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Flow Metering InsertsInstallation and Operation Guide

#60-3233-056 of Assy #60-3234-064Template FilesCopyright © 1990. All rights reserved, Teledyne Isco, Inc.Revision G, March 10, 2011

http://www.isco.com

Foreword

This instruction manual is designed to help you gain a thorough understanding of theoperation of the equipment. Teledyne Isco recommends that you read this manualcompletely before placing the equipment in service.

Although Teledyne Isco designs reliability into all equipment, there is always the possi-bility of a malfunction. This manual may help in diagnosing and repairing the malfunc-tion.

If the problem persists, call or e-mail the Teledyne Isco Technical Service Departmentfor assistance. Simple difficulties can often be diagnosed over the phone.

If it is necessary to return the equipment to the factory for service, please follow theshipping instructions provided by the Customer Service Department, including theuse of the Return Authorization Number specified. Be sure to include a notedescribing the malfunction. This will aid in the prompt repair and return of theequipment.

Teledyne Isco welcomes suggestions that would improve the information presented inthis manual or enhance the operation of the equipment itself.

Teledyne Isco is continually improving its products and reserves the right tochange product specifications, replacement parts, schematics, and instruc-tions without notice.

Contact Information

Customer Service

Phone: (800) 228-4373 (USA, Canada, Mexico)

(402) 464-0231 (Outside North America)

Fax: (402) 465-3022

Email: [email protected]

Technical Support

Phone: (800) 775-2965 (Analytical)

(866) 298-6174 (Samplers and Flow Meters)


Return equipment to: 4700 Superior Street, Lincoln, NE 68504-1398

Other Correspondence

Mail to: P.O. Box 82531, Lincoln, NE 68501-2531


Web site: www.isco.com

Revised March 17, 2009

http://www.isco.com

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Flow Metering Inserts

Table of Contents

Section 1 Introduction

1.1 Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 Description of the Flow Metering Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2.1 Metering Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2.2 Multi-Section Pole Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2.3 Assembly and Flow Meter Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.2.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.4 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4.1 Entering the Manhole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31.4.2 Protection Against Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Section 2 Operating Procedures

2.1 Selecting the Metering Insert Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1.1 Size of Metering Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1.2 Selection of Flow Control Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1.3 Overlap in Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1.4 Construction of the Flow Metering Insert . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22.1.5 The 60° V-Notch Weir Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2 Calibration of the Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42.2.1 Setting the Bubble Rate (Model 4230 only) . . . . . . . . . . . . . . . . . . . . . . . . . 2-42.2.2 Setting the Zero Level Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52.2.3 Programming the Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.3 Field Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52.3.1 Multi-Section Pole Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52.3.2 Assembling the Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52.3.3 Assembling the Right-Angle Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62.3.4 Attaching the Flow Metering Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.3.5 Attaching the Insert to the Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.3.6 Attaching the Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.4 Insertion Into the Manhole and Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82.4.1 Checking the Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82.4.2 Installation in the Manhole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82.4.3 Installation in the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102.4.4 Inflating the Rubber Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112.4.5 Monitor the Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122.4.6 Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.5 Measuring the Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132.5.1 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.6 Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132.6.1 Deflating the Rubber Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132.6.2 Inspection of Metering Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132.6.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132.6.4 Field Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Flow Metering InsertsTable of Contents

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Section 3 Maintenance and Repairs

3.1 Cleaning and Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.1 Inspecting and Cleaning the Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2.1 Replacing the Rubber Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Appendix A General Safety Considerations

A.1 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1A.2 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1A.3 Adverse Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2A.4 Entering Manholes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2A.5 Traffic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3A.6 Falling Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3A.7 Removing the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3A.8 Other Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3A.9 Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3A.10 Field Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4A.11 Lethal Atmospheres in Sewers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Appendix B Replacement Parts List

B.1 Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

List of Figures2-1 Flow Metering Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22-2 Metering Insert Round Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32-3 Back of 60° V-Notch Weir Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32-4 Weir Plate, Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42-5 Right-Angle Tube, Assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62-6 Insert Attached to Right-Angle Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72-7 Lowering the Insert Into the Manhole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92-8 Insert Lowered to Bottom of Manhole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92-9 Insert Installed in Sewer Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102-10 Metering Insert With Collar Inflated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113-1 Removing the Metering Insert’s Rubber Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

List of Tables1-1 Technical Specifications for Flow Metering Inserts . . . . . . . . . . . . . . . . . . . . . . . . 1-5A-1 Hazardous Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

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Section 1 Introduction

This section of the Flow Metering Inserts instruction manualprovides a general introduction to the inserts. It consists of abrief discussion of the organization of the manual, an overalldescription of the inserts, safety precautions, and a table of tech-nical specifications.

1.1 Manual Organization The purpose of this manual is to provide the user with the infor-mation necessary to assemble, operate, maintain, and repair theFlow Metering Inserts. To do this, the manual is organized intothree sections. The first section is a general introduction to theFlow Metering Inserts. The second section is concerned withassembly and operating procedures for field use of the inserts.The third section includes information on routine maintenance,repair procedures, and replacement parts.

1.2 Description of the Flow Metering Inserts

Teledyne Isco Flow Metering Inserts are designed to allow therecording of accurate flow rate readings from a round sewer pipe.The inserts are installed from street level, generally withouthaving to enter the manhole. They may be used in 6", 8", 10", and12" diameter sewers in manholes as deep as 16 feet. The insertsmay be used with a Teledyne Isco Model 4230 Flow Meter, or aModel 730 Bubbler Module, and can measure flow rates rangingfrom one to 640 gallons per minute with 5% accuracy. See thespecific product manual for more information.

1.2.1 Metering Insert The Flow Metering Insert consists of the metal insert, inflatablerubber collar, a multi-section pole assembly, and a foot-poweredair pump. The metering insert is a calibrated flow control sectionthat generates an upstream head, or pressure, related to a par-ticular flow rate in the pipe. Metering inserts are available foruse in four different sizes of pipe: 6", 8", 10", and 12". Eachmetering insert has a built-in round orifice flow control sectionthat is 60% of the diameter of the pipe. For lower flow rates, anattachable 60° V-notch weir plate flow control section is also sup-plied with each metering insert. The flow rate ranges for thevarious sizes of metering inserts with both flow control sectionsare listed in Table 1-1. The metering insert is sealed in place inthe pipe by an inflatable rubber collar. A bubbler tube is perma-nently attached to the metering insert assembly, allowing theupstream pressure to be measured by the flow meter or module.

1.2.2 Multi-Section Pole Assembly

The multi-section pole assembly allows the metering insert to beinstalled in the sewer pipe from street level. The pole’s 21/2-footsections quickly snap together, allowing the unit to be conve-niently used in a range of manhole depths to 16 feet. Also sup-

Flow Metering InsertsSection 1 Introduction

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plied is a right angle tube assembly used to attach the insert tothe pole assembly. A foot-powered air pump is used to inflate therubber collar, sealing the metering insert in place. A pressuregauge is attached to the pump to allow the pressure in the collarto be monitored during installation.

1.2.3 Assembly and Flow Meter Preparation

The Flow Metering Inserts and multi-section pole are designed tobe easily assembled and disassembled in the field without usingtools. The multi-section pole, right angle tube assembly, andmetering inserts quickly snap together, which aids in instal-lation, transportation, and storage.

The bubble line from the insert is attached to the flow meter orbubbler module. Then the bubble rate is set and the flow meter’slevel is set to zero. (See Section 2.2)

Refer to the manual appropriate for the flow meter you are using,i.e. Model 4230, or the Model 730 Bubbler Module, if you areusing a 6700 series sampler.

