EngineeringGuideConsistency - M2070 - 3 - English - 20181101

User Manual
Engineering Guide Consistency

Copyright© 2018 BTG Instruments AB
The contents of this document are subject to revision without notice due to continued progress
in methodology, design, and manufacturing. BTG shall have no liability for any error or
damages of any kind resulting from the use of this document.
All rights reserved. No part of this document may be copied, photocopied, published,
reproduced, translated or converted into electronic or machine-readable form
without written permission of BTG Instruments AB.
Original Instructions
BTG Instruments AB, 2018

Table of contents
1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.1 Safety Regulations for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.2 Safety Regulations for Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 CE Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Installation Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Process Site Selection for Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Dilution Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Process Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Process Site Selection for MEK-3000 Transmitter . . . . . . . . . . . . . . . . . 10
3.1.1 MEK-3000 Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1.2 Weld-in Saddle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.3 Measuring Chamber with Weld-in Stud . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1.4 Measuring Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1.5 Sensing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Process Site Selection for MEK-2500 Transmitter . . . . . . . . . . . . . . . . . 16
3.2.1 MEK-2500 Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.2 Measuring Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.3 Measuring Chamber with Weld-in Stud . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.4 Sensing Elements and Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Process Site Selection for ACT-2500 Transmitter . . . . . . . . . . . . . . . . . 21
3.3.1 ACT-2500 Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 22
© BTG 2018 Engineering Guide Consistency M2070/3en I

3.4 Process Site Selection for Blade Transmitters . . . . . . . . . . . . . . . . . . . . 23
3.4.1 MBT-2500 Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.4.2 SBT-2400 Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4.3 Simplified Calming Length Dimensioning. . . . . . . . . . . . . . . . . . . . . . . . 27
3.4.4 Pulp Network Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4.5 Calming Length Calculation to obtain Plug Flow Conditions . . . . . . . . . 30
3.4.6 Vertical Pipe Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4.7 Horizontal Pipe Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.8 Multiple Bend Piping Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.9 Valve and Pump Influences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5 Process Site Selection for TCT and RET Transmitters . . . . . . . . . . . . . . 35
3.5.1 TCT and RET Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . 37
3.6 Process Site Selection for TCR Transmitters . . . . . . . . . . . . . . . . . . . . . 38
3.6.1 TCR Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7 Process Site Selection for TCS Transmitters . . . . . . . . . . . . . . . . . . . . . 41
3.7.1 TCS Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.8 Sampling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.8.1 MPS, and PPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.8.2 MCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
II Engineering Guide Consistency M2070/3en © BTG 2018

Safety Instructions
1 Safety Instructions
1.1 General
These products are designed according to Sound Engineering Practice and for
Heavy Pulp and Paper Mill Industry.
These safety instructions are based on a risk analysis carried out in
accordance with the requirements of relevant CE directives in order to comply
with European standards for CE marking.
In practice, a BTG product is not hazardous in operational mode.
Read these safety regulations before installing the transmitter. Be careful to
follow the safety routines when installing the transmitter, when removing the
unit for service, and when carrying out service. Use warning signs for safety
information!
Mounting parts, such as measuring vessels and weld-in studs, are dealt with in
accordance with the pressure vessel standards of specific countries.
Always take precautions when handling equipment in pressurized pipes.
All installation, operation, service, and other handling must be carried out by
trained and authorized personnel and according to valid standards.
NOTE!
Follow the specific products user manual during installation, operation, and
service.
For personal and functional safety: Use only parts that have been
manufactured or approved by BTG.
1.2 Conventions
The following conventions are used in this manual:
• DANGER!
A DANGER! admonition is used when there is a hazard with a risk for
injury or possible death to a person.
• WARNING!
A WARNING! admonition is used when there is a risk for damage to
program, device, machine, sampling valve and so on.
• CAUTION!
A CAUTION! admonition is used when there is a risk for system failure,
service interruption, disturbances to plant operation, a measuring
application and so on.
The admonitions above are hierarchic. A DANGER! admonition includes the
possibility of both a WARNING! and a CAUTION! admonition.
© BTG 2018 Safety Instructions - SI2070en Rev. A 1

Safety Instructions
1.3 Safety Regulations
DANGER
1.3.1 Safety Regulations for Installation
CHECK PIPES!
Risk for corrosive, All welding or bolting must take place in accordance with current standards
toxic, or aggressive
liquids or gases and regulations.
with high pressure or
high temperature.
All handling of electrical units must take place in accordance with current
standards and regulations.
DANGER Use approved lifting gear during installation to prevent injury. Ensure that the
Hazardous voltage measuring vessel/weld-in stud and transmitter is anchored solidly during
in the equipment
installation.
DANGER
Crushing
1.3.2 Safety Regulations for Service

DANGER
Hazardous voltage All handling of electrical units must take place in accordance with current
in the equipment
standards and regulations.
If the motor is switched on so that the transmitter rotates, there is risk of injury
by crushing or cutting if the covers have been removed. This applies to the
DANGER cover over the motor’s drive belt wheel, the cover over the measuring part and
the inspection cover. Also take care when working close to the propeller and
Crushing the sensor if these are exposed.
Take every professional precaution before servicing. Do not wear gloves or
rings which may get caught!
DANGER Before removing the transmitter from the measuring chamber or opening the
inspection cover, check carefully that the line is empty. Hot or corrosive
Cutting liquid flowing out under pressure may cause serious chemical burn
injuries!
Take care when opening the cover of the communication platform with built-in
power supply unit. This contains live parts which may cause electric
DANGER shocks. Live parts are protected against normal contact provided that the
CHECK PIPES!
Risk for corrosive,
connections are made correctly.
toxic, or aggressive
liquids or gases
with high pressure or
When the transmitter is exposed to dangerous basic or acidic corrosive media,
high temperature. it should be removed from the pipeline regularly for inspection. Replace any
damaged seals. If pressurized parts on the transmitter or weld-in stud have
corroded, check that the material is correct for the application. Leakages may
cause personal injury or damage to equipment due to corrosion or
burning!
2 Safety Instructions - SI2070en Rev. A © BTG 2018

