Water Meter Test Systems - Large Meters


MARS Large Water Meter Test Bench

Large Meter Test Bench Systems

The Large Meter Test Bench System developed by MARS Company employs the latest in design and process control technology, setting the worldwide standard for the large meter testing and management industry. This versatile system can be configured to meet the testing needs of virtually any large meter management organization.

MARS Test Bench Systems are designed to meet / exceed American Water Works Association (AWWA) recommendations, National Institute for Standards and Technology (NIST) Handbook 44 Specifications, ISO 4064 Specifications and other standards and requirements.

Revenue Recovery

Understanding how your meters perform in the field will allow you to reduce unaccounted for water in your system.

Increase Confidence

Designed to operate using Volumetric or Gravimetric technology and to meet/exceed AWWA, ISO and NIST specifications.

Simplify Operations

Automation is available with Gravimetric and MARS M3 Meter Management Software integrations.

Typical Applications

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Water utilities or water meter manufacturers requiring the testing of meters from 3" to 16" sizes (larger sizes available)

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Tests meters of all lengths and types

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Where testing to a higher standard of accuracy and repeatability is required

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Where improvements to revenue, manpower utilization, efficiency, and safety are needed

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Tests turbine, compound, and fire-line meters of all lengths and types

Tests detector check valves and backflow preventers from 3” to 16” sizes

Standard and Optional Features

Available on every configuration of MARS Large Meter Test Bench.
* Denotes Optional Items, contact MARS for details.

Test Tanks

10 Gal./1 Cu.Ft. and 100 Gal./10 Cu.Ft. Stainless Steel Duplex Tank with scale.

1500 / 2500 / 3500 / 5000 Gallon Stainless Steel Test Tank with load cells

Flowrate Registration

Three (3) precision rotameters that cover a flow range from .1 – 160 GPM and Gravimetric Control.

Corrosive Protection

Corrosive Protection (polyester coated steel bench frame).

Supplies and Adapters

All meter adapters, meter and adapter gaskets, manual flow control valves, document station, electric actuated clamping device, meter support fixtures.

Recirculation System*

The Recirculation System recycles the test water used on the MARS Test Bench, maintaining volume and pressure to test the meters at the recommended AWWA Specifications, per Table 5-3 of the current AWWA M6 Manual.  

Benefits include but are not limited to: compliance with local, state and/or Federal laws and regulations as it reduces the chemicals released into the environment; an immediate reduction in consumption and water dumped to waste after each test; Improved customer perception as the Water District sets an example for water conservation practices.

Test Spool Assemblies

Provided in all sizes relevant to test bench size parameters and constructed of Sch. 40 steel pipe with 1D flanges welded at both ends and modified to accept o-rings using square groove technology on reducing spools and spacer flanges.

All spools are coated inside and out according to frame specifications and select spools are configured with straightening vanes to minimize or reduce turbulence and allow for conformance with AWWA specifications and recommendations.

Gravimetric Control and Automation with M3

The MARS Company Gravimetric System includes a scale, console, computer, printer, display and the MARS M3 Meter Management Software. 

The Test Bench, with the Gravimetric System, is traceable to NIST (National Institute for Standards and Technology) Handbook 44 specifications, providing 1/10% repeatable accuracy.

MARS Calibration Certification*

With MARS Certified, you can protect both MARS and selected third-party equipment with technical assistance, software upgrades, preventative maintenance, spares management and on-site maintenance. 

Not only is the equipment upkeep essential, but ensuring all operators are fully trained on meter testing practices and procedures is critical.


Standard System Specifications

Specifications are subject to change at any time.  Please contact MARS for the latest specifications.

MARS Large Water Meter Test Bench
Three Inch (3") to Six Inch (6") Test Bench

-  Designed to test meters from 3” to 6” diameters

-  Includes spool spacers from 3” to 6” diameters at varying lengths

-  The test benches described above are based on standard 
   dimensions and are built to standard specifications

-  If there is not a standard bench that can meet a particular output 
   requirement, one can easily be custom designed and fabricated

MARS Large Water Meter Test Bench
Three Inch (3") to Eight Inch (8") Test Bench

- Designed to test meters from 3” to 8” diameters

- Includes spool spacers from 3” to 8” diameters at varying lengths

- The test benches described above are based on standard 
  dimensions and are built to standard specifications

- If there is not a standard bench that can meet a particular output 
  requirement, one can easily be custom designed and fabricated