1.2.4 Installation For installation, the various pieces of the insert are snappedtogether with enough sections of the pole to reach the bottom ofthe manhole. Next, with the operator at ground level, theassembly is lowered into the manhole, and the metering insertmaneuvered into the entrance pipe (upstream side) of themanhole.

The metering insert is then sealed into the sewer pipe byinflating its rubber collar using the foot-powered pump andpressure gauge. The bubble line from the insert is attached to theflow meter or module, which is suspended from a rung or othermeans inside the manhole. The flow meter can then begin torecord flow through the insert.

The insert channels all flow in the sewer through the flow controlsection (either the round orifice or the V-notch weir). For removalof the Flow Metering Insert from the manhole, first release theair pressure from the inflated rubber collar. Do this by pressingthe valve stem in the insert’s air supply hose, and then pullingthe unit out of the pipe and lifting it from the manhole. It maythen be quickly disassembled for storage or transportation to thenext site.

1.3 Unpacking The Flow Metering Insert is shipped in two separate containers.The following items will be found in these containers. The flatbox contains the upper riser pole, the lower riser pole, and thetubing sleeve which make up the right angle tube, thefoot-powered air pump, and the six 21/2 - foot pole sections. Therectangular box contains the metering insert with theinflation/bubbler hose assembly, the instruction manual, and theaccessory package. The insert is shipped with the hoses attachedand coated with sealant to prevent leakage. Do not disconnectthem unless you are replacing the hose assembly.


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1.4 Safety Precautions There are certain safety considerations that should be clearlyunderstood before attempting to use the Teledyne Isco FlowMetering Inserts. Please read and pay special attention to thefollowing advisory notes.

DANGERHAZARD OF ELECTROCUTION! Contacting electric power lines with any part of the Flow Metering Insert and pole assembly will cause severe injury or death. Keep the pole away from any overhead wires.

The inserts are nearly 18 feet long with the maximum number of pole sections attached. This is enough to reach most power lines.

Before installing or removing these inserts, look overhead for interference. Make sure the pole assembly cannot possibly come close to any overhead utilities as it is lowered into or removed from a manhole.

If there are overhead utility wires anywhere near the installation, either:1. Do not attempt to use the insert, or2. Lower the insert, attached to the right-angle tube assembly, into the manhole. Then, attach pole sections one at a time as needed while the insert is being lowered into the manhole.

Reverse the process when removing an insert from service: disconnect each pole section one at a time as the insert is being lifted out of the manhole.

1.4.1 Entering the Manhole In some instances, it may not be possible to install the insertfrom street level due to the methods of construction used in themanhole or the presence of debris. In such cases, it may becomenecessary to enter the manhole.


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DANGERDo not enter the manhole without observing proper safety precautions. Do not enter the manhole if you are working alone. Poisonous gases present in most sewers can KILL you quickly without warning. See Appendix A.

1.4.2 Protection Against Electric Shock

The pole sections are connected together by plastic insulatingsleeves, which are intended to reduce the hazard of electricshock, should an accident occur. However, the insulating value ofthe plastic will be seriously reduced if the handle becomes wet orif the weather is damp or very humid. Use good judgment. Donot depend on the plastic to protect you if you shouldtouch a wire. Do not try to stand the pole assemblyupright without first looking overhead for wires.

In many manholes, the sewer has been opened by simplybreaking off the top half of the pipe with a sledge hammer afterthe manhole has been built over it. In such cases the openingsmay be very rough, or debris may accumulate around them, pre-venting installation of the flow insert from street level.

CAUTIONThe Flow Metering Inserts cause a restriction in the flowstream. While they may be used in some instances for anextended period of time, they should be used with caution inany flow streams that have suspended solids or high greasecontent. They may cause clogging and may require mainte-nance. Check such installations frequently. The inserts arenot recommended for permanent installation under anycircumstances. The inser ts must be installed on theupstream (inlet side) of the sewer. They cannot be used onthe downstream (outlet side) of the sewer pipe.

Where permanent monitoring of the pipe is required, theuse of flow metering inserts will almost certainly cause cloggingsooner or later, unless the flow stream contains neither solids norgrease. Instead, use a bubble line outlet attached to a TeledyneIsco mounting ring, either a Spring Ring, or for pipes larger than15 inches in diameter, a Scissors Ring. Refer to the Model 4230Flow Meter Instruction Manual or contact Teledyne Isco for addi-tional information on these rings.

The inserts are made of anodized aluminum and the inflatablecollar from tough butyl rubber; both are resistant to chemicalattack. However, avoid flow streams that contain any chemicalagents capable of attacking either the aluminum, (strongalkalies), or the inflated rubber collar, (certain organic solvents).


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Whenever an insert is removed from service, check to see that itdoes not have any debris trapped in the orifice. If debris is foundobstructing the orifice, clean the insert and re-run the test. Evenpartial clogging will cause the flow rate to be inaccurate.

1.5 Technical Specifications

The following table contains technical specifications for theTeledyne Isco Flow Metering Inserts.

Table 1-1 Technical Specifications for Flow Metering Inserts

Equipment Provided Six 21/2-foot pole sections, 17° riser pole, 12-inch tubing sleeve, 73° riser pole, one flow metering insert with detachable weir plate, and a foot-powered air pump. Each insert is provided with a 20-foot bubble line (clear) and a 20-foot air line (black rub-ber) used to inflate the rubber collar. Hoses are connected lengthwise.

Maximum Depth of Manhole 16 feet

Typical Accuracy of the Inserts(for pipe slopes of 21/2% or less)

± 1 GPM up to 20 GPM

± 2 GPM for 20 to 40 GPM

± 5% of reading above 40 GPM

Calibrated Ranges Gallons per Minute Gallons per Day (Max.)

6" Flow Metering InsertV-Notch WeirRound Orifice

1 to 905 to 180

129,600259,200


1 to 16010 to 320

230,400460,800


1 to 23020 to 480

331,200691,200


1 to 32040 to 640

460,800921,600


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2-1


Section 2 Operating Procedures

The following sections contain procedures for the field use of theinserts. Included are sections covering selection of the properinsert, field assembly of the unit, lowering the unit into themanhole and pipe, measuring the flow rate, and removal and dis-assembly.

2.1 Selecting the Metering Insert Configuration

The first step in using the Flow Metering Insert is to decidewhich insert is best suited for the site. This means choosing aninsert to match the diameter of the sewer pipe where the mea-surement will be made, and then deciding whether the roundorifice or V-notch flow control section will be used.

2.1.1 Size of Metering Inserts As discussed in Section 1, the Flow Metering Inserts aredesigned to be used in 6", 8", 10", and 12" inside diameter sewerpipes. The actual outside diameter of each metering insert isapproximately 90% of the pipe diameter, to allow for an under-sized pipe or for a pipe that is out of round. Normally, a 6"metering insert is selected to be used in a 6" ID pipe, and so on.However, in some cases, as described in Section 2.4.6, it may benecessary to use the next smaller size; for example, an 8" insertin 10" pipe.

2.1.2 Selection of Flow Control Sections

Once the size of the metering insert to be used has been selected,the round orifice or V-notch flow control sections must beselected. This decision is normally made on the basis of theamount of flow present in the pipe. As shown in the flow rateranges for the various size metering inserts in Table 1-1, theround orifice flow control section is used with higher flow rates,while the V-notch section is used with lower flow rates. Ingeneral, if the sewer is flowing more than 1/4 to 1/3 full, flowshould be measured using the round orifice flow control section.If the sewer is flowing less than this, the V-notch flow controlsection should be used.