Safety Instructions
1.4 CE Declarations
When using the units in combinations other than those tested for, BTG can not
guarantee CE directive conformity.
The units in combination with customer-installed external devices may conform
with EMC and safety requirements when properly installed and CE-marked
equipment is used.
The system operator is responsible for CE directive conformity.
Conformity must be verified by inspection.
CE-declarations are provided in the User Manuals for each transmitter
and sampling valve.
© BTG 2018 Safety Instructions - SI2070en Rev. A 3

Safety Instructions
4 Safety Instructions - SI2070en Rev. A © BTG 2018

Installation Planning
2 Installation Planning
This guide is an introduction in how to prepare installation of BTGs products for

consistency measurement and control, and for the related sampling valves.
For more basic information about consistency measurement the handbook
Accurate Consistency is recommended.
2.1 Process Site Selection for Transmitters

Careful siting of the transmitter is essential for optimum performance and ease
of maintenance.
The transmitter can be installed in a vertical, horizontal or sloping pipe. If
installed in a horizontal or sloping pipe, the location should be carefully
selected so that air is not trapped into the pipe where the transmitter is
installed.
Your BTG sales engineer can help you select the suitable equipment and find
out the location that will give the best results in line with your specific control
strategy.
Important recommendations:
There are a number of considerations to take into account:
1. To ensure minimum time lag, install the transmitter as close as possible to
the point where the dilution water is injected, considering minimum calming
length.
2. Never install the transmitter in a pipe section where turbulence is expected.
Make sure the straight sections before and after the transmitter are
sufficiently long.
3. If the transmitter is installed too close to a pump, valve or pipe elbow, it may
seem flow dependent, as it is measuring an in homogeneous flow. Two
consecutive pipe elbows may also cause a spiral flow, that cannot be
directed, even though the recommended straights are kept.
Where it is not possible to arrange for sufficiently long straights, or if there
might be a risk of a spiral flow, a flow aligner can be installed in the pipe
upstream of the transmitter.
4. The transmitter must be installed on the side of sloping or horizontal pipes.
Avoid installing it on top of the pipe, as air bubbles, if any, may disturb the
measuring.
5. It is important to choose a location with sufficient space when inserting and
removing the transmitter and when opening the cover. Remember to leave
sufficient room for insertion and removal.
6. Install the transmitter so that it is protected from direct mechanical damage.
Install under a roof if there is any risk of frequent water or pulp spray.
7. Protect the transmitter from heavy vibration.
© BTG 2018 Installation Planning - IP2070en Rev. A 5

2.2 Dilution Water Supply

Dilution water must be pressure controlled or otherwise protected from major
pressure variations.
To ensure good control, dilute no more than 20% in each dilution stage,
though a higher percentage may be acceptable early in the process.
If considerable dilution is required it should be carried out in two stages, 70%
to 80% of the water being added in the bottom part of the pulp chest and the
remainder in the form of a fine dilution upstream of the pump.
To avoid consistency variations, thoroughly mix the bottom of the pulp chest
upstream of the transmitter.
The dilution water pipe must be inserted in such a way that it extends
15 – 50 mm [0.6 – 2 inch], depending on the pipe size, into the main pipe on
the suction side of the pump, see fig 1 on page 7. The pipe must be inserted
perpendicular to the suction stud. The pipe should be located at 1/3 of the
distance between the pump and the chest, measured from the pump, to avoid
back flow into the chest.
At the point of injection the dilution water pipe should be dimensioned to
produce a rate of flow three to four times larger than the flow in the main pipe.
Typically this means a dilution water flow 3 – 5 m/s [10–16.5 ft/s] at max flow in
the suction pipe. The dilution water pipe should have the same or larger
dimension as the valve bore to prevent the valve from being plugged by pulp at
water pressure loss.
Choose a dilution water valve with linear characteristics. The pressure drop
over the valve should be at least 0.5 bar [7 psi] and should exceed 25% of the
total pressure drop in the dilution water line. The valve and its actuator must
operate with the least possible backlash and smallest possible dead zone. The
valve must be tight when in its closed position.
NOTE!
The shut off valve (valve A in fig 1) must never be used to control the flow. It
must be kept fully open at all time of operation.
6 Installation Planning - IP2070en Rev. A © BTG 2018

Fig 1 Dilution Water Supply

= pressure drop, min. 0.5 bar [7 psi]
V1 = Inlet water flow velocity, 3 - 5 m/s [10 - 16.5 ft/s]
V2 = Recommended flow velocity
L = Recommended calming length
G = Water nozzle penetration,
min. 15 - 50 mm [0.6 - 2 inch] depending on suction pipe size.
A = Shut off valve, full opening valve (crate valve is recommended)
B = Full opening valve (crate valve is recommended) Tx
V2
L
)D
A B
V1
G
2/3 1/3
© BTG 2018 Installation Planning - IP2070en Rev. A 7

8 Installation Planning - IP2070en Rev. A © BTG 2018

Process Site Selection
3 Process Site Selection
When a process site is selected for installation there are several things to
consider. This chapter gives guidelines on how to select the best process site
to place the transmitter and the sampling valve.
NOTE!
In order to obtain the best measuring results, it is strongly recommended that
the transmitter is mounted in relation to the piping and other equipment as
shown in the figures.
© BTG 2018 Process Site Selection PS2070en Rev. A 9

