Centrifugal Gas Separator ZGA Operating Manual - Bopp & Reuther ...

Centrifugal Gas Separator 

Operating Manual 

Bopp & Reuther Messtechnik GmbH 

Am Neuen Rheinhafen 4 

67346 Speyer - Germany 

Phone: +49 (6232) 657 - 0 

Fax: +49 (6232) 657 - 505 

www.bopp-reuther-mt.de 

info@bopp-reuther-mt.de 

Dimensions, weights and other 

technical data are subject to changes. 

Printed in the 

Federal Republic of Germany 

ZGA 

A-EN-03661-00RevC 

Latest Mod. 0909-001 

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ZGA Centrifugal Gas Separator 

Table of Contents 

1 IDENTIFICATION...................................................................................................................................... 3 

1.1 SUPPLIER/MANUFACTURER 3 

1.2 TYPE OF PRODUCT 3 

1.3 NAME OF PRODUCT 3 

1.4 DATE OF RELEASE 3 

1.5 VERSION NO. 3 

2 AREA OF APPLICATION.......................................................................................................................... 3 

3 SYSTEM DESIGN ..................................................................................................................................... 3 

4. TECHNICAL DATA................................................................................................................................... 4 

4.1 OPERATING TEMPERATURE 4 

4.2 NOMINAL PRESSURE: 4 

4.3 PRESSURE DROP AND THROUGHPUT 4 

5 CONSTRUCTIVE DESIGN ....................................................................................................................... 4 

5.1 MODEL/DIMENSIONS 4 

5.2 WEIGHTS 6 

5.3 MATERIALS 7 

5.4 PORT AND SIGHT GLASS POSITIONS 8 

6 CERTIFICATES AND APPROVALS ......................................................................................................... 8 

7 ORDER INFORMATION ........................................................................................................................... 8 

8 STANDARDS AND DIRECTIVES ............................................................................................................. 8 

9 COMMISSIONING AND OPERATION...................................................................................................... 8 

10 SAFETY INFORMATION ........................................................................................................................ 9 

11 DISPOSAL AND DECOMMISSIONING.................................................................................................. 9 

12 MAINTENANCE ...................................................................................................................................... 9 

13 REPAIRS................................................................................................................................................. 9 

14 SERVICE ADDRESSES........................................................................................................................ 10 

Page 2 of 10 Bopp & Reuther Messtechnik GmbH

1 Identification 

1.1 Supplier/Manufacturer 


1.2 Type of Product 

ZGA centrifugal gas separator with float-deaeration 

device and sight glass 

1.3 Name of Product 


1.4 Date of Release 

September 2009 

1.5 Version No. 

03661 - 00RevC 

2 Area of Application 

In order to prevent measuring errors caused by free 

air or gas when using volumetric meters to 

measure liquid quantity, gas separators are 

installed in front of the meter (forward flow) for 

liquids with a dynamic viscosity of < 20 mPa.s (at 

20°C). 

The German weights and measures regulations 

(Eichordnung) specify the use of gas separators for 

liquids up to 20 mPas in measuring systems with 

pump operation which are subject to calibration. 

Centrifugal gas separators in connection with oval 

wheel meters comply with the regulations for the 

calibration of measuring systems in Germany and 

other countries. 

Bopp & Reuther centrifugal gas separators have 

EEC qualification approval and are therefore 

approved for EEC initial calibration. 

3 System Design 


The gas separator is made of a welded pressure 

vessel with an integrated automatic float-deaeration 

device. For liquid gas measuring systems, it is also 

possible to use gas separators with an orifice plate 

installed between 2 valves in the degassing or 

return pipe (to the storage tank). The orifice plate is 

designed to allow a backflow of max. 5%. The 

valves are sealed in an open position. The liquid 

enters tangentially at the upper port, resulting in a 

swirling flow inside the gas separator. This swirling 

motion is sustained by the tangential outgoing 

liquid at the outlet port. 

The distribution of pressure in the swirling flow 

causes any air or gas to escape via the ventilating 

valve. 

The direction of flow is indicated by an arrow on the 

inlet port. The sight glass is used to monitor the 

float and the liquid. 

A sign attached to the gas separator specifically 

indicates two important points: 

• The maximum flow rate permitted by the 

German Board of Weights and Measures. 

• Only draw liquid when it is visible in the 

sight glass. Throttle if foam forms. 