2.1.3 Overlap in Ranges As shown in Table 1-1, there is an overlap in the calibrated rangeof flow rates for the round orifice and V-notch weir flow controlsections for a given size metering insert. For example, the roundorifice of a 6" metering insert has a calibrated range of 5 to 180GPM, while the V-notch insert has a range of 1 to 90 GPM. Thus,for a 6" insert, the two flow control sections have an overlappingrange of 5 to 90 GPM. In general, when the flow rate in the seweris likely to be in the overlapping range and accuracy is the mainconsideration, it is preferable to use the V-notch weir flow controlsection to measure the flow rate.

Flow Metering InsertsSection 2 Operating Procedures

2-2

The V-notch flow control section is generally more accurate thanthe round orifice in this overlapping range, and is less affected byincreased pipe slopes. However, this is simply a recommendationto maximize accuracy; the round orifice flow control section willfunction throughout its calibrated range to the accuracy stated inTable 1-1. If the installation will be left unattended for anyperiod of time, the round orifice should be used to reduce thechances of clogging.

2.1.4 Construction of the Flow Metering Insert

A metering insert is shown in Figure 2-1. The metering insert ismade of anodized aluminum for corrosion resistance. The inserthas three integral ribs which form two circular channels. Aninflatable rubber collar is installed in the front channel. Thepurpose of the collar is to seal the metering insert in the pipe,when inflated, and force all the pipe’s flow through the flowcontrol section of the insert. The rear channel in the meteringinsert is provided to aid in properly aligning the insert in thepipe by providing a longer section.

An aluminum bubbler tube is permanently attached to the insideof the metering insert. The bubbler tube, which ends at thebottom center of the upstream face of the insert, is part of thesystem that allows the Flow Metering Insert to measure thepressure or head upstream from the insert. The metering inserthas a handle section which is used to attach it to the right angletube and the pole assembly, and also has two tubes. One tubeconnects the insert’s rubber collar to the foot-powered air pump,allowing the collar to be inflated. The other tube is a bubble lineconnected to the flow meter or module.

Figure 2-1 Flow Metering Insert

60°V-Notch

Weir Plate

Bubbler TubeOpening

Rubber Collar

Handle

Hose Assembly


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2.1.5 The 60° V-Notch Weir Plate

As shown in Figure 2-1, the metering insert is shipped from thefactory with the removable V-notch flow control section installed.When the V-notch weir plate is removed, as shown in Figure 2-2,the round orifice flow control section that is an integral part ofthe metering insert may be seen. The diameter of the opening isapproximately 60% of the pipe diameter. To remove the V-notchweir plate, loosen the two captive wing nuts on the back side ofthe weir plate (inside the metering insert). Then, pull the weirplate up and out of the metering insert. Note that the removableweir plate has a hole near the bottom that slips over themetering insert’s bubbler tube, and two small studs on its rearside that hold the V-notch orifice in the insert. The hole andstuds properly align the weir plate on the insert.

Figure 2-2 Metering Insert Round Orifice

Figure 2-3 Back of 60° V-Notch Weir Plate

Retaining Plate

Studs


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To attach the V-notch weir plate to the metering insert, com-pletely loosen the two wing nuts. Then, line up the hole in thebottom of the V-notch weir plate above the bubbler tube on thefront of the metering insert and below the bottom of the orifice.Reach through the insert, and grasp the retaining plate on theback of the weir plate.

At the same time, slip the retaining plate over the back of theround orifice plate in the metering insert, and slide the weirplate down along the face of the orifice towards the bubbler tube.Then, slip the hole in the weir plate over the insert’s bubblertube, being sure that the studs on the back of the weir plate fallinside the orifice opening. Finally, holding the weir plate in place,tighten the two wing nuts, locking the V-notch weir plate in placeby pressing the retaining plate down on the orifice plate of theinsert.

Figure 2-4 Weir Plate, Installed

2.2 Calibration of the Flow Meter

It may be necessary to calibrate the flow meter used with theinsert before the insert is installed. The reason is that neitherthe bubble rate nor the zero level can readily be set, viewed, oradjusted accurately once the insert is installed in a sewer. TheModel 730 Bubbler Module is non-adjustable, as it has a built-infixed orifice.

2.2.1 Setting the Bubble Rate (Model 4230 only)

Refer to the appropriate flow meter manual for bubble rateadjustment information. Set the insert upright in a large pan ofwater deep enough to cover the bubble line outlet on the insert bya couple of inches. Adjust the bubble rate for one to two bubblesper second. As stated previously, there is no adjustment for theModel 730 Bubbler Module.


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2.2.2 Setting the Zero Level Offset

Like the bubble rate, the flow meter zero level must be set beforethe insert is installed, because there will already be some levelinside the sewer. After the bubble rate is set as described previ-ously, remove the insert from the container of water. Using thePURGE button on the flow meter, blow out any water whichmight be inside the bubble line. Be sure all water is removed.This is important, as any water remaining inside the bubble linewill affect the accuracy of the zero setting. If necessary, shake theflow metering insert vigorously to remove all traces of water. Donot attempt to set the zero point before setting the bubble rate;the bubble rate affects the zero level and must be set first. Whenthe line is dry and the insert is sitting in open air, adjust the levelreading on the flow meter’s display to zero; this can be done bygoing to the ADJUST LEVEL step in the flow meter’s programand using the number or the arrow keys on the flow meter’skeypad. If necessary, refer to the flow meter’s manual.

2.2.3 Programming the Flow Meter

Programming differs between the flow meter and the Model 730Bubbler Module. Refer to the appropriate manual for the flowmeter/module you are using for information on programming forthe flow metering inserts.

2.3 Field Assembly After the metering insert and flow control section have beenselected, the next step is to assemble the various pieces, whichare disassembled for convenience of storage and transportation.This consists of putting together the multi-section pole and theright-angle tube; attaching the metering insert to the right-angletube and attaching the air pump to the multi-section poleassembly.

2.3.1 Multi-Section Pole Assembly

The main structure of the Flow Metering Insert for reachingdown into the manhole is the multi-section pole assembly. Thepole assembly consists of six 21/2-foot regular pole sections. Oneor more of the regular pole sections may be connected together toform a pole assembly ranging in length from 21/2 feet (one regularsection) to 15 feet (six regular sections). The regular sectionsconsist of a 11/8" diameter anodized aluminum pole, with a blackplastic union permanently attached to the top end and astainless steel snap button near the bottom end. The regular sec-tions have an actual overall length of 321/4" and an effectivelength of 291/2". The pole assembly is multi-sectioned to allow itto be broken down into small sections for storage and transportand to allow its length to be easily adjusted to match themanhole depth.

2.3.2 Assembling the Pole The first step in putting together the Flow Metering Inserts is toassemble the multi-section pole to the correct length for thedepth of the manhole. The pole should be assembled with a totallength somewhat greater than the distance from the top of themanhole to the bottom of the invert.

The sections of the pole assembly are attached to each other bystainless steel snaps that pop into mating holes in the matchingsection, similar to some vacuum cleaner attachments. To join two


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sections, press in on the snap, slide the smaller diameter sectioninto the larger section such that the snap is aligned with themating hole, and push the smaller section in until the snap popsinto the hole, securing it in place. The sections are disassembledby pressing in on the snap and pulling the sections apart. Addpole sections this way until the necessary overall pole length isreached.