3.1 Process Site Selection for MEK-3000

Transmitter
Fig 1 Recommended
minimum calming
length - distance
between pump/pipe
elbow/shut-off valve
and consistency
transmitter
Flow
The minimum distance the
Flow
Flow
transmitter should be located LU LU LU LU

downstream of a pump, bend
or elbow is the greater of two
numbers:
Upstream the
transmitter, LU:
1 m [3 ft], or the diameter of
the pipe multiplied by 3
where consistency is <8%;
Ld
and 0.5 m [1.5 ft], or the
diameter of the pipe
multiplied by 1.5 where
consistency is >8%.
Downstream the Flow
transmitter, Ld: Flo

w
For all consistencies, the

minimum distance between LU
the transmitter and a pump,
bend or elbow located Ld
downstream is similarly the
greater of two numbers: LUx
1.5
0.5 m [1.5 ft], or the diameter
of the pipe multiplied by 1.5
NOTE! Flow
Always choose the largest of
the values calculated above.
10 Process Site Selection PS2070en Rev. A © BTG 2018

NOTE!
shown in the figures above.
Fig 2 Installation of the

transmitter close to a
A B C
pipe elbow
NOTE!
Flow
Flow
Flow
Alternative A is the most
suitable.
Avoid alternative C.

3.1.1 MEK-3000 Dimensions and Mounting
Fig 3 Dimensions and

recommended
clearances
8.4"
214
min. 125
5.0"
1.6"
41
min. 500
A B ØD
20"
Dimensions Ø180 mm Ø270 mm

and weights flange flange
A 302 mm [12.0"] 283 mm [11.1"]
B 89 mm [3.5"] 111 mm [4.4"]
ØD 180 mm [7.1"] 270 mm [10.6"]
Transmitter 15 kg [33 lb] 19 kg [42 lb]

weight

3.1.2 Weld-in Saddle
NOTE!
For installation where the pipe diameter is less than 200 mm, the pipe must be
coned to a diameter of at least 200 mm before the weld-in saddle can be
installed.
Saddle can only be used on Ø180 mm flange and in consistency range of

2 - 12% Cs. Distances in 3.1 are the same for saddle as for stud/vessel.
Fig 4 Weld-in saddle
18 5"
470
³100 302 100 ³200 190
4" 12" 4" 8" 7.5"

3.1.3 Measuring Chamber with Weld-in Stud
NOTE!
For installation of small flanges where the pipe diameter is less than 200 mm,
the pipe must be coned to a diameter of at least 200 mm before the weld-in
stud can be installed. For large flanges the pipe diameter must be at least
300 mm otherwise a measuring vessel should be used.
The M-measurement is measured from the inside of the pipe (see figure
below). It is determined in advance and may be either 45 or 150 mm
(consistency, < 4% = 150,  4% = 45).
In installations where M = 45 or 150 mm and the pulp is unscreened, deflectors
must be installed in the pipe.
Fig 5 M-measurement
(Measuring Chamber)
M
M-measurement
Ø180 mm Ø270 mm
Consistency
flange flange
M
< 4% N/A 150 mm [6"]
> 4% 45 mm [1.8"] 70 mm [1.8"]
3.1.4 Measuring Vessel

Measuring vessels for use in low pressure installations may be of left-hand or
right-hand design depending on the flow direction (see fig 6).
Fig 6 Measuring Vessels B

A = Left hand design 1150
B = Right hand design 45.3"
475 675
18.7" 26.6"

3.1.5 Sensing Elements
Sensing Consistency range Default range values

Fiber Feedback
element Characteristic type in water
type Lower limit Upper limit Lower limit Upper limit
A Long
Short
0.8%
0.8%
2.5%
2.5%
1.00% 2.50% 22%
3" m
8. m
0
(MEK-3050 only)
Sludge 1.5-2% 10-15%
21
B m
Long
Short
1.0%
1.0%
5.0%
6.5%
2.00% 4.00% 15.5%
m
8 5 3"
(MEK-3050 only) 1 7 .
--
C Long
Short
2%
2.0%
7%
8%
3.00% 6.00% 9%
--
120
4.7"
H Long
Short
5%
6%
10%
11%
8.00% 10.00% 11%
125
5"
I Long
Short
7%
8%
12%
13%
10.00% 13.00% 7%
100
4"
J Long
Short
10%
11%
16%
18%
12.00% 15.00% 6%
80
3.5"

3.2 Process Site Selection for MEK-2500

Transmitter
Fig 7 Recommended
minimum calming
length - distance
between pump/pipe
elbow/shut-off valve
and consistency
transmitter
Flow
Flow
Flow
transmitter should be located LU LU LU
numbers:
Upstream the
transmitter LU:
the pipe multiplied by 3
where consistency is <8%;
and 0.5 m [1.5 ft], or the Ld
diameter of the pipe
multiplied by 1.5 where
consistency is >8%.
Downstream the Flow
transmitter Ld: Flo
w
For all consistencies, the

minimum distance between
LU
the transmitter and a pump,
bend or elbow located
Ld
downstream is similarly the
greater of two numbers:
0.5 m [1.5 ft], or the diameter 1.5
LUx
NOTE!
Flow
NOTE!
shown in the figures above.


transmitter close to a
pipe elbow A B C
NOTE!
suitable.
Flow
Flow
Flow
3.2.1 MEK-2500 Dimensions and Mounting
Fig 9 Dimensions and min. 125

recommended 5.0"
clearances
10.6"
270
min. 500
20"
342 122 Ø270

13.5" 4.8" 10.6"
Transmitter weight:
36 kg [80 lb]

3.2.2 Measuring Vessel

Measuring vessels for use in low pressure installations may be of left-hand or
right-hand design depending on the flow direction (see fig 10).
Fig 10 Measuring Vessels B

