 650 1000 50 32 1 114 3113
DN 200 G 1000 1600 80 50 0.1 116 3167
G 1600 2500 130 80 0.1 67 2025
G 1000 1600 80 50 0.1 58 2111
DN 250 G 1600 2500 130 80 0.1 58 2111
G 2500 4000 200 130 0.1 34 1223
G 1600 2500 130 80 0.1 32 1181
DN 300 G 2500 4000 200 130 0.1 32 1181
G 4000 6500 320 200 0.1 19 680
G 2500 4000 200 130 0.1 13 444
DN 400 G 4000 6500 320 200 0.1 13 444
G 6500 10000 500 320 0.1 7.0 285

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II. DESIGN AND FUNCTION

Operation of the turbine gas meter is based on the principle of proportionality of the speed of
rotation of a turbine rotor to the linear velocity or the volumetric flow of gas. The gas flowing
into the gas meter (fig 2) is directed via an inlet straightener into the measurement assembly
and triggers the rotation of the rotor. The rotational motion of rotor is transmitted to the
counter by means of cog gears and magnetic clutch. The counter mechanism totals up the
volume flowing through the device, and an 8-digit counter indicates the total volume. Each
gas meter of the CGT-02 series is verified in the range of Qmin to Qmax (Table 2), and in that
range the accuracy of the meter is verified.

Fig. 2 Cross-section of the turbine gas meter CGT-02

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The turbine gas meter CGT-02 (Fig. 2) is built of the following basic elements:

Main body. The main body carries all loads originating from both the gas pressure and the
system connections. Bodies of the gas meters with nominal diameters of DN50 to DN200 and
PN16 or PN 20 connections may be manufactured in two versions - either as machined steel
forgings or spheroidal cast iron castings. Bodies with PN25, PN40, PN50, PN63/64, PN100
and PN110 are available only in the steel version. Larger bodies, with nominal diameters of
DN250 and above are always made of welded steel. Each body is complete with two
connection flanges with type “B” faces and connection dimensions compliant with the PN-
EN1092-1:2006 and the PN-ISO 7005-1:1996 standards. The flange dimensions, as well as
overall dimensions and estimated weights of the gas meters in their standard embodiments are
listed in Tables 3a and 3b and indicated in Figure 18. By special orders, the body may be
delivered with different types of flanges compliant with: Polish Standards (e.g. with protruded
lips or grooves) or with ISO, ANSI or GOST standards. The gas meter body is complete with
connectors for high frequency signal emitters and sockets for pressure gauges and sockets for
temperature pockets for thermometers (see section III).
Measurement turbine assembly. The measurement turbine assembly consists of the turbine,
the gear system and the inlet straightener. The turbine rotor is placed along the gas meter body
axis and seated on two high precision ball bearings. The flow straightener placed in front of
the turbine makes the gas flow symmetrical and directs it onto the turbine blades. The gear
system (consisting of a worm gear and a cylindrical gear) reduces and transfers the rotational
speed and transmits the drive onto the magnetic clutch.
Drive transmission assembly. The drive transmission assembly consists of a magnetic clutch
with gas-tight partition. The driving part of the clutch is located inside the partitioned
chamber, while the driven part is located outside the partitioned chamber. The clutch
transmits the drive from the pressure zone to the counter assembly, located outside the gas
flow area. The driven part of the clutch may be complete with a reference wheel acting as an
inducer for the high frequency emitter.
The counter assembly. The counter assembly further reduces the rotational speed (by means
of a worm gear and cylindrical gears) to drive the mechanical counter and the elements that
induce the low frequency electric signal emitters. The assembly is also complete with sockets
for transmitting the low and high frequency electric signals outside the gas meter. The gas
meter counter may be optionally equipped with a mechanical outlet.
Lubrication system. The lubrication system is used to lubricate the turbine rotor bearings.
The remaining mechanisms of CGT-02 gas meters are not subject to external lubrication and
make use of bearings equipped with grease reserves. The greasing may be accomplished by
means of a manual plunger pump with integrated oil reservoir (capacity of 20 cm3) or via a
special lubrication gear.
The gas meters are available in the following versions:
- maintenance-free version (not designed for external lubrication),
- version featuring a special valve for external lubrication,
- version with plunger pump.
By default, DN50 gas meters are not designed for external lubrication. Optionally, they may
be equipped with plunger pumps or lubrication valves.

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III. READOUT DEVICE AND MEASUREMENT OUTPUTS

The gas meter CGT-02 is equipped with a readout device in the form of a mechanical
counter with electric signal outputs. The body of the gas meter is complete with sockets for
implementation of external HF emitters and outlets for the (optional) measurement of pressure
and temperature. The outlets allow to monitor the gas meter operation and to connect the
external equipment. Fig. 3 shows the location of the measurement outlets on the gas meter.
The mechanical counter is located inside the counter assembly and visible through a
polycarbonate inspection window. The counter allows direct readout of the actual volume of
gas that has flown through the gas meter under particular pressure and temperature conditions.
The counter assembly may be rotated around its axis in a range of ca. 350o, allowing for
convenient readout of the counter from virtually all directions.