2.3.3 Assembling the Right-Angle Tube

The right-angle tube (Figure 2-5) is made up of three separatepieces which must be put together. One piece (the lower riserpole) contains a sharp bend of 73°; this is the bottom section ofthe right-angle tube. The end closest to the bend will be snappedto the flow insert. The short, straight sleeve connects the 73°section to the other section with a bend. Push the two angledpieces into the sleeve until they lock. The other angled section(17°, the upper riser pole) should be inserted so that the endclosest to the angle is farthest from the sleeve.

Figure 2-5 Right-Angle Tube, Assembled


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2.3.4 Attaching the Flow Metering Insert

After the pole has been assembled, the next step is to attach themetering insert to the pole assembly using the right angle tube.Normally, the right angle tube is then attached to the bottom ofthe pole assembly in the position shown in Figure 2-5. To achievethe placement shown in the illustration, the 17° angle end of thetube should be attached to the pole assembly.

This places the front face of the metering insert approximately21/2 feet from the center line of the pole; this has been found to bethe preferred alignment for many manhole situations. However,the tube is designed so that it is reversible, and may be turned inthe opposite direction. This alignment may be helpful in certainunusual or difficult manhole configurations. When the tube isreversed, the distance from the front face of the insert to thecenter line of the pole is approximately 41/3 feet.

2.3.5 Attaching the Insert to the Tube

After the right angle tube has been attached to the poleassembly, the metering insert should be attached to the end ofthe right angle tube, with the body of the insert hanging down, asshown in Figure 2-6.

Figure 2-6 Insert Attached to Right-Angle Tube

2.3.6 Attaching the Hose Assembly

The inflation/bubbler hose assembly is already attached to themetering insert. The 7/16" OD black butyl rubber inflation hoseconnects to the foot-powered air pump and the 1/4" OD clearplastic bubbler hose connects to the bubble line fitting on theflow meter. This hose assembly is 20 feet long. Secure the hoseassembly to the foot-powered air pump by attaching the valvestem on the inflation hose to the chuck on the air pump. Inshallow manholes, there will be extra footage of hose. Any excesshose may be coiled near the top of the pole. It should not beallowed to dangle loosely in the flow stream or hang lower thanthe top of the insert.


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2.4 Insertion Into the Manhole and Pipe

After the various pieces of the Flow Metering Insert have beenassembled in the field, the next step is to lower it into themanhole and secure it in the upstream sewer pipe. As a generalrule, the Flow Metering Inserts may be used in manholes up to16 feet deep. At this depth, with all six regular pole sectionsbeing used, the sixth section will be slightly above ground level.The Flow Metering Inserts may also be used in shallow man-holes.

DANGERHAZARD of ELECTROCUTION! Contacting overhead electric power lines will cause severe injury or death. Keep the pole away from any overhead lines.You can be killed instantly if this product comes in contact with overhead power lines. Look up and check overhead for the presence of any utility wires before raising the pole assembly upright. If there is any chance of touching a wire, stop!

Take the pole assembly apart. Snap on one section and lower theinsert into the manhole. Then add extra pole sections, one at atime, until the bottom of the manhole is reached. When removingthe insert, lift the pole just enough to snap off the top polesection; then remove the other sections one at a time until theinsert can be lifted from the manhole.

2.4.1 Checking the Length Before putting the insert into the manhole, the overall length ofthe unit should be checked to be sure that it is about right for thedepth of the manhole. In general, it is recommended that the topof the pole assembly be about waist- to chest-high, when themetering insert is installed in the sewer. If the length is notcorrect, add or remove pole sections as necessary.

2.4.2 Installation in the Manhole

After the length of the pole assembly has been checked, the flowinsert should be lowered into the manhole, as shown in Figure2-7, with the user at street level. Note that it may be necessary totilt the unit to get the metering insert and right angle tubethrough the manhole opening, as shown.


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Figure 2-7 Lowering the Insert Into the Manhole

Figure 2-8 Insert Lowered to Bottom of Manhole


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2.4.3 Installation in the Pipe Lower the unit down toward the invert of the pipe in the bottomof the manhole until the metering insert is resting in the pipe. Ifthe length of the multi-section pole assembly is not correct, theunit should be pulled out of the manhole at this time, and thelength adjusted as necessary. The metering insert should befacing into the flow coming out of the entrance (upstream) pipeof the manhole, as shown. Then, slide the metering insert intothe entrance pipe, as shown in Figure 2-9.

The metering insert should be completely slid into the pipe sothat the back end of the insert is totally surrounded by a fullsection of the pipe; this is to provide maximum natural centeringof the insert in the pipe. Depending on conditions in the manholeand pipe (for example, a high flow, an oval or undersized pipe,etc.), sliding the metering insert into the pipe may be difficult. Insuch cases, rock the insert from side-to-side or top-to-bottom,while also pushing the insert into the pipe.

Figure 2-9 Insert Installed in Sewer Pipe

Upstream face of metering insert per-pendicular to oncom-ing flow

Back end of insert totally surrounded by a full section of the pipe


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2.4.4 Inflating the Rubber Collar

Secure the metering insert in place by inflating its rubber collar.The foot-powered air pump is used to inflate the insert’s rubbercollar.

Figure 2-10 Metering Insert With Collar Inflated

The pressure in the collar can be monitored on the pressuregauge attached to the pump. The smaller inserts (6" and 8")should be inflated to a pressure of 15 to 20 psi while the largerinserts (10" and 12") should be inflated to a pressure of 10 to 15psi. This should secure the metering insert in place in the pipeand seal it, channeling all the flow through the flow controlsection. If the flow inserts are to be installed for an extendedperiod of time, the collars should be inflated to pressuresapproaching the higher end of the ranges given (15 and 20 psi.)

NoteWhen inflating the rubber collar, make sure the pole is cen-tered over the pipe or invert at the bottom of the manhole asclose to straight up-and-down as possible. This will help theflow metering insert line up correctly inside the pipe, which isnecessary for the readings to be accurate and to ensure agood seal.Install the insert as carefully as possible because you cannotreadily check or view the vertical alignment after installation.The center line of the V-notch weir or round opening should bestraight up-and-down and the upstream face of the meteringinsert should be perpendicular to the oncoming flow.


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2.4.5 Monitor the Pressure If the flow insert will be left in the sewer for an extended periodof time, the pressure in the collar should be checked periodicallyto make sure it is not leaking. Deflation will cause the insert toleak and become dislodged in the flow stream. If the pressurefalls slowly, the connectors or the valve stem may be leaking. Ifthis is not the case, check the tubes and the connections betweenthe tubes and flow insert. If the insert has been used before andthe pressure drop is fairly rapid, remove the insert and inspectthe collar for punctures. It is a good idea to check the pressure inthe collar again later in the same day or the next day. Thereafter,it is usually sufficient to check the pressure only when thebattery on the flow meter is changed.

If the air pump has been disconnected from the hoses, there willbe a slight loss of pressure each time the pump is re-connected tothe air hose; this is normal as long as it does not exceed a poundor so. Eventually, the collar may have to be reinflated.

2.4.6 Problems Although the outside diameters of the metering inserts areapproximately 90% of the pipe inside diameters, there may becases where the insert may not be successfully lowered into thepipe invert or slid into the entrance pipe. Typically, theseproblems are encountered with inverts where the top half of thepipe was not completely removed or the entrance is partiallyblocked by solid debris. There may be extra concrete left fromconstruction extending out over the entrance pipe. If these condi-tions are found, the best solution is to enter the manhole (fol-lowing proper safety procedures) and take necessary measures toopen up the pipe invert or remove the entrance pipe blockage.

DANGERDo not enter the manhole without observing proper safety precautions. Do not enter the manhole if you are working alone. Toxic fumes present in the sewer may kill you. Read Appendix A Safety Considerations. Also, you should be familiar with and observe OSHA regulations governing work in confined spaces.

