Flow Sensor Installation into Cast Iron Pipe

Models 225/226 Hot Tap Sensors

THE SYSTEM

NOTES

Municipal water companies and other industries have used cast iron
pipe for years. It has proven economical to use and exhibits some
good qualities for this type service.

1. The assembled coupling, nipple, and valve must project from

the inside pipe wall a minimum of 8-1/2" and a maximum of
111/2" to allow a correct sensor insertion depth of 1-1/2".

THE PROBLEM

2. Badger Meter does not warrant piping, fittings, and valves not
purchased from Badger Meter, Inc.

Cast iron pipe does present some problems when installing service
taps or instrumentation such as pressure sensors or flow probes. In
larger pipe sizes service saddles become expensive and difficult to
install. The use of a welded fitting would provide a simple solution
if ductile steel pipe were being used, but cast iron does not weld
easily and the welding operation can affect the pipes structural
integrity within the heat zone of the weld.

THE SOLUTION
For the above reasons, it has become common practice to drill a
hole in the pipe wall and tap with a standard AWWA tapered thread.
A corporation stop capable of accepting the instrument or other
pipe fittings is then threaded directly into the pipe wall.

3. The users and installers of this assembly are entirely responsible

for the correct drilling, tapping, assembly and protection of
those components. We recommend review of AWWA standards
C600 for valve and fitting installation, C800 for threading details,
and C151 for pipe wall thickness.
As required by these standards the assembly should be
protected by enclosing in a valve box or otherwise restrained
to prevent stress on all parts of the assembly, especially on the
threads tapped in the cast iron pipe. Care must be taken in
tapping depth so that full thread engagement results without
excessive stress on the threads. Pipe wall thickness should be
chosen to provide effective thread engagement of 4 threads
if possible and 3 threads as a minimum. (See AWWA C151,
tableA.2.)

The attached drawing shows a method of installing the

BadgerMeter Hot Tap Sensor, using a Ford Meter Box Co. 2" full
port #FB1600 Ball Corp. This Ball Corp. has a 2" AWWA tapered (CC
or CS) threaded inlet and 2" NPT outlet, allowing it to thread directly
into the pipe wall, while accepting standard 2" NPT fittings.

4. A total of 50" from the outside of the pipe should be provided as

clearance for use of the hot tap installation tool if the pipe is to
remain pressurized during installation or removal.

Equipment Required:

Advantages

Badger Meter PN#813145-1211 Model 225B Hot Tap Sensor w/o

valve and nipple.

1. Simple installation procedure.

Badger Meter, Inc. Model HTT Hot Tap Installation Tool.

(One tool can be used for installing or removing any number of
sensors under pressure.)

Standard 2" NPT bronze coupling (2.2" face-to-face).

3" long schedule 80 red brass nipple.

Ford Meter Box Co. #FB1600-7 Ball Corp. valve.

Inlet 2" AWWA taper external thread.
Outlet 2" NPT internal thread.

2. Universal components allow a minimum inventory to handle all

pipe size requirements.
3. Economically priced.
4. Sensor can be installed and removed without system
interruption.
17-1/2" max
3" LONG x 2" NPT
NIPPLE SCH. 80
STANDARD 2" NPT
BRONZE COUPLING

2" FB 1600 FORD

BALL CORP.

Ford Meter Box Company

P.O. Box 443
Wabash, IN 46992-0443
www.fordmeterbox.com
DIC PN#813145-1211
225B SENSOR & HEX ADAPTER

8-1/2" min. 11-1/2" max

ISOLATION VALVE ASSY.
1-1/2" INSERTION DEPTH
16-3/8" SENSOR LENGTH
NOTE: ALL DIMENSIONS ARE FOR REFERENCE ONLY.
CUTTING TOOL MAY BE REQUIRED FOR ADDITIONAL CLEARANCE

IND-AS-01223-EN-02 (December 2014)

Application Data Sheet

Flow Sensor Installation into Cast Iron Pipe, Models 225/226 Hot Tap Sensors

Control. Manage. Optimize.

DATA INDUSTRIAL is a registered trademark of Badger Meter, Inc. Other trademarks appearing in this document are the property of their respective entities. Due to continuous
research, product improvements and enhancements, Badger Meter reserves the right to change product or system specifications without notice, except to the extent an
outstanding contractual obligation exists. 2014 Badger Meter, Inc. All rights reserved.

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