Fig. 3. Location of measurement outlets in CGT-02 gas meters.

Fig. 4. Mechanical outlet clutch dimensions

Mechanical counter outlet The gas meter may be optionally equipped with a mechanical
outlet. A paddled tip of the counter shaft is located on the left side of the counter and covered
by a protective cap. The mechanical outlet may be used to drive external devices. The
rotational speed of the shaft is identical to the speed of the fastest counter barrel. The shaft
rotates in clockwise direction. Maximum allowable momentum of the shaft tip is 0.25 Nmm.

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Electrical counter outlets There are two possible types of electric signal outlets: low
frequency (LF) outlets and high frequency (HF) outlets. The counter may be equipped with
the maximum of two sockets and six electric pulse emitters.
- two inductive high frequency emitters (HF),
- two inductive low frequency emitters (LFI),
- Two low frequency reed contact emitters (LFK),
and with a control circuit featuring a normally closed reed relay switch AFK or, alternatively,
any other emitter.
The reed relay emitters LFK are designed to work with a battery-powered or grid/battery-
powered data logger and volume converter located in the vicinity of the gas meter (up to ca.
2 m). The induction emitters, both of the LFI and the HF type, may emit electric current
signals over significantly longer distances (up to ca. 200 m, depending on conditions). Due to
high power consumption, they are designed to work only with grid-powered volume
converters. Gas volumes corresponding to individual pulses of the LF emitter are presented in
Table 2.
The number of HF pulses per one cubic meter of gas is determined individually for each gas
meter and listed on the type plate.
All emitters located in the gas meter counter assembly are connected to Tuchel C091 31N006
100 2 sockets located in the back wall of the counter case. Cords connected to sockets should
be equipped with Tuchel C091 31H006 100 2 plugs. Tuchel connections in CGT-02 gas
meters are in the IP67 protection class. Table 3 presents potential connections of emitters to
individual electric signal output sockets.
Table 3. Potential connections of gas meter emitters to counter output sockets
polarity
conta LFK 1 LFK 2 AFK LFI 1 LFI 2 HF 1 HF 2
ct
1  S O
4 + S O
Socket 1 2  O P P O O
5 + O P P O O
3  O P
6 + O P
1  P O
4 + P O
Socket 2 2  O O P O
5 + O O P O
3  O P
6 + O P

S – standard connections
P – preferred connections
O – optional connections

Standard embodiment of the CGT-02 gas meter features only one

low frequency reed contact emitter LFK 1.

One of the inductive emitters HF3 to HF6 installed in the gas meter body may act as a control
element in the CGT-02 meter. The constants for emitters HF3-HF6 are listed on the type
plate.

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In line with the conditions for use, the CGT-02 gas meters should be equipped with emitters
allowing for at least II 2G Ex ib IIC T5 Gb protection. This condition is satisfied for
instance by the following emitters used in the counter:
- HF type Bi1-EG05-Y1(1) by Hans Turck GmbH; II 1G Ex ia IIC T6.
- LFI type Si5-K09-Y1-LF(1) by Hans Turck GmbH; II 1G Ex ia IIC T6.
- LFK type CLFK-02 by Common S.A. II 2G Ex ia IIC T6.
(1) – required linear characteristics of the emitter power circuit.
Intrinsic safety parameters of the emitters installed in the gas meter are listed on the
type plate.
Acceptable intrinsic safety parameters
HF LFI LFK
Ui = 20 V DC Ui = 20 V DC Ui = 15.5 V DC
Ii = 60 mA Ii = 60 mA Ii = 52 mA
Pi = 200 mW Pi = 130 mW Pi = 169 mW
Li = 150 μH Li = 350 μH Li ≈ 0
Ci = 150 nF Ci = 250 nF Ci ≈ 0
Nominal operating parameters of the emitters:
reed contact emitter CLFK-02:
closed switch resistance Rz = 100 ÷ 2 k ,
open switch resistance Ro > 100 M ,
max. switching frequency fp = 2 Hz .

inductive emitters Si5-K09-Y1-LF Bi1-EG05-Y1

max. switching frequency fp = 2 Hz, fp = 0.5 kHz.
The remaining nominal operating parameters of the emitters used in the gas meters are in line
with the requirements of the PN-EN 60947-5-6:2002 standard.
Electrical outlets for HF emitter signals in the gas meter body
The high frequency pulse emitter may be placed in the main body of the gas meter above the
turbine rotor or above the reference wheel with the number of cogs equal to the number of
turbine blades. In such case, the magnetic field of the HF emitter is modulated by the turbine
rotor or the reference wheel, respectively. The emitter is mounted in a slot in location shown
in Fig. 3. The slot is complete with a M16 x 1.5 threaded socket (Fig. 5).

Installation of the HF emitter in the gas meter body requires high precision and the use
of electronic control equipment and as such must be performed only by a representative
of the manufacturer or a company authorized by the manufacturer.