MARS Large Water Meter Test Bench
Three Inch (3") to Ten Inch (10") Test Bench

- Designed to test meters from 3” to 10” diameters

- Includes spool spacers from 3” to 10” diameters at varying lengths

- The test benches described above are based on standard 
  dimensions and are built to standard specifications

- If there is not a standard bench that can meet a particular output 
  requirement, one can easily be custom designed and fabricated

MARS Large Water Meter Test Bench
Three Inch (3") to Twelve Inch (12") Test Bench

- Designed to test meters from 3” to 12” diameters

- Includes spool spacers from 3” to 12” diameters at varying lengths

- Includes concentric reducers up to 12”

- The test benches described above are based on standard 
  dimensions and are built to standard specifications

- If there is not a standard bench that can meet a particular output 
  requirement, one can easily be custom designed and fabricated

MARS Large Water Meter Test Bench
Three Inch (3") to Sixteen Inch (16") Test Bench

- Designed to test meters from 3” to 16” diameters

- Includes spool spacers from 3” to 16” diameters at varying lengths

- Includes concentric reducers up to 16”

- The test benches described above are based on standard 
  dimensions and are built to standard specifications

- If there is not a standard bench that can meet a particular output 
  requirement, one can easily be custom designed and fabricated

NOTE: Test Bench Selection According to Length

- The length of the test bench depends upon the testing output 
   requirements (i.e. the more production required, the longer 
   the test bench should be)

- Standard test bench lengths have been established to ensure a 
   wide range of outputs, and will likely fall within the output standard

- The test benches described above are based on standard 
  dimensions and are built to standard specifications

- If there is not a standard bench that can meet a particular output 
  requirement, one can easily be custom designed and fabricated

Additional Specifications for this Series

 
Intrinsically safe

Eliminates shock and explosive hazards from hydraulic conditions

Designed to minimize physical fatigue

Built to withstand any forces applied within the scope of its use

Easy to operate controls to minimize operator errors

Meter Support Fixtures

Referred to as “trolleys”

Designed to support the meters during installation and testing

Equipped with rollers made of UHMW nylon, or suitable rubber

Roll entire length of test bench

Constructed of welded steel and coated to frame specifications

Equipped with adjustable V-blocks for lifting meters and spools into place

Control Panel

Nema-4 or 12 enclosure

Grey enamel finish

Completely pre-wired to operate all test system functions

Equipped with Emergency Stop and Power On switch

Industrial momentary and multi-position selector switches

Meter Clamping

Utilizes hydraulic driven cylinder to compress meters and the spool spacers, eliminating the need for nuts and bolts

The motion operator is controlled by an easy to use control box at moving end of the bench

The movable flange section is designed to adapt to all meter sizes within the specified parameters of the test bench

Movable flange range of motion is eighteen inches

Movable flange is equipped with locator pins to align meters and prevent accidental misalignment and blowouts

Utilizes 5/16” O-rings and square groove technology 

Motion operator and movable flange have a working pressure rating of 150 PSI and has been safely tested at 300 pounds static

Movable flange section is supported by a support tower which is a welded steel frame coated exactly like the test bench

Pressure release valve to ensure safety by prohibiting the bench to open until pressure is released.

Tethered user-friendly remote-control module to provide extra level of safety while loading or unloading meters.

NOTE: In order to enhance safety and leak prevention, it is recommended that meters 8” and above be bolt assisted to hold 
       the meters in place when being tested. The required compression force to safely test these larger meters exceeds the 
       3” through 6” meters’ compression limits.

 
Frame

Fabricated steel

Welded in accordance to standard industry practices and certifications

Capable of compressive and hydraulic forces equal to fifteen thousand pounds of pressure

Total weight rating of ten thousand pounds without distortion or misalignment

Stainless steel load bearing surface at side rails

Coating

Polyester Coating in MARS Blue

Minimum of 20 years resistance to corrosion

High impact resistance

All steel is fully sandblasted and treated with Atochem rust proof primer before being coated for total bonding 

Frame is not touched by human hands within at least 2 hours of drying

Coating is applied using the electrostatic method, then placed in an oven at 495 degrees F until fully bonded 

The frame is electrostatically spark tested to detect defects

Splash Pans

Stainless steel construction

Extends full width and length of test bench

Built in panels of 10 feet or less to facilitate removal and cleaning

Drip free

1 inch in 10 feet slope to lowest point where a stainless-steel nipple will be welded for drain tie-in

Flex Joint Assembly

Bench is connected to water supply line utilizing a flex joint assembly

Allows the travel not less than 18 inches

Supported by a welded and coated stand

Document Station

Designed to cover motion operators and hold forms, pencils, etc.