Furthermore, a lead seal at the information sign is 

used to fix a calibration mark after measuring 

system calibration. 

The gas separator can also be equipped with a 

level limit switch or level indicator. 

Bopp & Reuther Messtechnik GmbH Page 3 of 10


4. Technical Data 

4.1 Operating Temperature 

Standard: -10 to max. +100 °C 

Low temperature model 

(-140 to -10 °C) on request 

4.2 Nominal Pressure: 

PN 10, 16, 25 and 40 

PN 63 and 100 on request 

5 Constructive Design 

5.1 Model/Dimensions 

DN Inch Container 

25 

32 

1“ 

1¼“ 

capacity [ℓ] 

Effective 

volume [ℓ] 

Max. permissible. Dimensions and installation dimensions 

flow rate Q 

(ℓ / min) 

4.3 Pressure Drop and Throughput 

Centrifugal gas separator pressure drops 

depending on the flow rate and liquid viscosity. 

Dimensions in mm Draining port 

A B C D E F G H J K L M mm Inch 

29 10 100 75 200 460 219 ≥50 665 ~985 ~1300 13 198 480 20 - 

50 2“ 54 25 300 90 220 645 273 ≥50 900 ~1180 ~1500 13 220 540 20 - 

65 2½“ 120 60 700 120 290 840 368 ≥80 1100 ~1385 ~1600 13 280 650 20 - 

80 3“ 180 95 1200 150 350 1030 419 ≥50 1330 ~1625 ~1900 20 360 750 0 32 1 ¼“ 

100 4“ 180 95 1200 130 380 1060 419 ≥50 1360 ~1655 ~1930 20 360 750 - 32 1 ¼“ 

100 4“ 300 180 2000 170 400 1250 500 ≥70 1520 ~1885 ~2200 20 440 850 - 32 1 ¼“ 

100 4“ 470 295 3000 200 400 1530 559 ≥60 1780 ~2100 ~2400 20 440 850 - 32 1 ¼“ 

150 6“ 470 295 3000 180 420 1530 559 ≥60 1780 ~2100 ~2400 20 440 850 - 32 1 ¼“ 

150 6“ 1000 675 5000 285 600 1800 800 ≥135 2125 ~2500 ~2800 35 660 1150 - 40 1 ½“ 

200 8“ 1000 675 5000 260 600 1800 800 ≥135 2125 ~2500 ~2800 35 660 1200 - 40 1 ½“ 

250 10“ 1000 675 5000 235 600 1800 800 ≥135 2125 ~2500 ~2800 35 660 1300 - 40 1 ½“ 

200 8“ 2200 1500 10000 385 750 2250 1050 ≥170 2725 ~3180 ~3500 35 880 1500 - 50 2 “ 

250 10“ 2200 1500 10000 325 750 2250 1050 ≥170 2725 ~3180 ~3500 35 880 1500 - 50 2 “ 

300 12“ 2200 1500 10000 300 750 2250 1050 ≥170 2725 ~3180 ~3500 35 880 1600 - 50 2 “ 

300 12“ 2700 1900 12000 360 865 2465 1150 ≥200 2785 ~3325 ~3700 35 880 1700 - 50 2 “ 

300 12“ 5000 2800 20000 500 900 2600 1500 ≥240 2965 ~3670 ~3990 35 1140 1900 - 80 3 “ 

400 16“ 5000 2800 20000 450 950 2650 1500 ≥240 2965 ~3670 ~3990 35 1140 1900 - 80 3 “ 

300 12“ 7000 5000 25000 550 1000 3200 1600 ≥250 4580 ~5300 5700 35 1250 2200 - 100 4 “ 

400 16“ 7000 5000 25000 500 1000 3200 1600 ≥250 4580 ~5300 5700 75 1250 2200 - 100 4 “ 

Page 4 of 10 Bopp & Reuther Messtechnik GmbH 

DN 

ISO 

228-G ½ 

(or ½ - 14 

NPT)

DN 25 - DN 65 

DN 80 - DN 400 

1 Draining port ISO 228 – G 1/2 (or ½ - 14 NPT) 


2 Deaeration connection ISO 228 – G 1 A (or 1 – 11 ½ NPT) 

3 Sight glass 

4 Inlet port 

5 Outlet port 

6 Manufacturer and information sign with details and calibration seal of 

the German Board of Weights and Measures. 