Maximum of four near field inductive high frequency emitters (HF) may be installed in the
gas meter:
- two HF emitters at the turbine rotor, and
- two HF emitters at the optional reference wheel.
The emitters should allow for at least 2G Ex ib IIC T5 Gb protection. These conditions
are satisfied, for example, by the following emitters:

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- CHFI-01 by Common S.A., equipped with Bi1-EG05-Y1(1) sensors (Hans Turck

GmbH), – II 1G Ex ia IIC T6,
- CHFI-03 by Common S.A., equipped with Bi3-EG12-RY1/S1000(1) sensors (Hans
Turck GmbH), – II 1G Ex ia IIC T6,
(1) – required linear characteristics of the emitter power circuit.

Fig. 5. The dimensions of the tap for installation of the HF pulse emitter.
Acceptable intrinsic safety parameters:
CHFI-01 CHFI-03
Ui = 20 V DC Ui = 20 V DC
Ii = 60 mA Ii = 60 mA
Pi = 200 mW Pi = 200 mW
Li = 150 μH Li = 350 μH
Ci = 150 nF Ci = 180 nF
Intrinsic safety parameters are listed in the type plate located at the emitter casing (Fig.
10).
The emitters are equipped with 4-pin Tuchel C091 31W004 100 2 connectors. They should be
connected to cords with Tuchel C091 31D004 100 2 slots. The emitter is connected to pins 3
and 4. Figure 6 presents a diagram of the connection of the emitter with the measurement
circuit.

Fig. 6. Diagram of the HF emitter connection.

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The number of HF pulses per one square meter of gas is determined individually for each gas
meter and listed on the electrical outlets type plate. (Figs. 9 and 10), placed at the top of the
counter.
The HF outlet is particularly useful for tracking changes in the flux of the agent flowing
through the gas meter.
Pressure measurement outlet.
Pressure measurement outlets (pulse openings) are located at both sides of the main body
(Fig. 3). Openings are complete with ¼ NPT threaded slots (Fig. 7).

a.) b.)
Fig. 7. ¼ NPT pressure measurement slot.
The outlets are used to connect pressure transducers, either directly to the socket (Fig. 7b) or
via three-way valves. Outlets that not in use are blinded with plugs (Fig. 7a). Both plugs and
sockets may be protected by installation seals.

Temperature measurement outlet.

The turbine gas meter CGT-02 allows temperature measurements only when delivered as a
special order version; temperature pockets are not available in the standard version.
Temperature measurement outlets are located at both sides of the main body (Fig. 3).
Temperature pockets are placed in the main body openings (Fig. 8). Temperature pockets are
complete with M12 x 1.5 threaded sockets. Electric thermometer tips or temperature
transducers are immersed in silicone oil in the temperature pockets (Figs. 8a and 8b).
Temperature pockets which are not in use (Fig. 8c) are blinded with plugs. Outlets that are not
in use are blinded with ¼ NPT plugs (Fig. 7a).

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a) type 1 b) type 2 c) plugged temp. pocket

Fig. 8 Temperature pockets

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IV. LABELING AND PROTECTION

Information on the basic technical parameters of the gas meter along with the serial
number and manufacture year is listed on type plates (Figs. 9a and 9b) screwed to the counter
casing. The top of the gas meter body features signs informing about the direction of gas flow
and the locations of pressure and temperature measurement outlets (Fig. 11).

Fig. 9a. Type plates – standard version

Fig. 9b. Type plates – special version example

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Fig. 10. HF emitter type plate

Fig. 11. Markings of pressure and temperature measurement outlets, HF outlets, mechanical outlet,
and example of oil & oil pump type.

Following verification by the authorized manufacturer laboratory, each gas meter is protected
with seals placed in locations shown in Fig. 12. Seal P1 features the original validation or
revalidation stamp (Fig. 13) while seals P2, P3, P4, P5, P6, P7, P8, P9, P10 feature protection
stamps.
By request of the customer, the gas meter may be delivered along with the verification
certificate that documents its verification.

Retaining the original verification stamp seal is required for the gas meter to be
considered a legal measurement device.

Installation seals placed at the connectors of the pressure transducers P7, HF emitters P8,
temperature transducers P9 and possibly at the mechanical outlet P10 may feature stamps
placed by the manufacturer, gas supplier or authorized installer. In addition, installation seals

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should be placed on the blinders (plugs) of unused electrical outlets and possibly on the three-
way valve connected to the volume converter (see section VIII.)
The original verification period depends on metrological regulations in the country of
installation. Before the end of the verification period, the gas meter should be submitted for
secondary verification at an authorized laboratory (one should also provide for the waiting
time before the actual legal approval date)
Common S.A. offers renewed legal approval at manufacturer's laboratory, allowing for
adjustments or repairs of the gas meters, if required.