Hinged lid

Angled writing surface with lip

White Formica construction

Stainless steel hardware

Test Spool Assemblies

Provided in all sizes relevant to test bench size parameters

Coated in and out according to frame specifications

Equipped with alignment spacer flanges

Select Spools are configured with straightening vanes to minimize or reduce turbulence and allow for conformance 
       with AWWA specifications and recommendations

Constructed of Sch. 40 steel pipe with 1D flanges welded at both ends

Modified to accept O-rings using square groove technology on reducing spools and spacer flanges

Stainless alignment pins are uncoated 316 stainless steel

Equipped with lifting handle for ease of movement and safety

 
Three Precision Rotameters

Low flow measurement of .1 to 1.5 GPM

Medium flow measurement of 1.5 to 15 GPM

High flow measurement of 15 to 60 GPM or 6 to 160 GPM

Low Flow Measurement Tanks

One set of 10/100 Gallon Stainless Steel Duplex Tanks STANDARD for all test bench sizes

Tank volumes of 10 Cu.Ft. / 100 US gallons and 1 Cu.Ft. / 10 US gallons

Tank option: one duplex tank 10/100 or one (1) 10 Gallon Tank and one (1) 100 Gallon Tank 

Based on standard dimensions, but, custom tanks can be fabricated upon request

Stainless steel construction

Built in accordance with industry safety and seismic standards

Automated select valves to migrate from low-flow to high-flow (or vice versa)

High Flow Measurement Tanks

Size of tanks depend upon the test bench parameters and output requirements

Standard sizes are as follows: 1500 US gallons, 2500 US gallons, 3500 US gallons, 5000 US Gallons

All standard sizes are based on standard dimensions, but custom tanks are fabricated upon request 

Stainless steel construction

All tanks are built in accordance with industry safety and seismic standards

Automated select valves to migrate from low-flow to high-flow (or vice versa)

 
Ball Valves

Chrome plated ball with Teflon seat

Full port

3-piece stainless steel body

150 PSI rating

Butterfly Valves

Lug or wafer style

Cast or ductile iron body with EPDM or Buna-N liner

Stainless steel valve discs

150 PSI service pressure

Max flow rates based on pipe diameter

Electric Ball Valve Actuators

Nema-4x enclosures, zinc plated, two-part polyurethane Open/Closed Angle position indicator and 
       90-degree operation from full open to full close in 7 seconds

Manual override hand wheel

Torque switches

30% duty cycle

Mechanical travel stops

Internal heater

Ball bearing 110 VAC motor with thermal protection

Temperature range –4 to 158 degrees F

Life cycle: 100,000 operations minimum

 
Municipal Supply with Drain to Waste

Utilizes municipal (public) service to supply the needed water to the test system

The water is drained from the measurement tank and then directed to the storm drain, 
       municipal sewer, or wherever the user sees fit

The water service must be able to provide a pre-determined flow at a specific pressure 
       (requirement depends on bench size and specifications) in order to achieve proper test results

Not recommended in situations where the cost of water is high or water conservation is desired

Recirculation System
Gravimetric Test Control

Motion detection range setting unit

Alarm to prevent over-flow

Run test sequence by time or volume

Five selectable units of measure (gallons, cu. ft., cu. meters, imperial gallons and pounds) 
       the units can be modified per customer request

User selectable test names or line names (example: Q-Min or .5” line)

Auto drains the tanks after the test or holds the water in the tank in order to stack test 
       (scale automatically zeros after each test)

Built in leak detection on scale, after the test with a variable leak check

Selectable purge of one line or all lines based on a time which is operator adjustable

Emergency stop or test abort in all phases

Auto compensating free-fall adjustment (PRE-ACT) to stop test on target value

Units are set up for computer and or printer interface

Control software is upgradeable

The scales are a NIST approved class III weighing device

The weighing devices are traceable to Handbook 44 specifications

System accuracy is ¼ of one percent and repeatable to 1/10 of one percent

M3 Enterprise Software

Is your Meter Shop Certified?

With MARS Maintenance Calibration Certification (MCC), you can protect both MARS and selected third-party equipment with technical assistance, software upgrades, preventative maintenance, spares management and on-site maintenance. Not only is the equipment upkeep essential, but ensuring all operators are fully trained on meter testing practices and procedures is critical.

MCC
MARS Large Water Meter Test Bench

Learn More

Contact us today to learn more about Water Meter Test Systems.

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