Another possible solution, recommended only for spot-checkflows, is to use the next size smaller metering insert. Sometimesthe insert may be inflated enough to seal under these conditions.However, this will reduce the maximum flow which may be mea-sured and may weaken or damage the insert’s collar. If the nextsmaller size insert is used, inflate the collar with the lowestpressure necessary to seal the metering insert in place. Pres-sures less than 10 psi would be recommended to avoid possiblybursting the collar. Extra care should be given to the proper posi-tioning of the metering insert to minimize loss of accuracy in theflow readings.


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2.5 Measuring the Flow Rate

After the metering insert has been installed in the entrance pipeof the manhole, the next step is to actually measure the flow ratein the pipe.

2.5.1 Accuracy The accuracy of the flow rate measurement for the FlowMetering Inserts is as specified in Table 1-1. Note that thesespecifications apply only to the inserts and characterize pipeswith slopes of 21/2 % and less. If the pipe in which the flow isbeing measured has a slope greater than this, a correction to thereading obtained should be applied to get the most accurate flowrate measurement. The accuracy specification for the Model 4230Flow Meter will be found in the flow meter’s manual.

2.6 Removal and Disassembly

After the desired flow rate readings in the pipe have beenobtained, the Flow Metering Insert may be removed from thepipe and manhole, and disassembled for transportation. The firststep in this process is to disconnect the bubble line from the flowmeter.

2.6.1 Deflating the Rubber Collar

Depress the valve stem inside the threaded metal fitting on theend of the inflation hose. This will release the pressure from theinflatable rubber collar around the metering insert, freeing theinsert from the pipe. The metering insert may then be pulled outof the pipe into the invert in the manhole and the entire unitpulled up and out of the manhole.

DANGERHAZARD of ELECTROCUTION! Contacting electric power lines will cause severe injury or death. Keep the pole away from power lines.

Release the insert from the sewer and lift the pole slowly fromthe manhole. Disconnect the pole sections one at a time as thepole is drawn out of the manhole. This will reduce the possibilityof touching any overhead utility wires.

2.6.2 Inspection of Metering Insert

As the unit is being removed from the manhole, it is goodpractice to inspect the metering insert for the presence of any sig-nificant obstructions or debris which may have caught and stuckon it. If there are any, the accuracy of the flow readings would bedoubtful and should be rechecked.

2.6.3 Disassembly After the insert has been removed from the manhole, it may bedisassembled for transportation and storage. Typically, thisinvolves removing the metering insert and the right-angle tube,then disassembling the pole assembly and right-angle tube.


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2.6.4 Field Cleaning It may be desirable to wash the metering insert and right angletube immediately after use. A container of water may be used toaccomplish this by simply pouring a quantity of water over themetering insert and right angle tube. Some users have foundthat metering inserts may be conveniently transported from siteto site enclosed in a large plastic bag.

CAUTIONBefore any equipment is installed, the proper safety precau-tions must be taken. The discussions of safety procedures inAppendix A are only general guidelines. Each situation inwhich you install a flow metering insert varies. You must takeinto account the individual characteristics of your installation.Additional safety considerations, other than those discussed inthis manual, may be required.

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Section 3 Maintenance and Repairs

The following section describes basic care of the Flow MeteringInserts. Included are cleaning and routine maintenance proce-dures to keep the unit in top operating condition, and somegeneral repair procedures. Also included is a table of replacementparts.

3.1 Cleaning and Routine Maintenance

The metering insert and right angle tube (the parts of the FlowMetering Insert actually in the flow stream) should probably bewashed after each use. At a minimum, the entire lower section ofthe Flow Metering Insert should be thoroughly cleaned at theend of each use. This may be done best by using a hose andbrush. The V-notch weir plates should be removed from any ofthe metering inserts that were used, the inserts and weir plateswashed and dried, and then reassembled.

3.1.1 Inspecting and Cleaning the Hose Assembly

Periodically, the inflation/bubbler hose assembly should beinspected for cuts or the presence of contamination or moisture.The bubble line may be cleaned by forcing water through it, fol-lowed by pressurized air to dry it. Be sure to dry it completelyafter such a procedure. Water left in the bubble line will causethe flow meter readings to be inaccurate. A replacement hoseassembly is available; see Appendix B Replacement Parts List forthe Isco part number.

3.2 Repair Procedures The only normal repair procedure for the Flow Metering Inserts(besides replacing damaged metal components, hoses, and con-nectors) concerns the replacement of the insert’s inflatablerubber collar. The collar is made of heavy gauge, tough butylrubber, and is generally designed to withstand the rough envi-ronment of a sewer. However, over-inflation or sharp edges insidethe manhole or around the outfall may puncture the collar.

3.2.1 Replacing the Rubber Collar

Replacement inflatable collars and clamps are available fromTeledyne Isco. Refer to Appendix B Replacement Parts List forthe appropriate part numbers. The collars are listed as FlowMeter Seals in the Replacement Parts List.

The collar may be replaced as follows: First, remove the weirplate from the front of the metering insert to provide freer accessto the inside of the insert. Then, loosen the swivel-nut from themetal stem (a pair of pliers may be necessary).

Next, peel the collar off the insert, starting opposite the stem. Toinstall the new collar, first feed the stem through the hole in theinsert, with the stem facing the end with the handle. Then, rollthe collar onto the metering insert. Next, secure the swivel-nut to

Flow Metering InsertsSection 3 Maintenance and Repairs

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the stem. Apply a coating of pipe sealant to the second and thirdthreads on the stem and hand-tighten. Finally, test for airleakage between the stem and the inflation hose by filling thecollar with several pounds of air pressure. This may be doneeither by holding the inflated collar under water and looking forbubbles around the stem joint, or brushing a soapy watersolution on the joint and looking for bubbles.

Figure 3-1 Removing the Metering Insert’s Rubber Collar

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Appendix A General Safety Considerations

The following procedures are those used by Black & Veatch, arespected consulting firm, and are published here by their kindpermission:

“Field personnel must keep safety uppermost in their minds atall times. When working above ground, rules of common senseand safety prevail. However, when entering manholes, strictsafety procedures must be observed. Failure to do so could jeop-ardize not only your own life, but also the lives of other crewmembers.

A.1 Hazards There are many hazards connected with entering manholes.Some of the most common hazards are:

1. Adverse AtmosphereThe manhole may contain flammable or poisonous gases or the atmosphere may be deficient in oxygen. Forced ventila-tion may be necessary.

2. Deteriorated RungsManhole steps may be corroded and not strong enough to support a man. It may be difficult to inspect the rungs because of poor lighting.

3. TrafficWhenever manholes are located in the traveled way, barri-cades and warning devices are essential to direct traffic away from an open manhole.

4. Falling ObjectItems placed near the manhole opening may fall and injure a worker in the manhole.

5. Sharp EdgesSharp edges of items in or near a manhole may cause cuts and bruises.

6. Lifting InjuriesUnless proper tools are used to remove manhole covers, back injuries or injuries to hands and feet may result.

A.2 Planning Advance planning should include arrangements for testequipment, tools, ventilating equipment, protective clothing,traffic warning devices, ladders, safety harness, and adequatenumber of personnel. Hasty actions may result in seriousinjuries. Time spent in the manhole should be kept to aminimum.

Flow Metering InsertsAppendix A General Safety Considerations

A-2

A.3 Adverse Atmospheres Refer to Table A-1. Before entering a manhole, tests should bemade for explosive atmosphere, presence of hydrogen sulfide,and oxygen deficiency. Since combustible or toxic vapors may beheavier than air, the tests on the atmosphere must be run atleast 3/4of the way down the manhole.