Fig. 12. Locations of seals on CGT-02 gas makers

Fig. 13. Original verification stamp

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V. PACKAGING, TRANSPORT AND STORAGE

The gas meter is supplied in factory-made packaging which provides appropriate protection
during transport and storage. For gas meter sizes from DN50 to DN100, the packaging
consists of reinforced cardboard box and profiled cardboard inserts. Side walls of the box
feature handle holes for transporting the gas meter. Gas meters sized DN150 and larger are
placed on appropriate wooden pallets and protected by profiled inserts and cardboard covers.
Appropriate information regarding the contents and restrictions regarding gas meter
loading/unloading and transport is printed on the packaging.
Gas meters submitted for repair or renewal of legal verification should be sent in factory-
made packaging or other packaging providing at least equal protection during transport.
Each turbine gas meter by Common S.A. is supplied with the following:
- a 6-pin Tuchel C091 31H006 100 2 plug to be used for connecting a volume
converter or recorder to the low frequency electric signal outlet (in case the converter
has not been connected to the gas meter in the factory);
- a 4-pin Tuchel C091 31D004 100 2 socket if the gas meter is equipped with a HF
emitter in the main body;
- a bottle of oil for the gas meter lubrication system (0.25 L);
- the technical manual.

The turbine gas meter is a high precision measurement device

and should be handled with appropriate caution.

Following principles should be observed during transport and storage of the gas meters:
1. Gas meters should not be thrown, turned over or subjected to strong impacts (e.g. during
fast transport using carts without springs).
2. Due to the possibility of oil leaks, the gas meters should be transported only in the target
operation position, i.e. with the oil reservoir cap pointing upward. Position changes
required by the installation process should last as shortly as possible (maximum a dozen
or so seconds) The above does not apply to gas meters of size DN50.
3. One must not lift the gas meter by holding the counter assembly case. Transport of heavy
gas meters should be performed using ear-handle screws placed in the gas meter flanges.
4. Special care should be taken when loading, unloading and handling high pressure gas
meters, as they are characterized by large weights.
5. Factory-placed covers or other shields of gas meter orifices should not be removed until
directly before installation.
6. The storage site should protect the gas meter from atmospheric precipitation and moisture.
7. Care should be taken of the seals placed on the gas meter. Damage of seals may lead to
warranty voidance and legal consequences as regards the clearance of accounts
between the gas supplier and the customer.
8. It is not necessary to lubricate the bearings of gas meters when stored at the warehouse.

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Fig. 14. Packaging of the DN50 turbine gas meter.

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Fig. 15. Packaging of the DN50 turbine gas meter with pump.

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Fig. 16. Packaging of the DN80 and DN100 turbine gas meters.

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Fig. 17. Packaging of the DN150-DN400 turbine gas meters.

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VI. INSTALLATION AND OPERATION

Before installing the gas meter ensure that it is suitable for the system's operational
parameters. In particular, following type plate information should be taken into consideration:
 Acceptable gas meter gauge pressure [MPa), labeled pmax.
3
 Maximum actual flow [m /h], labeled Qmax .
 Acceptable working position as indicated on the type plate:
- H horizontal (standard version),
- VD vertical; downward vertical flow (option – by request),
- VD vertical; upward vertical flow (option – by request),

Maximum load of the gas meter may be exceeded

by not more than 25% for not longer than 30 minutes.

The CGT-02 gas meters can be used both indoors in stabilized temperature conditions and
outdoors (open location). In the latter case, it is recommended that the gas meter is shielded
from direct exposure to atmospheric factors (metal containers, casings, roofs, shields etc.)
The gas meter must be placed between pipes of appropriate nominal diameter, with axial
alignment of the gas meter relative to the pipes according to gas industry regulations. The
static load of the system of pipes should not exceed values provided for in the PN-EN
12261:2003 standard. Table 6 lists the maximum torsion and bending moment values. Gas
meters with weights of more than 50 kg should rest on supports so that their weight poses no
burden to the pipeline. Gas meters should not be installed at the lowest point of the system
lines, as condensate and impurities may accumulate in that area.
Dimensions listed in Tables 3a and 3b and illustrated in Figure 18 may be helpful when
designing the location for the installation of the gas meter.

Fig. 18. Basic dimensions of CGT-02 turbine gas meters.

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Table 3a part I Basic dimensions and weights of CGT-02 turbine gas meters

DN connection L H A B C E F G N P R S T   mass
body
mm (flange) mm mm mm mm mm mm mm mm mm mm mm mm mm   kg
PN10/PN16/PN25 cast 281 – 20 11
PN20/ANSI150 iron 273 – 20 11
PN10/PN16 281 – 20 12
150
PN20/ANSI150 273 – 20 11
50 PN25/PN40 150 281 198 42 58 – 22 157 91 – 85 39 45 90 12
PN50/ANSI300 steel 281 – 23 12
PN63/64 288 – 26 15
PN100 296 – 194 28 17
PN110/ANSI600 281 – 33 13
PN10/PN16/PN25 cast 301 – 27 19
60 59
PN20/ANSI150 iron 296 – 27 18
PN10/PN16 301 – 21 – 24
146
PN20/ANSI150 296 – 25 – 24
80 PN25/PN40 240 301 201 95 – 25 169 137 – 103 – 45 45 25
PN50/ANSI300 steel 306 80 – 29 – 27
PN63/64 309 – 28 – 28
PN100 316 – 212 31 – 32
PN110/ANSI600 306 – 38 – 30
PN10/PN16 325 – 30 24
cast
PN20/ANSI150 330 – 30 66 60 25
iron
PN25 3330 – 30 25
PN10/PN16 325 157 – 23 32
PN20/ANSI150 330 – 25 34
100 300 215 101 124 181 171 85 116 40
PN25/PN40 333 – 25 36
PN50/ANSI300 steel 343 – 32 85 65 42
PN63/64 340 – 30 39
PN100 348 – 223 35 46
PN110/ANSI600 353 – 45 52
PN10/PN16 375 – 32 47
cast
PN20/ANSI150 415 125 – 32 110 55 46
iron
PN25 392 – 32 47
PN10/PN16 375 185 – 25 64
PN20/ANSI150 415 – 26 64
150 450 242 180 208 231 141 142 35
PN25/PN40 392 – 29 70
PN50/ANSI300 steel 432 155 – 36 141 60 80
PN63/64 415 – 35 86
251
PN100 420 – 43 96
PN110/ANSI600 420 – 260 54 105