A = Left hand design 1150
B = Right hand design 45.3"
475 675
18.7" 26.6"
3.2.3 Measuring Chamber with Weld-in Stud
NOTE!
For installations where the pipe diameter is less than 300 mm a measuring
vessel should be used.
The M-measurement is measured from the inside of the pipe (see figure
below). It is determined in advance and may be either 70 or 150 mm
(consistency, < 4% = 150,  4% = 70).
In installations where M = 70 mm and the pulp is unscreened, deflectors must
be installed in the pipe.
Fig 11 M-measurement
(Measuring Chamber)
M
Consistency M-measurement
M
< 4% 150 mm [6"]
> 4% 70 mm [2.8"]

3.2.4 Sensing Elements and Propellers
Consistency range Default range values Feedback in water

Sensing
element Fiber
Characteristic
type Lower Upper Lower Upper
type 50 Hz 60 Hz
limit limit limit limit
A Long
Short
0.8%
0.8%
2.5%
2.5%
1.00% 2.50% 27% 32%
" m
Sludge 1.5-2% 10-15%

8.3 10 m
2
B Long
Short
1.0%
1.0%
5.0%
6.5%
2.00% 4.00% 20% 25%
m
5m --
18 .3 "
7
C Long
Short
2%
2.0%
9%
10.0%
3.00% 6.00% 13% 14%
--
120
4.7"
G Long
Short
5%
6%
10%
11%
6.00% 8.00% 19% 22%
150
6"
H Long
Short
7%
8%
12%
13%
8.00% 10.00% 13% 15%
125
5"
I Long
Short
9%
10%
14%
15%
10.00% 13.00% 10% 11%
100
4"
J Long
Short
11%
12%
16%
18%
12.00% 15.00% 7% 8%
80
3.5"

Propeller Consistency
Characteristic “M”-measure
type range
210
8.3"
Large 1.5 - 5% 150 mm
130
5.1"
Small < 1.5% 150 mm
Hub > 5% 70 mm

3.3 Process Site Selection for ACT-2500

Transmitter
Fig 12 Recommended
minimum calming LB LA LB
length - distance
between pump/ pipe
elbow/ shut-off valve
and consistency
transmitter
LA

transmitter should be located
numbers:
LB
Upstream the
transmitter LB:
the pipe multiplied by 3.
Downstream the
transmitter LA:
The minimum distance
between the transmitter and
a pump, bend or elbow
located downstream is
similarly the greater of two
numbers:
0.5 m [1.5 ft], or the diameter
NOTE!


transmitter in relation
to a pipe elbow
NOTE!
Alternative A is the most A B C
suitable.
If possible, avoid using
alternative B and C.
3.3.1 ACT-2500 Dimensions and Mounting

recommended
clearances
Min 200 59
8.0" 2.4"
6.3"
155
5.3"
131
131
160 48 5.3"
6.5" 1.9"
Transmitter weight: 5.5 kg [12.1 lb]
Min. pipe diameter: 100 mm [4"]

3.4 Process Site Selection for Blade Transmitters

This chapter gives guidelines on how to select the best process site to place
the blade transmitter.
The transmitter can be installed in a vertical, horizontal, or sloping process
line. If the transmitter is installed in a horizontal or sloping process pipe, it must
be mounted on the side of the pipe. Any other form of mounting must be
avoided due to the risk of air bubbles that disturb measurement. See Fig 15.
Fig 15 Mounting alternatives

for a blade transmitter
3.4.1 MBT-2500 Dimensions and Mounting
Fig 16 Dimensions and A

Min 200
recommended
8"
clearances
B
5.2"
131 131
160 43
5.2"
6.3" 1.7"

Sensing Characteristic Dimension A Dimension B Consistency Min. Pipe

Element Diameter
200 mm
7.92"
L 43 mm [1.7"] 200 mm [8"] 1.5% - 5% 125 mm [5"]
35º
1.2"
30
LM 43 mm [1.7"] 200 mm [8"] 1.5% - 5% 100 mm [4"]
200 mm
7.92"
150 mm
5.9"
S 43 mm [1.7"] 150 mm [6"] 3% - 8% 100 mm [4"]
35º
1.2"
30
SM 43 mm [1.7"] 150 mm [6"] 3% - 8% 80 mm [3"]

150 mm
5.9"
215 mm
8.52"
LC 53 mm [2.1"] 218 mm [8.6"] 1.5% - 5% 125 mm [5"]

3.4.2 SBT-2400 Dimensions and Mounting
Fig 17 Dimensions and 115 Y

recommended 4.5"
clearances 22
0.8"
3.1"
5.7"
3.8"
145
79
96
Min. 500
20.7"
X
1.9"
49
4.7"
120

Blade Characteristic Dimension X Dimension Y Consistency Min. Pipe

Diameter
A 240 mm [9.5"] 93 mm [3.7"] 1.5% - 7% 100 mm [4"]
B 220 mm [18.7"] 93 mm [3.7"] 2% - 8% 100 mm [4"]
C 61 mm [2.5"] 66 mm [2.6"] 4% - 16% 80 mm [3.2"]
D 240 mm [9.5"] 93 mm [3.7"] 1.5% - 8% 100 mm [4"]

3.4.3 Simplified Calming Length Dimensioning
NOTE!
For most cases the Simplified Calming Length Dimensioning is preferably
selected. At lower consistency cases (below 2-3%) and the velocity is fairly
high (> 1.5-2 m/s) the Detailed calculations in section 3.4.5 to section 3.4.8
may bring unreasonable long calming length distances. At more favourable
conditions the Detailed dimensioning may however bring shorter calming
length and can thus be used particularly when the actual piping installation has
space limitations.
Fig 18 Recommended 10 x D 5xD 10 x D

minimum calming
length - distance
LB LA LB
between pump/ pipe
elbow/ shut-off valve
and consistency
transmitter
5xD
LA

downstream from a pump,
bend or elbow is:
10 x D
Upstream the
LB
transmitter LB:
The diameter of the pipe
multiplied by 10.
Downstream the
transmitter LA:
The diameter of the pipe
multiplied by 5.
NOTE!


transmitter in relation
to a pipe elbow
NOTE!
suitable.
If possible, avoid using
alternative B and C.

