State-of-the-art signal processing and innovative modularity offers customers incomparable performance, accuracy, flexibility and the most maintenance-free solution amongst all flow technologies.

ETL/CE Certfied

As thousands of customers have come to know, the UltraFlow 100 & 150 offer outstanding benefits over other technologies, including:

• Non-intrusive probe design mitigates corrosion, erosion and agglomeration of the transducers…leading to years of uninterruptible operation and reliability
• Flow measurement is intrinsically independent of flue gas composition, pressure, temperature, viscosity, etc…thereby eliminating continual corrections to flow equations
• Long-path average measurement methodology…leading to far superior accuracies versus single point systems like pitot tubes and thermal flow systems
• Ultra-low drift operation <1.0%…eliminating the hassles of continual calibration
• Full system calibration checks…ensures total system integrity
• Measurement technique intrinsically rejects cyclonic flow…no high bias as with pitot tubes
• Advanced signal processing and affordable x-pattern configuration rejects pitch effects…eliminating errors of other ultrasonic technologies

Building on the successful performance of the UltraFlow 100 in over 1300 installations, Teledyne Monitor Labs has substantially improved and updated the design of our new UltraFlow 150. Our objective in our redesign was to further improve system accuracy, reliability and availability, while simplifying maintenance and user ability. Some of the UltraFlow 150’s new features and benefits include:

• New lower mounting angles (>=15º) can improve ability of the monitor to reject flow pitch effects

• 5ft. vertical offsets between transducers eliminates the need for a 2nd platform

• Can be installed on existing 45º angles with ease

• Six-fold increase in resolution provides even greater accuracy (2-5% not unusual)

• Programmable response time for process control applications

• Modularity supports direct interface models (Model 150DI & 150XDI) as well as "X"-patterns

• One Transducer Interface Enclosure (TIE, stack electronics) can handle an “X”-pattern (two sets of transducers)

• One Enhanced Remote Panel can handle two Transducer Interface Enclosures ( or two “X”-Patterns or four identical equivalent stacks/ducts) to reduce capital cost

• Digital signal conditioning and processing eliminates any drift problems

• All programming capable through the Enhanced Remote Panel or Transducer Interface Enclosure

• Windows application program to support programming, archiving, diagnostics, etc. to make life easier

• Operator capability to program curve coefficients through the panel or RS232 port

• Polynomial or three-point look-up table for the correlation curve

• Three point look-up table for the temperature R-factor for improved temperature calculation

• Support for a stack-mounted barometric pressure transducer and RTD inputs

• Local User Display available in the Transducer Interface Enclosure

• Signal/Noise diagnostic check to predict transducer fouling or failure

• Quick disconnects/connects on transducer assemblies for easy extraction and insertion

• Ability to view pre-and-post curve corrected velocity or flow data

• Purge system and weather hood are optional in many cases

• Single pair of wire to communicate between the stack and remote panel

Principle of Operation:

The UltraFlow 150 is a non-contacting gas flow and temperature monitor. The system measures the transit times of tone bursts through the gas stream to determine both flow and temperature. Transducer assemblies are usually mounted opposite each other at a 15-45º angle to the flow on each side of the stack or duct with one transducer upstream from the other. In unusual locations, a dual set of transducer assemblies (four) can be installed at a much-reduced angle of offset. This “X”-Pattern provides an average flow measurement directly up the stack and has the added benefit of multiple certifications of both transducers assembly sets. This ensures nearly 100% uptime. The system accurately measures the time required for the tone bursts to traverse
the gas stream in each direction. The flow velocity is directly related to the difference in propagation time, t1 and t2 of the tone bursts with and against the gas flow. Based on the cross-sectional area of the stack or duct, the flow velocity is converted to volumetric flow. This flow measurement is independent of the temperature, density, viscosity and particulate or condensate concentration.

Differential pressure or thermal flow methods place one or more sensing elements inside the stack in direct contact with flue gas. These devices are then subject to erosion, corrosion, plugging or fouling. Verification of the total system integrity and performance under these conditions must include visual inspection of the pitot tube openings or hot wire sensing element under Method 2 testing. 

Competing ultrasonic technologies lack the integral design of the UltraFlow 150 and therefore have not performed in many applications as expected. Low signal power and transducer problems in non-purged systems have verified that certain designs lack the accurate and reliable results of the UltraFlow 150.