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Table 3a part II. Basic dimensions and weights of CGT-02 turbine gas meters

DN connection L H A B C E F G N P R S T   mass
body
mm (flange) mm mm mm mm mm mm mm mm mm mm mm mm mm   kg
PN10/PN16 435 – 30 70
cast
PN20/ANSI150 438 30 70
iron
PN25 445 – 30 71
PN10/PN16 435 – 30 70
206
PN20/ANSI150 438 – 30 71
200 PN25 600 445 265 212 240 – 30 223 333 168 157 168 30 55 80
PN40 453 – 34 90
steel
PN50/ANSI300 455 – 49 100
PN63/64 473 – 49 115
PN100 480 – 272 54 130
PN110/ANSI60 475 – 62 140
0
PN10 491 – 27 130
PN16 496 – 31 130
PN20/ANSI150 496 – 31 130
232
PN25 506 – 32 140
250 PN40 steel 750 518 293 270 330 – 38 244 425 258 178 225 30 55 150
PN50/ANSI300 516 – 54 175
PN63/64 528 – 54 190
PN100 546 – 298 61 230
PN110/ANSI60 548 – 70 250
0
PN10 541 – 36 190
PN16 548 – 37 190
PN20/ANSI150 561 – 37 200
258
PN25 561 – 38 220
300 PN40 steel 900 576 318 300 350 – 42 268 448 278 202 245 30 55 240
PN50/ANSI300 578 – 59 260
PN63/64 583 – 59 270
PN100 611 – 324 67 330
PN110/ANSI60 598 – 74 340
0
PN10 637 29 350
PN16 644 32 350
PN20/ANSI150 654 37 390
PN25 664 40 420
400 PN40 steel 1200 684 354 500 400 – 387 50 306 570 348 240 348 90 30 450
PN50/ANSI300 679 58 480
PN63/64 689 60 490
PN100 712 80 610
PN110/ANSI60 697 84 580
0

CGT/IO12/MID
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Table 3b. Dimensions of the connections of CGT-02 turbine meters (DN50-DN250).

DN connection DZ D0 d0 n DN connection DZ D0 d0 n
mm (flange) mm mm mm pcs. mm (flange) mm mm mm pcs.
PN10/16 165 125 18 4 PN10 395 350 22 12
PN20/ANSI150 150 120.5 18 4 PN16 405 355 26 12
PN25/40 165 125 18 4 PN20/ANSI150 405 362 26 12
50 PN50/ANSI300 165 127 18 8 PN25 425 370 30 12
PN63/64 180 135 22 4 250 PN40 450 385 33 12
PN100 195 145 26 4 PN50/ANSI300 445 387.5 29.5 16
PN110/ANSI600 165 127 18 8
PN63/64 470 400 36 12
PN100 505 430 39 12
PN10/16 200 160 18 8
PN110/ANSI600 510 432 35.5 16
PN20/ANSI150 190 152.5 18 4
PN25/40 200 160 18 8 PN10 445 400 22 12
80 PN50/ANSI300 210 168.5 22 8 PN16 460 410 26 12
PN63/64 215 170 22 8 PN20/ANSI150 485 432 26 12
PN100 230 180 26 8 PN25 485 430 30 16
PN110/ANSI600 210 168.5 22 8 300 PN40 515 450 33 16
PN10/16 220 180 18 8 PN50/ANSI300 520 451 32.5 16
PN20/ANSI150 230 190.5 18 4 PN63/64 530 460 36 16
PN25/40 235 190 22 8 PN100 585 500 42 16
100 PN50/ANSI300 255 200 22 8 PN110/ANSI600 560 489 35.5 20
PN63/64 250 200 26 8 PN10 565 515 26 16
PN100 265 210 30 8 PN16 580 525 29.5 16
PN110/ANSI600 275 216 26 8 PN20/ANSI150 600 540 29.5 16
PN10/16 285 240 22 8 PN25 620 550 36 16
PN20/ANSI150 280 241.5 22 8 400 PN40 660 582 39 16
PN25/40 300 250 26 8 PN50/ANSI300 650 571.5 35.5 20
150 PN50/ANSI300 320 270 22 12 PN63/64 670 585 42 16
PN63/64 345 280 33 8 PN100 715 620 48 16
PN100 355 290 33 12 PN110/ANSI600 685 603 42 20
PN110/ANSI600 355 292 29.5 12
PN10 340 295 22 8
PN16 340 295 22 12
PN20/ANSI150 345 298.5 22 8
PN25 360 310 26 12
200 PN40 375 320 30 12
PN50/ANSI300 380 330 26 12
PN63/64 415 345 36 12
PN100 430 360 36 12
PN110/ANSI600 420 349 32.5 12