3.4.4 Pulp Network Strength

How to interpret the fiber network strength factor:
• This is a simplified way to find one very important factor, the fiber network
strength factor. This factor is necessary for finding out if you have
turbulent or plug flow conditions in the pipe at the location of the
transmitter. Do not consider it to be exact in every possible condition but
use as a guideline for deciding the calming length upstream the
transmitter. Do not use it for other, more scientific, purposes.
• High fiber network strength factor (High strength). Low fiber network
strength factor (Low strength).
• The division between the two factors is not exact. In borderline cases
preferably use the Low strength-factor since it brings a more reliable result
(longer calming length).
• If you have a borderline case and found that the Low strength-factor
should be used but then recognize that actual space limitations makes it
impossible to find a good location of the transmitter it may be possible to
decrease the calming length somewhat. In such a case please consult
BTG.
Shear force/Fiber network strength
Network
Pulp type Process Fiber treatment strength
factor*
Softwood Kraft Unbleached High strength
Softwood Kraft Bleached High strength
Hardwood Kraft Unbleached Low strength
Hardwood Kraft Bleached Low strength
Nonwood Kraft Not specified Low strength
CTMP Mechanical Not specified High strength
TMP Mechanical CSF<200 High strength
TMP Mechanical CSF<200 Low strength
ONP Recycled Not specified Low strength
OCC Recycled Not specified Low strength
NOTE! *
The network strength factor is only a general recommendation.
If unsure contact BTG.

3.4.5 Calming Length Calculation to obtain Plug

Flow Conditions
The nomogram in fig 20 shows the recommended lengths of straight pipe at
different operating flow velocities and consistency levels when a fiber network
with high strength is in use. Multiply the calming length factor (L/D) with the
tube diameter (D) to get the minimum length for plug flow condition.
Plug flow conditions will always obtain for length longer then the calculated.
For a fiber network with low strength, the straight pipe length must be
multiplied by 1.25.
Straight pipe length formula:
LB = L/D x D x Ic x Mp
LA = 0.5 x LB
LD = LB or more
Explanation of variables:
LB = Straight pipe length upstream of the transmitter
LA = Straight pipe length downstream of the transmitter
LD = Length before transmitter in multiple bend scenario
D = Pipe diameter
V = Pulp velocity
Cs = Pulp consistency in percent
L/D = Calming length factor (from the nomogram)
Ic = Installation constant (For horizontal installation Ic = 1.5, for
vertical installation Ic = 1)
Mp = Pulp type constant
(For High strength Mp = 1, for Low strength Mp = 1.25)
Fig 20 Nomogram Calming Length Factor

3.4.6 Vertical Pipe Installation

The following installation scenario is recommended.
Calculation example for a vertical pipe:
D = 200 mm
Cs = 3.5%, Low strength
V = 2.4 m/s
The nomogram shows a calming length factor (L/D)  7.5. The Mp constant
is 1 and the Ic constant is also 1.
LB = L/D x D x Mp x Ic
LB = 7.5 x 200 x 1 x 1 = 1500 mm.
LA = 0.5 x LB
LA = 750 mm
The recommended length upstream (LB) the transmitter is 1500 mm and the
recommended length downstream (LA) the transmitter is 750 mm.
Fig 21 Transmitter
installation examples
LA
LA
Min. 1m
LB
LB
D D

3.4.7 Horizontal Pipe Installation

If there is no vertical pipe section with the correct length available, a horizontal
installation on the side is recommended.
Note that the straight section must be 50% longer than the vertical example (Ic
constant).
Calculation example of a horizontal pipe:
D = 200 mm
V = 2.4 m/s
The nomogram shows a relative length (L/D)  7.5. The Mp constant is 1
and the Ic constant is 1.5.
LB = 7.5 x 200 x 1 x 1.5 = 2250 mm.
LA = 0.5 x LB
LA = 1125 mm
The recommended length upstream of the transmitter is 2250 mm and the
recommended length downstream of the transmitter is 1125 mm.
Fig 22 Horizontal pipe LB LA

installation

3.4.8 Multiple Bend Piping Installation

If there are multiple bends upstream of the transmitter, then the LD must be
equal to LB or longer. If not, flow guides must be installed.
Two successive pipe bends can also create uncontrolled twisting flow that
cannot be straightened, even if the recommended straight sections are used.
Calculation example for pipe with multiple bends
D = 200 mm
V = 2.4 m/s
The nomogram shows a relative length (L/D)  7.5. The Mp constant is 1
and the Ic constant is 1.
LB = 7.5 x 200 x 1 x 1 = 1500 mm.
LA = 0.5 x LB
LA = 750 mm
LD = LB or more
LD = 1500 mm or more
The recommended length upstream of the transmitter is 2250 mm and the
recommended length downstream of the transmitter is 1125 mm. The
recommended LD value must be 1500 mm or more.
Fig 23 Multiple bends

scenario
LA
LB
LA
LB
LD
LD

3.4.9 Valve and Pump Influences

If a valve is mounted directly after a pump, the flow characteristics from the
pump are influenced. The axis of the butterfly valve should be parallel to the
axis of the pump for best flow results.
A control valve can cause the pulp to thicken. The thickening effect is
dependent on the type of pulp and its consistency, and varies with flow rate. If
the transmitter is installed too close to a pump or a valve, the output signal
from the transmitter will be flow dependant.
Fig 24 Valve influence

3.5 Process Site Selection for TCT and RET

Transmitters
To make an accurate and reliable measurement, it is critical to find the correct
installation point.