The following is a short comparison between Pilot Tubes and Ultrasonics:

With the UltraFlow 150’s new quad-probe handling capability, improved resolution and faster response time, the monitor is ideally suited for both small and large stacks and less than ideal locations. The quad probe design rejects all pitch angle flow while signal processing improvements enable provide quicker response time and better accuracy.  In certain applications where stack pressure is negative, the purge system may be eliminated with an offset of more preventive maintenance.

The UltraFlow 150 has been designed as a modular unit. The Enhanced Remote Panel is optional and the Transducer Interface Enclosure (TIE) can interface directly with a PLC, datalogger or DAS. Each TIE can support an x-pattern (or two stacks with the same cross-section and full-scale flow). The Enhanced Remote Panel can also support up to four independent stacks through two TIE units, or two “X”-Patterns (TIE 1, Path A&B, TIE 2, Path A&B). The purge system and weather hood is also optional at times.

Components:

Transducer Interface Enclosure (TIE)

Electrical signals corresponding to acoustic transmit and receive signals are conveyed via cables between the transducers and the TIE. The TIE houses pre-amp driver boards that amplify receive signals and transmit pulses. A signal processing board containing a Field Programmable Gate Array controls timing, data collection, filtering, boxcar integration and other functions. A microprocessor board evaluates the box car data and determines time-of-flight, flow velocity, volume, speed of sound, temperature and signal-to-noise ratio. All these data values may be viewed via the Enhanced Remote Panel or the optional Local User Interface (LUI)

Purge Air System

The transducer assemblies are continuously purged by a purge blower. One blower is provided for each set of transducers. The purge system consists of a blower, hoses, air filter, mounting plate, and protective weather cover. The platform mounted purge system blows cool, clean air past the transducers and prevents condensation and material buildup. Though the purge system may be optional in certain applications, additional maintenance will be required

Transducer Assemblies

Each of the two transducers acts both as transmitters and receivers. The purge nozzles are constructed of acid-resistant Teflon with stainless steel or Hastelloy hardware for easy cleaning and a long service life. The transducer assemblies are lightweight aluminum stock and can be easily extracted from its mounting port by disengaging four draw latches.

 

Enhanced Remote Panel (ERP)

The ERP uses a large, back-lit, LCD graphics display with English-language menu-driven screens, providing ready access to all information needed for full use of the system. The keypad is a rugged 20-button ensemble inlaid under a tough, hard-coated, scratch and chemical resistant Lexan coating, that can be used to:

• Display measured parameters

• Configure the analog outputs, digital inputs and contact relays

• Set calibration values and time parameters

• View event logs of alarms and faults

• Edit all software parameters

• Load linearization curves for correlation to Method 2

• Graph various measured values for predictive maintenance

• Diagnostic viewing with numerical and alphanumerical explanations

Standard with the Enhanced Remote Panel is a security keylock for protection of important calibration parameters. System elements communicate over a single twisted pair (FFT) using Lonworks communication protocol. Bright LED indicator lights are used to indicate faults and alarms as well as diagnostics.

Local User Interface

A ten-key Lexan keypad is available in the Transducer Interface Enclosure for use in diagnostics, control, servicing, initiation of calibration, and display of measured values. Three banks of menus are available through the keypad which greatly simplifies maintenance on the monitor.

Upgradeability

The former Model 100 can be easily upgraded to a UltraFlow 150. The upgrade consists of using the existing transducers, transducer assemblies, purge system and weather hood, the stainless steel stack electronic assembly box and cabling and wiring. The internal electronics are swapped out of the existing stack electronics assembly box with the new 150 electronics. Transducers can remain in their existing 45° orientation if desired, or can be lowered to a shallower angle. 
Call or email for details.

How to Begin?

In the event you decide the UltraFlow 150 is your choice of flow monitoring technology, Teledyne Monitor Labs engineering will work with your team to make the installation and operation of the monitor as simple as possible. To begin the process, engineering needs for your team to fill out the Model 150 Installation Guide and fax it back to: (724) 444-5050 or electronically fill out the Model 150 Installation Checklist and submit it by clicking the “Submit” button at the bottom of the form. We thank you for your business.
 

» UltraFlow 150 Installation Drawings & Specifications

» UltraFlow 150 Installation Guide

» UltraFlow 150 Installation Checklist

» UltraFlow 150 Wiring Diagrams » Download brochure