Impurities contained within the gas and the system may cause mechanical damage to the gas
meter and reduce the measurement accuracy. Therefore, a filter with efficacy not worse than
10 m should be placed in front of the gas meter (particularly when the flowing gas contains
high amounts of impurities). In addition, the inflow side of the system should be thoroughly
cleaned before installing the gas meter. Conical sack filter may be placed at the inlet of the
inflow section; the filter should be removed after 1  2 months of operation. If the filter is not
removed, monitoring of the filter impurity level should be provided by means of pressure
drop measurements or regular check-ups. If clogged, the sack filter may be destroyed by the
gas pressure, and filter residue may seriously damage the gas meter.

CGT/IO12/MID
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The manufacturer is not responsible for any damages or stoppage of the gas
meter resulting from insufficient filtration of the gas flowing through the meter.
The user should be aware of certain risks associated with changes in the gas flow intensity. If
the gas flow was relatively low for a long time after system initiation, the assembly-related
contaminants (e.g. welding residues) are retained in front of the gas meter. Only after the flow
is significantly increased, the contaminants may be swept away by the gas, causing gas meter
damage. For this reason, the sack filter may prove useful in the period in which maximum
system capacity is being reached. In all cases, protection of the gas meter from mechanical
damage is in the user's best interest.
Before final installation of the gas meter ensure it is properly oriented, i.e. that the arrow on
the meter body points in the direction of the gas flow.
The gas meter should be connected to pipeline flanges using screws meeting the requirements
of the PN-EN 1515-1, PN-EN 1515-2, PN-EN ISO 898-1, and ZN-G-4008:1995 standards.
For the sake of easier screw selection, table 4 lists the minimum required limits for the
plasticity of material in screws used for flange connections of CGT-02 gas meters.
Table 4. Minimum limits for the plasticity of screw material Re [MPa] .

PN10 PN25 PN40

PN16 PN20 PN50 PN63/64 PN100 PN110
DN50 200 200 170 220 350 190 375 410 420

DN80 150 150 270 170 275 205 285 310 445

DN100 180 180 185 140 225 285 255 305 435

DN150 165 165 185 155 245 310 250 260 360

DN200 220 150 265 160 210 305 220 345 420

DN250 190 130 165 165 235 235 305 405 340

DN300 225 160 215 165 235 255 305 340 360

DN400 175 155 170 170 255 225 240 400 350

Appropriate seals should also be selected for specific flange types and nominal pressures.
Flange connections should be sealed using seals made of asbestos-free plates with properties
conforming to ZN-G-4008 and WUDT-UC-WO-O/19 standards. Flat seals can be used for
standard flanges with type “B” faces and pmax= 2 MPa (according to PN-EN 1514-1:2001 or
PN-EN 12560-1:2002), while values of pmax > 2 MPa require corrugated seals (according to
PN-EN 1514-4:2001 or PN-EN 12560-4:2002), 12560-4:2002).

Appropriate screw lengths should be selected with consideration to dimensions

listed in Tables 3a and 3b and the thickness of seals being used.
Tables 5a and 5b list the required screw torque values for flange connections.

Table 5a. Required screw torque values for flange connections – smooth, lubricated threads;
Mnom [Nm].
PN16 PN25 PN40
PN10 PN20 PN50 PN63/64 PN100 PN110
DN50 44 44 38 44 68 37 144 270 82

DN80 33 33 60 33 53 78 108 203 171

DN100 40 40 41 53 86 115 169 291 288

CGT/IO12/MID
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DN150 70 70 75 101 161 118 323 336 344

DN200 95 63 101 104 199 201 390 609 548

DN250 81 97 109 157 309 225 536 920 603

DN300 97 117 143 155 309 331 540 993 634

DN400 129 151 163 294 583 397 1000 1797 1028

Table 5b. Required screw torque values for flange connections – smooth, non-lubricated
threads; Mnom [Nm].
PN16 PN25 PN40
PN10 PN20 PN50 PN63/64 PN100 PN110
DN50 82 82 71 82 127 69 267 501 153

DN80 61 61 112 62 99 144 201 377 317

DN100 74 74 76 99 159 208 312 544 534

DN150 131 131 139 187 299 219 601 626 643

DN200 177 118 187 193 372 373 730 1141 1021

DN250 150 180 201 293 575 421 1005 1718 1129

DN300 180 217 265 290 576 617 1011 1863 1187

DN400 239 282 305 551 1089 743 1877 3379 1929

Table 6. Maximum torsion and bending moments exerted by the pipe system on the gas meter;
Mmax [Nm].
DN80 DN150 DN200
DN50 DN100 DN250 DN300 DN400
440 760 1220 2710 4470 7050 7050 7050