TCT/RET probe in
relation to a pump Install the sampling valve according
to the figure, but not closer than 0.5 m
[1.5 ft] to the transmitter to avoid
disturbance. Install the sampling
valve at the same side of the pipe and
in line with the TCT probe.
NOTE!
It is essential that the TCT/RET
probe is placed where there is
turbulent flow. The TCT/RET
probe should be placed as
close as possible to the pump
90 degrees to its axis and on Install the probe as close
the side of the pipe where the as possible to the pump.
pulp is pumped against.

TCT/RET probe near a
pipe elbow
NOTE!
suitable.
A B C
L
The minimum distance (L) the
downstream from a bend or
elbow is the largest of the
following:
• 1 m [3 ft]
• The diameter of the pipe
multiplied by 3
NOTE!
For other installation cases, see recommendations in section 3.2 on page 16

1. Do not install the probe where there is trapped air or where air may be
sucked into the process.
2. If there is risk of flocculation in the pulp suspension, install the probe where
the flow rate exceeds 1 m/s (3.3 ft/sec).
This applies particularly for long-fiber pulp suspensions.
3. Install the probe so that it is protected from direct mechanical damage.
4. Protect the probe from heavy vibration such as cavitation or unbalanced
pumps. One method is to install a rubber bellows in the line.
If the probe is installed in a horizontal pipe, always install it at the side of
the pipe rather than at the top or bottom to avoid problems caused by
trapped air or dirt. Remember the clearance requirements.
5. The unit should be mounted at a 90° angle to the pipe line.
6. The unit should be mounted on the side of the pipe line. A small angle
downwards makes it possible for the pulp to evacuate when the probe is
removed and also makes the insertion of the probe easier. See Fig 27
below.

TCT/RET probe in a
horizontal pipe

3.5.1 TCT and RET Dimensions and Mounting

recommended
clearances
Transmitter, sluice valve variant Transmitter, weld-in stud variant

Weight: Weight:
Transmitter: 3.4 kg [6.8 lb] Transmitter: 1.3 kg [2.9 lb]

Sluice valve: 4 kg [8.9 lb] Stud: 0.4 kg [0.9 lb]
80 338 Min 300 80 100 300

3.15" 13.3" 12" 3.15" 4" 12"
6.1"
155
200
8"
Min Ø100 / 4" Min Ø100 / 4"
Ø50
4.3"
108
2"
Ø46
1.8"
3.5"
90
250
10"
Sensor electronics box

Weight: 0.3 kg [0.7 lb]
52
114 23
25
1"
2" Ø4.5 4.6" 0.9"

0.2"
Ø9
0.4"
126
3.5"
5"
90
13
19 101.5 0.5"
0.7" 4"
250
10"

3.6 Process Site Selection for TCR Transmitters

installation point.

TCR probe in relation Install the sampling valve according
to a pump to the figure, but not closer than 0.5 m
[1.5 ft] to the probe to avoid
disturbance. Install the sampling
valve at the same side of the pipe and
in line with the probe.
NOTE!
IThe best position for the unit is
90 degrees to the pump axis
and on the side of the pipe
where the pulp is pumped
against.
Install the probe as close as
possible to the pump.

TCR probe near a pipe
elbow
NOTE!
suitable.
L
following:
• 1 m [3 ft]
multiplied by 3
NOTE!
For other installation cases, see recommendations in section 3.2 on page 16

1. Do not install the probe where there is trapped air or where air may be
2. Install the probe where the flow rate exceeds 1.3 m/s (4.3 ft/sec).
3. Install the probe so that it is protected from direct mechanical damage.
4. Protect the probe from heavy vibration such as cavitation or unbalanced
pumps. One method is to install a rubber bellows in the line.
If the probe is installed in a horizontal pipe, always install it at the side of
the pipe rather than at the top or bottom to avoid problems caused by
trapped air or dirt. Remember the clearance requirements.
5. The unit should be mounted at a 90° angle to the pipe line.
6. The unit should be mounted on the side of the pipe line. A small angle
downwards makes it possible for the pulp to evacuate when the probe is
removed and also makes the insertion of the probe easier. See Fig 31
below.

TCR probe in a
horizontal pipe

3.6.1 TCR Dimensions and Mounting

recommended
clearances
Transmitter, sluice valve variant Transmitter, weld-in stud variant

Weight Transmitter: 3.1 kg [6.8 lb] Weight Transmitter: 1.0 kg [2.2 lb]
Weight Sluice valve: 4 kg [8.9 lb] Weight: Stud: 0.4 kg [0.9 lb]
(1) (2) (1) (2)

22 / 9 338 / 351 Min 300
0.9" / 0.4" 13.3" / 13.8" 12"
(1) (2) (1) (2)
23 / 10 154 / 167 300
6.1" 0.9" / 0.4" 6.1" / 6.6" 12"
155
200
8"
Min Ø100
4"
Min Ø80 / 3.2"
Ø50
2"
4.3"
108
Ø46
1.8"
3.5"
90
250
10"
1) 1)
Normal TCR Normal TCR
Installations Installations
2) 2)
TCR pulper TCR pulper
installations installations

52
114 23
25
1"
Weight: 0.3 kg [0.7 lb] 2" Ø4.5 4.6" 0.9"

0.2"
Ø9
0.4"
126
3.5"
5"
90
13
19 101.5 0.5"
0.7" 4"
250
10"