Whenever adverse atmosphere is encountered, forced ventilationmust be used to create safe conditions. After the ventilatingequipment has been operated for a few minutes, the atmospherein the manhole should be retested before anyone enters themanhole.

When explosive conditions are encountered, the ventilatingblower should be placed upwind to prevent igniting any gas thatis emerging from the opening. When a gasoline engine blower isused, it must be located so that exhaust fumes cannot enter themanhole.

If testing equipment is not available, the manhole should beassumed to contain an unsafe atmosphere and forced ventilationmust be provided. It should never be assumed that a manhole issafe just because there is no odor or the manhole has beenentered previously.

A.4 Entering Manholes Since the top of the manhole is usually flush with the sur-rounding surface, there may not be anything for the person whois entering the manhole to grab on to steady himself.

Persons who are entering manholes should not be permitted tocarry anything in their hands as they enter the manhole, toensure that their hands are free to hold on or grab if they slip. Agood method for entering a manhole is to sit on the surface facingthe manhole steps or ladder, with the feet in the hole and thearms straddling the opening for support. As the body slidesforward and downward, the feet can engage a rung, and the backcan rest against the opposite side of the opening. If there is anydoubt about the soundness of the manhole steps, a portableladder should be used.

A person should never enter a manhole unless he is wearing per-sonal safety equipment, including a safety harness and hard hat.Two persons should be stationed at the surface continuouslywhile anyone is working inside a manhole, to lift him out if he isovercome or injured. One man cannot lift an unconscious manout of a manhole. The persons stationed at the surface shouldalso function as guards to keep people and vehicles away fromthe manhole opening. To avoid a serious injury, a person shouldnot be lifted out of a manhole by his arm unless it is a dire emer-gency.

When more than one person must enter a manhole, the firstperson should reach the bottom and step off the ladder before thesecond one starts down. When two men climb at the same time,the upper one can cause the lower one to fall by slipping orstepping on his fingers.


A-3

A.5 Traffic Protection In addition to traffic cones, markers, warning signs, and barri-cades, a vehicle or heavy piece of equipment should be placebetween the working area and oncoming traffic. Flashingwarning signals should be used to alert drivers and pedestrians.Orange safety vests should be worn by personnel stationed at thesurface when the manhole is located in a vehicular traffic area.

A.6 Falling Objects All loose items should be kept away from the manhole opening.This applies to hand tools as well as stones, gravel and otherobjects.

A.7 Removing the Covers Manhole covers should be removed with a properly designedhook. Use of a pick axe, screwdriver, or small pry bar may resultin injury. A suitable tool can be made from 3/4inch round or hexstock. Two inches of one end should be bent at a right angle andthe other end should be formed into a D-handle wide enough toaccommodate both hands. Even with this tool, care must be exer-cised to prevent the cover from being dropped on the toes. Thetwo inch projection should be inserted into one of the holes of thecover, the handle grasped with both hands, and the cover liftedby straightening the legs, which have been slightly bent at theknees.

A.8 Other Precautions Other precautions which should be taken when entering amanhole are:

• Wear a hard hat.

• Wear coveralls or removable outer garment which can readily be removed when the work is completed.

• Wear boots or non-sparking safety shoes.

• Wear rubberized or waterproof gloves.

• Wear a safety harness with a stout rope attached.

• Do not smoke.

• Avoid touching yourself above the collar until you have cleaned your hands.

A.9 Emergencies Every member of the crew should be instructed on procedures tobe followed in cases of an emergency. It is the duty of each crewchief to have a list of emergency phone numbers, including thenearest hospital and ambulance service, police precinct, firestation, and rescue or general emergency number.


A-4

A.10 Field Equipment The following equipment must be available for use:

A.11 Lethal Atmospheres in Sewers

The following is an article written by Dr. Richard D. Pomeroy,and published in the October 1980 issue of Deeds & Data of theWPCF. Dr. Pomeroy is particularly well known for his studies,over a period of nearly 50 years, in the field of the control ofhydrogen sulfide and other odors in sewers and treatment plants.He has personally worked in a great many functioning sewers. Inthe earlier years he did so, he admits, with little knowledge of thegrave hazards to which he exposed himself.

“It is gratifying that the subject of hazards to people working insewers is receiving much more attention than in past years, andgood safety procedures are prescribed in various publications onthis subject. It is essential that people know and use correct pro-cedures.

It is less important to know just what the hazardous componentsof sewer atmospheres are, as safety precautions should ingeneral be broadly applicable, but there should be a reasonableunderstanding of this subject. It is disturbing to see statementsin print that do not reflect true conditions.

One of the most common errors is the assumption that peoplehave died from a lack of oxygen. The human body is able tofunction very well with substantially reduced oxygen concentra-tions. No one worries about going to Santa Fe, New Mexico, (elev.2100 m), where the partial pressure of oxygen is equal to 16.2percent (a normal atmosphere is about 21 percent) oxygen. Whenfirst going there, a person may experience a little ‘shortness ofbreath’ following exercise. People in good health are not afraid todrive over the high passes in the Rocky Mountains. At LovelandPass, oxygen pressure is 13.2 percent of a normal atmosphere. Atthe top of Mt. Whitney, oxygen is equal to 12.2 percent. Manyhikers go there, and to higher peaks as well.

After adequate acclimation, they may climb to the top of Mt.Everest, where oxygen is equal to only 6.7 percent.

Blowers Gloves

Breathing Apparatus Hard Hats

Coveralls Harnesses

First Aid Kits Manhole Irons

Emergency Flashers Pick Axes

Flashlights Rain Slickers

Mirrors Ropes

Gas Detectors Safety Vests

Gas Masks Traffic Cones

Waders


A-5

The lowest oxygen concentrations that I have observed in a seweratmosphere was 13 percent. It was in a sealed chamber, near sealevel, upstream from an inverted siphon on a metropolitan trunk.A man would be foolish to enter the chamber. Without venti-lation, he might die, but not from lack of oxygen.

It seems unlikely that anyone has ever died in a sewer from suf-focation, that is, lack of oxygen. Deaths have often beenattributed to ‘asphyxiation.’ This is a word which, according tothe dictionary, is used to mean death from an atmosphere thatdoes not support life. The word has sometimes been misinter-preted as meaning suffocation, which is only one kind of asphyxi-ation.

In nearly all cases of death in sewers, the real killer is hydrogensulfide. It is important that this fact be recognized. Many citiesdiligently test for explosive gases, which is very important, andthey may measure the oxygen concentration, which usually isunimportant, but they rarely measure H2S. Death has occurredwhere it is unlikely that there was any measurable reduction inthe oxygen concentration. Wastewater containing 2 mg/l of dis-solved sulfide, and at a pH of 7.0, can produce in a chamber withhigh turbulence, a concentration of 300 ppm H2S, in the air. Thisis considered to be a lethal concentration. Many people have diedfrom H2S, not only in sewers and industries, but also fromswamps and from hot springs. In one resort area, at least fivepersons died from H2S poisoning before the people were ready toadmit that H2S is not a therapeutic agent. Hardly a year passesin the U.S. without a sewer fatality from H2S as well as deathselsewhere in the world.

The presence of H2S in a sewer atmosphere is easily determined.A bellows-and-ampoule type of tester is very satisfactory for thepurpose, even though it is only crudely quantitative. When usinga tester of this type, do not bring the air to the ampoule by way ofa tube, as this may change the H2S concentration. Hang theampoule in the air to be tested, with a suction tube to the bulb orbellows.