H Valve expansion height 

Port and sight glass position, sketch of model a 1 (see 5.4) 

with deaeration device 

1 Draining port 

2 Deaeration connection ISO 228 – G 1 A (or 1 – 11 ½ NPT) 

3 Sight glass 

4 Inlet port 

5 Outlet port 

6 Manufacturer and information sign with details and calibration seal of the 

German Board of Weights and Measures 

H Valve expansion height 

Cover design for DN 65 

Port and sight glass position, sketch of model a 1 (see 5.4) 

Bopp & Reuther Messtechnik GmbH Page 5 of 10


5.2 Weights 

Nominal size 

DN 

Container 

capacity 

[ℓ] 

Effective Max. permissible 

volume 

[ℓ] 

Flow rate Q 

[ℓ/min] 

Weight [kg] 

PN 10 PN 16 PN 25 PN 40 

25 29 10 100 78 78 100 10 

32 29 10 100 78 78 100 100 

50 45 25 300 120 120 160 160 

65 120 60 700 145 145 170 170 

80 180 95 1200 165 165 210 210 

100 180 95 1200 170 170 220 220 

100 300 180 2000 220 220 260 300 

100 470 295 3000 250 250 360 520 

150 470 295 3000 250 250 360 520 

150 1000 675 5000 420 520 730 860 

200 1000 675 5000 420 520 730 860 

250 1000 675 5000 420 520 730 860 

200 2200 1500 10000 850 1100 1450 2280 

250 2200 1500 10000 850 1100 1450 2280 

300 2200 1500 10000 850 1100 1450 2280 

300 2700 1900 12000 1080 1375 1880 2900 

300 5000 2800 20000 1 ) 1800 2200 2700 4300 

400 5000 2800 20000 1 ) 1800 2200 2700 4300 

300 7000 5000 25000 1 ) 2400 3050 3500 6050 

400 7000 5000 25000 1 ) 2400 3050 3500 6050 

1) with 2 deaeration devices 


5.3 Materials 

Material Model A Model F 

Casing: 

Wear allowance: 

Floor: 

Ports: 

Flanges: 

Cover and 

welding flange: 

P265 GH (HII) 

C2 = 1 mm (for wall thickness < 30 mm) 

P265 GH (HII) 

P235 GH (ST 35.8 I) 

According to DIN C 22.8 1 ) 

According to ANSI C 21 (A105 1 ) 


Bopp & Reuther Messtechnik GmbH Page 7 of 10 

- 

1.4571 1 ) 

1.4571 1 ) 

1.4571 1 ) 

1.4571 1 ) 

P265 GH (HII) 1.4571 1 ) 

Bolts: C 35 E according to DIN 931 or 938 1.4751 1 ) according to DIN 931 or 938 

Nuts: 

Gaskets: 

Welding: 

Welding process: 

Welding Consumables: 

C 35 according to DIN EN 24032 

Novapress-Multi/Viton 

Electrofusion welding 

Root run: 141 (WIG) 

Filler run: 111 (TIG /GTAW), 135 (MAG) 

Final run: 111 (TIG/GTAW) 

141 (WIG) EN 1668 – W2Mo 

111 (TIG/GTAW) DIN EN 499 – 

E420RR12 

135 (MAG) EN 440 – G 46 2 C G4 Si 1 

Deaeration device: Cast brass/steel and chrome nickel steel 

1.4571 

1) Acceptance test certificate 3.1 B according to DIN EN 10204 

1.4571 1 ) according to DIN EN 24032 

Teflon 

Electrofusion welding 

Root run: 141 (WIG) 

Filler run: 111 (TIG /GTAW), 135 (MAG) 

141 (WIG) 

Final run: 111 (TIG/GTAW), 141 (WIG) 

141 (WIG) prEN 12072 – W 19 12 3 L Si 

111 (TIG/GTAW) EN 1600 – E 19 12 3 LR 32 

135 (MAG) 9rEN 12072 – G 19 12 3 L Si 

Chrome nickel steel 

1.4408 and 1.4571 

Deviations to normal A and F models as well as devices calculated and tested according to other 

construction regulations: On request.


5.4 Port and Sight Glass Positions 

Fig. 3 Port and sight glass positions of the 

centrifugal gas separator DN 25 - 400 

E Inlet port 

A Outlet port 

S Sight glass 

The arrows indicate the direction of flow. The inlet 

port E is always at the top, the outlet port A at the 

bottom. 