Before starting up the gas meter and after installation of the gas meter in the target system, the
reservoir should be filled with oil and the turbine mechanism should be lubricated according
to directions listed in section VII. Only the oil supplied with the gas meter should be used for
this purpose. Following oils may be used with gases listed in Table 1:
 Lubrina L12 gas meter oil – distributed by Common S.A.;
 Lubrina L23 gas meter oil – distributed by Common S.A.;
 VR09 (VELOL 9Q) machinery oil – distributed by Common S.A.;
 Shell Tellus T15 hydraulic oil.
In a typical installation setting, i.e. in a bypass system (Fig. 9), the gas meter start-up
procedure should proceed as follows:
1. The gas meter is installed with valves 1, 2, 5 being closed and the bypass valve 4
remaining open. The blow-off valve 3 remains open after system the system is degassed.
2. After tightening the screws connecting the gas meter and the system, air should be
removed from the system using valve 5, according to appropriate regulations. Valve 3
should remain open.
3. After deaeration, valve 3 is closed and system gas pressure is equilibrated with pressure
increase rate not larger than 30  10 kPa/s.

CGT/IO12/MID
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4. Valve 5 is closed when the gas meter counter stops indicating the flow (associated with
pressure equilibration).
5. Valve 1 is opened, followed by valve 2.
6. Bypass valve 4 may be closed after the valve 2 has been opened in full.
5
3
1 2

Fig. 19. A diagram of a bypass measurement system

When removing the gas meter, the above steps should be followed in reverse order, i.e.
1. Bypass valve 4 is closed first
2. Valve 2 is closed, followed by valve 1.
3. The measurement segment is slowly degassed using the blow-off valve 3, with pressure
drop not larger than 30  10 kPa/s.
The same principle should be followed in other installation settings, i.e. the flow of the gas
through the gas meter should be opened or closed very slowly. Rapid change in the flow
caused by sudden opening of the valve may damage the measurement turbine due to a large
difference of pressure upstream and downstream of the rotor.
If there is a risk of gas meter overload (i.e. exceeding Qmax by more than 25 %), during
exploitation, the use of a restrictor orifice is recommended. The orifice should be installed at a
distance of 510 nominal diameters (DN) behind the gas meter. The orifice dimensions are
selected individually on the basis of the nominal diameter and gas flow, pressure and
temperature. Common S.A. may design and deliver appropriate orifice at customer's request.
Counter readout correctness should be checked after installing the gas meter. Every barrel of
the counter should turn smoothly and a full turn of a barrel should turn the neighbouring left
barrel by 1/10 of a full turn.

Unused electrical outlet sockets must remain

plugged with factory-made plugs and installation seals.

CGT/IO12/MID
 30

VII. OPERATION MONITORING, MAINTENANCE, FAILURES, REPAIRS

In any doubt regarding the correctness of gas meter readings, the gas meter should be
removed from the system and submitted to an appropriate laboratory for verification of its
metrological characteristics. The test may be performed using the control element, without
breaking the legal verification seal. One of the HF emitters installed in the gas meter body
may act as a control element. If no HF emitter has been installed in the gas meter, either a
CHFI-02 or a CHFI-03 HF emitter should be connected to act as a control element. The
external control element may be installed in either of the HF3 and HF4 main body sockets
(Fig. 3), after the protection seal is broken and the plug is removed. The control element (HF
emitter) should be screwed in to a depth allowing for a proper (i.e. consistent with the Namur
standard) emitter signal to be obtained. After completion of the test and removal of the
control element, the hole should be tightly closed using a plug. A protection seal should be
placed on the plug.
The CGT-02 gas meters are equipped with a turbine bearing lubrication system (does not
apply to the standard version of DN50 gas meters). The only activity required as part of the
maintenance is periodic lubrication of bearings. Lubrication consists of pumping an amount
of oil from the oil reservoir into the turbine assembly. This is achieved by pressing a plunger
located under a protective cap at the front wall of the oil pump. One full plunger stroke (ca. 12
mm) pumps out ca. 1/3 cm3 of oil. Strength required for the plunger stroke is lower than
100N. At each lubrication, the level of oil in the reservoir should be inspected. The oil should
be visible through the transparent part of the reservoir wall.
Gas meters designed for pmax = 0.5 MPa may be equipped with a special lubrication valve
instead of the oil pump. Lubrication is achieved by injecting an appropriate dose of oil
through the lubrication valve from a syringe included in the set. Table 7 lists the
recommended oil doses.
For gases listed in Table 1, lubrication should be performed after each gas portion V [m3] as
stated in Table 7, but not less frequently than once every month.. For refinery gases, sewage
gases and sludge digestion gases, lubrication should be performed once every week.
Table 7. Recommended numbers of strokes (n) and oil volumes (Voil)

G V n Voil G V n Voil
3 3 3
[m ] strokes [cm ] [m ] strokes [cm3]
G100 100,000 6 2 G 1000 1,000,000 12 4
G160 160,000 6 2 G1600 1,600,000 20 7
G250 250,000 9 3 G2500 2,500,000 20 7
G400 400,000 9 3 G4000 4,000,000 25 8
G650 650,000 12 4 G6500 6,500,000 25 8

Information on the type of oil to be used is presented on the lid of the oil reservoir or
on the stopper of the lubrication valve.