3.7 Process Site Selection for TCS Transmitters

installation point.
Fig 33 Installation of the TCS

probe in relation to a
Install the sampling valve
pump according to the figure, but not
closer than 0.5 m [1.5 ft] to the
transmitter to avoid disturbance.
Install the sampling valve at the
NOTE! same side of the pipe and in line
with the TCS probe.
The best position for the
transmitter is 90 degrees to the
pump axis and on the side of Install the probe where the
the pipe where the pulp is flow rate exceeds 1.3 m/s
[4.3 ft/s].
pumped against.
In case of unscreen pulp

do not install the probe
next to the pump.

probe near a pipe
elbow
NOTE!
suitable.
L
following:
• 1 m [3 ft]
multiplied by 3

If the probe is installed in a horizontal pipe, always install it at the side of the
pipe rather than at the top or bottom to avoid problems caused by trapped air
or dirt. Remember the clearance requirements.

probe in a horizontal
pipe
The transmitter will function at its best if you take note of the following general
installation rules.
• Do not install the probe where there is trapped air or where air may be
• If there is risk of flocculation in the pulp suspension, install the probe
where the flow rate exceeds 1.3 m/s (4.3 ft/s).
This applies particularly for long-fiber pulp suspensions.
• Protect the transmitter from heavy vibration such as cavitating or
unbalanced pumps. One method is to install a rubber bellows in the line.
• Choose a location with sufficient room for insertion and removal of the
transmitter. See section 3.7.1: TCS Dimensions and Mounting for
dimensions and clearance recommendations.

3.7.1 TCS Dimensions and Mounting

recommended
clearances
Transmitter, Normal pulp Transmitter, Unscreened pulp

Weight:
Transmitter: 0.6kg [1.3 lb]

Sluice valve: 0.25 kg [0.6 lb]
20 4
(0,8") (0,2")
126 142
min 80 (5") min 80 (5,6")
450 450
(3") (17,7") (3") (17,7")

Weight: 0.3 kg [0.7 lb]
52
114 23
25
1"
2" Ø4.5 4.6" 0.9"
0.2"
Ø9
0.4"
126
3.5"
5"
90
13
19 101.5 0.5"
0.7" 4"
250
10"

3.8 Sampling Valve

The sampling valve should be installed close to the transmitter. This helps to
ensure that the laboratory sample is representative of the sample measured by
the transmitter.
Installing an appropriate BTG sampling valve, will ensure reliable results.
Avoid using a ball sampling valve.
Install the sampling valve up or downstream of the transmitter, but not closer
than 0.5 m (1.5 ft) to the transmitter to avoid disturbance. If possible, install the
sampling valve at the same side of the pipe as the transmitter.
It is highly recommended to install appropriate flushing valves and flushing
water for all sampling valves.
3.8.1 MPS, and PPS

Dimensions and Mounting
Fig 37 Dimensions and Min Ø80 (3.1")

recommended FRP min Ø100(3.9")
clearances
33 370 Min 200
(1.3") (14.6") (8")
(1.9")
Ø48
MPS-1000
(6.6")
167
(7.4")
187
Cleaning water Ø38

ISO-Rp 1/4" (1.5")
395 Min 200

(15.6") (8")
PPS-1000
125
(5")

Read the safety instructions carefully before installation. The sampling valve
DANGER works more efficient if the following rules are taken into consideration.
High pressure • The pipe diameter must not be less than 80 mm (3.15 inch).
in the equipment
When using an FRP-stud the pipe diameter should be at least 100 mm
(4 inch).
• Don’t install the sampling valve where it can be exposed to mechanical
DANGER! damage or heavy vibrations.
When installed in lines with • Install the sampling valve in a vertical pipe with upward flow.
more than 3 bar [44 psi], the
outlet must be provided with a
pipe of at least 0.5 m [1.6 ft.] to
avoid splashing.
Fig 38 Typical installation of ØD

MPS-1000 min. 200
8”
1 Sampling outlet
2 Cleaning water
L
connection, 1
ISO–Rp 1/4 2
3 Sampling vessel
4 Drain
3
L = Min. 1 m [3.3 ft.] or
4
(3x D)
• If the sampling valve must be installed in a horizontal or sloping pipe

position it according to fig 39.
Fig 39 Installation after

bends L
Horizontal bend
L
Horizontal line after
vertical bend
NOTE!
Do not install the sampling valve in a downward slope flow due to the risk for
air bounds in the pipe.
• Find a place close to the surface of a floor for easy handling of sampling
procedure.
• Choose a site close to the transmitter and where the pulp is well mixed.
The distance between the sampling valve and pump flange (L) must be at
least 1000 mm (40 inch) or 3 times the pipe diameter.
• Make sure drain and water for flushing is available.
• Always flush the valve clean after sampling is finished.

3.8.2 MCS
Dimensions and Mounting
Fig 40 Dimensions
Push button air valve
MCS-1000
53 66
MCS-1010 2.1" 2.6"
Ø7
[0.28"]
4.8"
123
ISO-G 1/8
Su
pp 6/4
or 52
t
FLOW
27.5"
~700
2.0"
445
17.5"
~422
16.6"
~84 ISO-G 3/8 ISO-G 1/8
3.3"
MCS-1000
3.8"
96
5.9"
150
25 - 40
1 - 1.6" Ø 6 [0.24"]
Min. Ø100 ~70 ISO-R 2

4" 2.75"
Su
pp
or
88,5 ISO-G3/8 t
3.48"
3.94"
100
3.78"
MCS-1010
96
FLOW
3.92"
99,5
Ø 6 [0.24"]
Min. Ø150
[5.9"] 74,5 ISO-R2
2.93"
427
16.8"
Sampling valve weight:

• MCS 1000 = 7 kg [17.0 lb]
• MCS 1010 = 7.7 kg [17.6 lb]