Lead acetate paper is very useful as a qualitative indicator. Itcannot be used to estimate the amount of sulfide, but it willquickly turn black in an atmosphere containing only a tenth of alethal concentration.

Electrodes or other similar electrical indicating devices for H2Sin the air have been marketed. Some of them are known to beunreliable, and we know of none that have proved dependable.Do not use one unless you check it at frequent intervals againstair containing known H2S concentrations. A supposed safetydevice that is unreliable is worse than none at all.

Remember that the nose fails, too, when it comes to sensing dan-gerous concentrations of H2S.

Various other toxic gases have been mentioned in some publica-tions. It is unlikely that any person has been asphyxiated in asewer by any of those other gases, except possibly chlorine.


A-6

The vapor of gasoline and other hydrocarbons is sometimespresent in amounts that could cause discomfort and illness, butunder that condition, the explosion hazard would be far moreserious. The explosimeter tests, as well as the sense of smell,would warn of the danger. Pipelines in chemical plants mightcontain any number of harmful vapors. They, too, are sensed bysmell and explosimeter tests if they get into the public sewer.Such occurrences are rare.

The attempt to instill a sense of urgency about real hazards isdiluted if a man is told to give attention to a long list of thingsthat in fact are irrelevant.

Be very careful to avoid high H2S concentrations, flammableatmospheres, and hazards of physical injuries. Remember thatmuch H2S may be released by the stirring up of sludge in thebottom of a structure. Obey your senses in respect to irritatinggases, such as chlorine (unconsciousness comes suddenly frombreathing too much.) Be cautious about strange odors. Do notdetermine percent oxygen in the air. There is a danger that theresult will influence a man’s thinking about the seriousness ofthe real hazards. Most important, use ample ventilation, and donot enter a potentially hazardous structure except in a goodsafety harness with two men at the top who can lift you out.”

Table A-1 Hazardous GasesGas Chemical

FormulaCommonProperties

Specific Gravity or

Vapor DensityAir = 1

PhysiologicalEffect*

MaxSafe

60 Min.Exposure

ppm

Max.Safe

8 HourExposure

ppm

Explosive Range

(% by vol.in air.)Limits

lower/upper

Likely Location

ofHighest

Concentration

MostCommonSources

Simplest andCheapest

Safe Methodof Testing

Ammonia NH3 Irritant and poison-ous. Colorless with characteristic odor.

0.60 Causes throat andeye irritation at 0.05%, coughing at 0.17%. Shortexposure at 0.5%to 1% fatal.

300to

500

85 16 25 Near top.Concentratesin closed up-per spaces

Sewers, chemi-calfeed rooms.

Detectableodor at lowconcentrations

Benzene C6H6 Irritant, colorlessanesthetic

2.77 Slight symptomsafter several hoursexposure at 0.16% to 0.32%. 2% rapidly fatal.

3,000to

5,000

25 1.3 7.1 At bottom. Industrial wastes,varnish, sol-vents.

Combustiblegas indicator

Carbon Bisulfide

CS2 Nearly odorless when pure, color-less, anesthetic.Poisonous.

2.64 Very poisonous,irritating, vomiting,convulsions, psychic disturbance.

— 15 1.3 44.0 At bottom An insecticide Combustiblegas indicator

Carbon Dioxide

CO2 Asphyxiant, Colorless, odorless. When breathed in large quantities, may cause acid taste. Non-flam-mable. Not generally present in dangerous amounts unless an oxygen deficiency exists.

1.53 Cannot be endured at 10% more than a few minutes, even if sub-ject is at rest and oxy-gen content is normal. Acts on respiratory nerves.

40,000to

60,000

5,000 — — At bottom;when heatedmay stratify at points above bottom.

Products of combustion, sewer gas, sludge. Also issues from car-bonaceous strata.

Oxygendeficiencyindicator


A-7

CarbonMonoxide

CO Chemical asphyxiant. Colorless, odorless, tasteless. Flammable.Poisonous.

0.97 Combines with hemo-globin of blood. Unconsciousness in 30 min. at 0.2% to 0.25%. Fatal in 4 hours at 0.1%. Headache in few hours at 0.02%.

400 50 12.5 74.0 Near top, espe-cially if present with illuminat-ing gas.

Manufactured gas, flue gas, products of combustion, motor exhausts. Fires of almost any kind.

CO ampoules.

CarbonTetra-Chloride

CCl4 Heavy, ethereal odor. 5.3 Intestinal upset, loss of consciousness, possi-ble renal damage, respiratory failure.

1,000to

1,500

100 — — At bottom. Industrial wastes,solvent, cleaning

Detectable odorat low concen-trations.

Chlorine Cl2 Irritant. Yellow-green color. Choking odor detectable in very low concentrations. Non-flammable.

2.49 Irritates respiratory tract. Kills most ani-mals in a very short time at 0.1%.

4 1 — — At bottom. Chlorine cylin-der and feed line leaks.

Detectable odor at low concen-trations.

Formal-dehyde

CH2O Colorless, pungent suf-focating odor.

1.07 Irritating to the nose. — 10 7.0 73.0 Near bottom. Incomplete combustion of organics. Com-mon air pollut-ant, fungicide.

Detectable odor.

Gasoline C5H12to

C9H20

Volatile solvent.Colorless. Odor notice-able at 0.03%. Flam-mable.

3.0to 4.0

Anesthetic effects when inhaled. Rapidly fatal at 2.4%. Danger-ous for short exposure at 1.1 to 2.2%.

4,000 to

7,000

1,000 1.3 6.0 At bottom. Service stations,garages, storagetanks, houses.

1. Combustible gas indicator.

2. Oxygendeficiencyindicator.**

Hydrogen H2 Simple asphyxiant. Colorless, odorless, tasteless. Flammable

0.07 Acts mechanically to deprive tissues of oxy-gen. Does not support life.

— — 4.0 74.0 At top. Manufactured gas, sludge digestion tank gas, electrolysis of water. Rarely from rock strata.

Combustible gas indicator.

HydrogenCyanide

HCN Faint odor of bitter almonds. Colorless gas

0.93 Slight symptoms appear upon exposure to 0.002% to 0.004%. 0.3% rapidly fatal.

— 10 6.0 40.0 Near top. Insecticide and rodenticide.

Detector tube

Gas Chemical Formula

CommonProperties

Specific Gravity or

Vapor DensityAir = 1

PhysiologicalEffect*

MaxSafe

60 Min.Exposure

ppm

Max.Safe

8 HourExposure

ppm

Explosive Range

(% by vol.in air.)Limits

lower/upper

Likely Location

ofHighest

Concentration

MostCommonSources

Simplest andCheapest

Safe Methodof Testing

Hydro-gen Sul-fide

H2S Irritant and poisonous volatile compound. Rotten egg odor in small concentrations. Exposure for 2 to 15 min. at 0.01% impairs sense of smell. Odor not evident at high concentrations. Color-less. Flammable.

1.19 Impairs sense of smell, rapidly as concentra-tion increases. Death in few minutes at 0.2%. Exposure to 0.07 to 0.1% rapidly causes acute poisoning. Para-lyzes respiratory cen-ter.

200to

300

20 4.3

45.0

Near bottom, but may be above bottom if air is heated and highly humid.

Coal gas, petro-leum, sewer gas.Fumes from blasting under some condi-tions.Sludge gas.

1. H2S Ampoule.

2. 5% by weight lead acetatesolution.