Dust and other impurities may be removed from the gas meter surface using a cloth soaked in
soap and water. Do not clean with solvents or other chemicals.

CGT/IO12/MID
 31

In case of any incorrectness in gas meter operation (e.g. irregular counter work or counter
stoppage, elevated noise, crackling, oil leaks), the gas meter should be immediately submitted
for repair.

Gas meter repairs may be performed only by the manufacturer or a company

authorized by the manufacturer. Users must not attempt to repair the gas makers
themselves!

Repairs associated with breaking the primary validation seals require renewed legal approval
of the gas meter.
The CGT gas meters are subject to manufacturer's warranty. The warranty proceedings are in
line with the general trade law regulations.

CGT/IO12/MID
 32

VIII. ADDITIONAL EQUIPMENT

Due to tariff requirements, it is often required (or recommended) for the gas meters to be
operated together with electronic devices such as data loggers or volume converters and data
transmission devices. Common S.A. manufactures such devices, e.g. battery/grid-powered
volume converters CMK-02 and data loggers CRS-03, CRI-02. Common S.A. may deliver
these devices by special orders, together with installation services. Example installations are
presented in Figs. 20 and 21.

Fig. 20. An assembly consisting of a CGT-02 gas meter and a CMK-02 volume converter
(the converter is installed in the inflow section)

Fig. 21. Connections of a located outside the Ex zone and powered from the 220 V power
grid.

The converter receives three input signals: the flow signal (from the low- or high-frequency
pulse emitter), the pressure signal and the temperature signal. The pressure signal is collected
at the pulse pressure measurement outlet. It is recommended that the pressure pulse is
measured using a three-way CKMT valve (Fig. 22) allowing the pressure being disconnected
from the sensor for the removal and inspection thereof.

CGT/IO12/MID
 33

Fig. 22. A three-way CKMT valve

The valve handle position is secured by a seal. The valve may be operated only under
supervision of the gas company representative; after operation, the handle is again secured
with an installation seal.
The temperature signal is collected from the emitter installed in appropriate temperature
pocket in the outflow section (downstream the gas meter) (Fig. 20) or in a temperature pocket
in the gas meter itself.

One should keep in mind that all activities associated with connection of additional
equipment to the gas meter are also associated with breaking the protection seals and
thus may be performed only by representatives of the gas company or the
manufacturer. Unused electrical outlet sockets must remain plugged with factory-made
plugs and installation seals.

CGT/IO12/MID
 34

IX. LIST OF STANDARDS AND TECHNICAL SPECIFICATIONS

 PN-EN 12261:2005 (EN 12261:2002+AC:2003)

Gas meters – Turbine gas meters
 PN-EN 12261:2005/A1:2008 (EN 12261:2002/A1:2006)
Gas meters – Turbine gas meters
 PN-EN 13463-1:2010 (EN 13463-1:2009)
Non-electrical Equipment For use in Potentially Explosive Atmospheres - Part 1:
Basic Method And Requirements
 PN-EN 60079-0:2009 (EN 60079-0:2009)
Explosive atmospheres – Part 0: Equipment – General Requirements
 PN-EN 60079-11:2010 (EN 60079-11:2007)
Explosive atmospheres – Part 11: Equipment Protection By Intrinsic Safety 'I'
 PN-EN 60947-5-2:2011 (EN 60947-5-2:2007)
Low-voltage switchgear and controlgear – Part 5-2: Control circuit devices and
switching elements – proximity switches.
 PN-EN 60947-5-6:2002 (EN 60947-5-6:2000)
Low-voltage switchgear and controlgear – Part 5-6: Control circuit devices and
switching elements – DC interface for proximity sensors and switching amplifiers
(NAMUR)
 WUDT/UC/2003
Requirements of office of Technical Inspection – Pressure Equipment

After ending the usage period, the gas meter should under no
circumstances be discarded into municipal waste containers. The
Waste Act of 27 April 2001 imposes an obligation for selective
collection of metallic waste. Gas meters should be best returned to
the manufacturer who would recycle them in an appropriate
fashion. If unable to do so, the user is obliged to deliver the gas
meter to an appropriate recycling point.
Gas meter packaging should never be discarded into municipal
waste containers. The packaging has been appropriately labeled;
pursuant to the Act of 11 May 2001 on packagings and packaging
waste, the user is obliged to submit the packaging for an
appropriate recycling process.

Note: Common S.A. reserves the right to modify the design of the gas meters while retaining the compliance
with relevant standards and requirements regarding accuracy and safety of operation.

CGT/IO12/MID