DANGER NOTE!
Use protective
Always use safety glasses and gloves during work with caustic and hot media.
clothing and
goggles The pulp sampling valve works more efficient if the following rules are taken
into consideration.
• For MCS-1000 the pipe diameter must not be less than 100 mm (4 inch).
DANGER When using an FRP-stud the pipe diameter should be at least 150 mm (6
inch).
High pressure
in the equipment • For MCS-1010 the pipe diameter must not be less than 150 mm (6 inch).
• Do not install the sampling valve where it can be exposed to mechanical
damage or heavy vibrations.
DANGER! • For safety reason, install a support according to fig 42 on page 48.
At high pressures (more than 5
• Choose primary to install the sampling valve in a vertical pipe with upward
bar [73 psi]), the control for
flow. It is also possible to install the sampling valve in a horizontal or
operating the sampling valve
should be mounted at least 3 m sloping pipe.
[10 ft.] away from the sampling
valve due to hazardous NOTE!
splashing. Do not install the sampling valve in a downward slope flow due to the risk
for air bounds in the pipe.
When installed in lines with
more than 3 bar [44 psi], the • Choose a place close to the surface of a floor for easy handling of
outlet must be provided with a
sampling procedure.
pipe of at least 0.5 m [1.6 ft.] to
avoid splashing. • Choose a site where the pulp is well mixed. The distance between the
sampling valve and pump flange must be at least 1000 mm (40") or 3
for safety reasons, a PN25 ball times the pipe diameter.
valve must be installed on the • Make sure water for flushing is available and a non return valve (clack
sampling outlet. valve) is installed in order to keep the sampling valve clean for adequate
function.
• On the sampling outlet a tube of maximum 5 m (16 ft.) and a PN25 ball
valve must be installed for safety reason.

Fig 41 Typical installation of Medium Consistency Sampler

MCS-1000
MCS-1000
1 sampling valve control 1 m [3.2 ft]
2 Sampling outlet
min. 0.5 m [1.6 ft]

R
A
3 Sampling vessel
max. 5 m [16 ft]

P
B
S
4 Connection top drain 5
5 PN25 ball valve for
safety stop
min. 3m [10 ft]
6 Cleaning water
connection,
ISO-G 3/8
1 2 3 4
Fig 42 Support installation
NOTE!
For safety reason the
supporting brace must be Su
pp
installed according to the figure. or
t
Su
pp
or
t

BTG Instruments AB
P.O. Box 602
SE-661 29 Säffle
Sweden
Phone: +46 533 426 00
www.btg.com

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User Manual

Engineering Guide Consistency

BTG Instruments AB, 2018

3 Process Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

© BTG 2018 Engineering Guide Consistency M2070/3en I

II Engineering Guide Consistency M2070/3en © BTG 2018

© BTG 2018 Safety Instructions - SI2070en Rev. A 1

1.3 Safety Regulations

1.3.2 Safety Regulations for Service

2 Safety Instructions - SI2070en Rev. A © BTG 2018

© BTG 2018 Safety Instructions - SI2070en Rev. A 3

4 Safety Instructions - SI2070en Rev. A © BTG 2018

This guide is an introduction in how to prepare installation of BTGs products for

2.1 Process Site Selection for Transmitters

© BTG 2018 Installation Planning - IP2070en Rev. A 5

2.2 Dilution Water Supply

6 Installation Planning - IP2070en Rev. A © BTG 2018

Fig 1 Dilution Water Supply

© BTG 2018 Installation Planning - IP2070en Rev. A 7

8 Installation Planning - IP2070en Rev. A © BTG 2018

3 Process Site Selection

© BTG 2018 Process Site Selection PS2070en Rev. A 9

3.1 Process Site Selection for MEK-3000

transmitter should be located LU LU LU LU

transmitter, Ld: Flo

For all consistencies, the

10 Process Site Selection PS2070en Rev. A © BTG 2018

Fig 2 Installation of the

© BTG 2018 Process Site Selection PS2070en Rev. A 11

3.1.1 MEK-3000 Dimensions and Mounting

Fig 3 Dimensions and

Dimensions Ø180 mm Ø270 mm

A 302 mm [12.0"] 283 mm [11.1"]

B 89 mm [3.5"] 111 mm [4.4"]

ØD 180 mm [7.1"] 270 mm [10.6"]

Transmitter 15 kg [33 lb] 19 kg [42 lb]

12 Process Site Selection PS2070en Rev. A © BTG 2018

3.1.2 Weld-in Saddle

Saddle can only be used on Ø180 mm flange and in consistency range of

Fig 4 Weld-in saddle

© BTG 2018 Process Site Selection PS2070en Rev. A 13

3.1.3 Measuring Chamber with Weld-in Stud

> 4% 45 mm [1.8"] 70 mm [1.8"]

3.1.4 Measuring Vessel

Fig 6 Measuring Vessels B

14 Process Site Selection PS2070en Rev. A © BTG 2018

3.1.5 Sensing Elements

Sensing Consistency range Default range values

© BTG 2018 Process Site Selection PS2070en Rev. A 15

3.2 Process Site Selection for MEK-2500

For all consistencies, the

16 Process Site Selection PS2070en Rev. A © BTG 2018

Fig 8 Installation of the

Fig 9 Dimensions and min. 125

342 122 Ø270

© BTG 2018 Process Site Selection PS2070en Rev. A 17

3.2.2 Measuring Vessel

Fig 10 Measuring Vessels B

3.2.3 Measuring Chamber with Weld-in Stud

18 Process Site Selection PS2070en Rev. A © BTG 2018

3.2.4 Sensing Elements and Propellers

Consistency range Default range values Feedback in water

Sludge 1.5-2% 10-15%