Methane CH4 Simple asphyxiant.Colorless, odorless, tasteless, flammable.

0.55 Acts mechanically to deprive tissues of oxy-gen. Does not support life.

Probably no limit, provided oxygen per-cent-age is suffi-cient for life.

— 5.0 15.0 At top, increas-ing to certain depth.

Natural gas, sludge gas, man-ufactured gas, sewer gas. Strata of sedimentary origin. In swamps or marshes.

1. Combustiblegas indicator

2. Oxygen defi-ciency indicator.

Nitrogen N2 Simple asphyxiant. Colorless, tasteless. Non-flammable. Prin-cipal constituent of air. (about 79%).

0.97 Physiologically inert. — — — — Near top, but may be found near bottom.

Sewer gas. sludge gas. Also issues from some rock strata.

Oxygendeficiencyindicator.

Table A-1 Hazardous Gases (Continued)


A-8

NitrogenOxides

NO

N2O

NO2

Colorless

Colorless, sweet odor.

Reddish-brown. Irritating odor.Deadly poison

1.04

1.53

1.58

60 to 150 ppm cause irritation and coughing.

Asphyxiant.

100 ppm dangerous.200 ppm fatal.

50 10 — — Near bottom. Industrial wastes.Common air pollutant.

NO2 detector tube.

Oxygen O2 Colorless, odorless, tasteless. Supports combustion.

1.11 Normal air contains 20.8% of O2. Man can tolerate down to 12%. Minimum safe 8 hour exposure, 14 to 16%. Below 10%, dangerous to life. Below 5 to 7% probably fatal.

— — — — Variable at dif-ferent levels.

Oxygen deple-tion from poor ventilation and absorption, or chemical con-sumption of oxy-gen.

Oxygen defi-ciency indicator.

Ozone O3 Irritant and poison-ous. Strong electrical odor. Strong oxidizer. Colorless. At 1 ppm, strong sulfur-like odor.

1.66 Max. naturally occur-ring level is 0.04 ppm. 0.05 ppm causes irrita-tion of eyes and nose. 1 to 10 ppm causes headache, nausea; can cause coma. Symp-toms similar to radia-tion damage.

0.08 0.04 — — Near bottom. Where ozone is used for disin-fection.

Detectable odorat 0.015 ppm.

SludgeGas

—*** Mostly a simple asphyxiant. May be practically odorless, tasteless.

Variable Will not support life. No data. Wouldvary widely with composition.

5.3 19.3 Near top of structure.

From digestion of sludge.

See compo-nents.

Sulfur Dioxide

SO2 Colorless, pungent odor. Suffocating, cor-rosive, poisonous, non-flammable.

2.26 Inflammation of the eyes. 400 to 500 ppm immediately fatal.

50 to

100

10 — — At bottom, can combine with water to form sulfurous acid.

Industrial waste, combustion, common air pol-lutant.

Detectable taste and odor at low concentration.

Toluene C5H12to

C9H20

Colorless, benzene-like odor.

3.14 At 200-500 ppm, head-ache, nausea, bad taste, lassitude.

200 100 1.27 7.0 At bottom. Solvent. Combustible gas indicator.

Turpentine C10H16 Colorless, Characteris-tic odor.

4.84 Eye irritation. Head-ache, dizziness, nau-sea, irritation of the kidneys.

— 100 At bottom. Solvent, used in paint.

1. Detectable odor at low

concentrations.2.Combustible

gas indicator.

Xylene C8H10 Colorless, flammable 3.66 Narcotic in high con-centrations. less toxic than benzene.

— 100 1.1 7.0 At bottom. Solvent Combustible gas indicator.

* Percentages shown represent volume of gas in air.** For concentration over 0.3%.***Mostly methane and carbon dioxide with small amounts of hydrogen, nitrogen, hydrogen sulfide, and oxygen; occasionally traces of carbon monoxide.

Table A-1 Hazardous Gases (Continued)

B-1


Appendix B Replacement Parts List

B.1 Replacement Parts List

A list of common replacement parts for the Flow MeteringInserts can be found on the following pages. When ordering areplacement part, be sure to include the Isco assembly or partnumber and a complete description of the Flow Metering Inserton which the part is to be used.

Replacement parts can be ordered by contacting Teledyne Isco’sCustomer Service Department.

Teledyne Isco, Inc.Customer Service DepartmentP.O. Box 82531Lincoln, NE 68501 USA

Phone: (800) 228-4373(402) 464-0231FAX:(402) 465-3022

E-mail:[email protected]

Flow Metering InsertsAppendix B Replacement Parts List

B-2


B-3

HOSE


B-4

Warranty

Before returning any instrument for repair, please call, fax, or e-mail the Teledyne Isco ServiceDepartment for instructions. Many problems can often be diagnosed and corrected over thephone, or by e-mail, without returning the instrument to the factory.Instruments needing factory repair should be packed carefully, and shipped to the attention ofthe service department. Small, non-fragile items can be sent by insured parcel post. PLEASEBE SURE TO ENCLOSE A NOTE EXPLAINING THE PROBLEM.

Shipping Address: Teledyne Isco, Inc. - Attention Repair Service4700 Superior StreetLincoln, NE 68504 USA

Mailing Address: Teledyne Isco, Inc.PO Box 82531Lincoln, NE 68501 USA

Phone: Repair service: (800) 775-2965 (lab instruments)(866) 298-6174 (samplers & flow meters)

Sales & General Information: (800) 228-4373 (USA & Canada)Fax: (402) 465-3001Email: [email protected]

March 8, 2011 P/N 60-1002-040 Rev E

Teledyne Isco One Year Limited Warranty*Factory Service for Teledyne Isco Flow Meters, Waste Water Samplers, and Syringe Pumps

This warranty exclusively covers Teledyne Iscoinstruments, providing a one-year limited warrantycovering parts and labor.Any instrument that fails during the warranty period due tofaulty parts or workmanship will be repaired at the factoryat no charge to the customer. Teledyne Isco’s exclusiveliability is limited to repair or replacement of defectiveinstruments. Teledyne Isco is not liable for consequentialdamages.Teledyne Isco will pay surface transportation charges bothways within the 48 contiguous United States if theinstrument proves to be defective within 30 days ofshipment. Throughout the remainder of the warranty period,the customer will pay to return the instrument to TeledyneIsco, and Teledyne isco will pay surface transportation toreturn the repaired instrument to the customer. TeledyneIsco will not pay air freight or customer’s packing andcrating charges. This warranty does not cover loss, damage,or defects resulting from transportation between thecustomer’s facility and the repair facility.

The warranty for any instrument is the one in effect on dateof shipment. The warranty period begins on the shippingdate, unless Teledyne Isco agrees in writing to a differentdate.Excluded from this warranty are normal wear; expendableitems such as charts, ribbon, lamps, tubing, and glassware;fittings and wetted parts of valves; and damage due tocorrosion, misuse, accident, or lack of proper maintenance.This warranty does not cover products not sold under theTeledyne Isco trademark or for which any other warranty isspecifically stated.No item may be returned for warranty service without areturn authorization number issued by Teledyne Isco.This warranty is expressly in lieu of all other warrantiesand obligations and Teledyne Isco specifically disclaimsany warranty of merchantability or fitness for aparticular purpose.The warrantor is Teledyne Isco, Inc. 4700 Superior,Lincoln, NE 68504, U.S.A.

* This warranty applies to the USA and countries where Teledyne Isco Inc. does not have an authorizeddealer. Customers in countries outside the USA, where Teledyne Isco has an authorized dealer, shouldcontact their Teledyne Isco dealer for warranty service.

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