6 Certificates and Approvals 

EEC Approval: D82 5.151.03. Manufactured by a 

welding specialist with HP0 approval 

(TRB200/TRD201) and TÜV (German Technical 

Inspection Authority) approval for welding quality 

requirements according to DIN-EN 729-2. 

7 Order Information 

When ordering please state: 

The product data, especially weight, temperature, 

pressure, viscosity, material, connection sizes, 

measuring range, desired accessories, required 

approvals, certificates and material certificates. 

See device selection according to model code. 

8 Standards and Directives 

• Designed and manufactured according to AD 

2000 directives. 

• Interpretation of measuring ranges and 

conversion of values should conform to VDE 

VDI 3513 directives. 

• Explosion protection directive 94/9/EC: 

The device complies with the standards 

EN1127-1 and EN13463-1 in accordance with 

ATEX100a. The operator should always 

observe respective regulations when installing 

and connecting the device in explosive areas. 

• Pressure equipment directive 97/23/EC: 

ZGA centrifugal gas separators are suitable for 

group 1 liquids. 

Classification generally within Category IV, with 

individual acceptance acc. to Module G of the 

pressure equipment device directive. 

9 Commissioning and Operation 

The gas separator should be connected to the 

process via the flanges (please observe the 

direction of flow!!). Depending on the application, 

the same applies for deaerating and draining 

connections. The gas separator has to be 

connected to earth via an earthing strap fixed to 

one of the feet. This ensures that the gas separator 

is included in the system’s equipotential bonding. 

Caution! 

Release the transportation lock at the float ball 

prior to commissioning. To achieve this, 

remove the housing cover with the device and 

subsequently retighten it carefully. 

The entire measuring system and pipework are 

deaerated via the ventilating valve during start-up. 


10 Safety Information 

The centrifugal gas separator should only be used 

for its intended area of application (see 2). Always 

observe the pressure and temperature limits stated 

on the type plate as well as all other technical data 

and safety information during device installation, 

commissioning and operation. 

Always observe national and international 

regulations concerning the operation of devices 

and systems under pressure. 

Prior to installation, the operator has to ensure that 

the pressure bearing parts have not been damaged 

during transportation. 

The devices have to be installed, operated and 

serviced by qualified personnel. The operator has 

the responsibility to ensure that the personnel have 

received sufficient and appropriate training. In 

cause of doubt, please contact the manufacturer. 

Only measure liquids to which the materials of the 

pressure bearing elements are resistant. 

Only release flanges, connections for deaerating or 

draining purposes, or the sight glass when the 

devices are depressurised. 

Only use the original spare parts specified by the 

manufacturer when replacing components. In the 

case of non-compliance, warranty shall not apply. 

Carefully select gaskets or sealing elements 

according to the operating instruction specifications 

(see 5.3). 


Type plate with pressure-relevant information 

The used abbreviations have the following 

meaning: 

Serial number: Clear identification no. 

Year: Year of construction 

PT: Achieved test pressure, and test 

Bopp & Reuther Messtechnik GmbH Page 9 of 10 

date 

DN: Nominal width 

Capacity: Container capacity in litres 

TS: Permissible operating temperature 

PS: Permissible excess operating 

pressure 

11 Disposal and Decommissioning 

Disposal or decommissioning should only be 

carried out by qualified personnel. Product residue 

has to be disposed of in accordance with legal 

regulations. 

12 Maintenance 

The centrifugal gas separator is maintenance-free. 

13 Repairs 

This device has been designed, produced and 

tested with the utmost care. In the unlikely event 

that a fault should occur, please contact our service 

department.

14 Service Addresses 


Service 


D-67346 Speyer 

Phone: +49 (6232) 657-402 

Fax: +49 (6232) 657 561 



67346 Speyer - Germany 

Phone: +49 (6232) 657 - 0 

Fax: +49 (6232) 657 - 505 

www.bopp-reuther-mt.de 

info@bopp-reuther-mt.de 

Dimensions, weights and other 

technical data are subject to changes. 

Printed in the 

Federal Republic of Germany 


Münchener Str. 23 

D-85123 Karlskron 

Industrial Estate Brautlach, on the B 13 

Phone: +49 (8450) 928330 

Fax: +49 (8450) 928332 

A-EN-03661-00RevC 

Latest Mod. 0909-001 

10 of 10

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