Centrifugal pumps shine when a processing line may require a wide range of flow rates. Altering the flow rate by closing or opening a discharge valve will stress a pump by causing it to operate outside of its best operating point. When the situation requires significantly more or less flow than the pump is producing net positive suction head, NPSH, cavitation, or vibrations can cause irreparable damage.
As a centrifugal pump operates pressure changes from inlet to outlet; negative pressure “pulls” fluid into the pump, and positive pressure “pushes” the fluid out of the pump. Because fluids may change phase at lower pressures, cavitation commonly occurs near the inlet of the pump. This phase change will cause the pumps to run dry, producing vibrations that wear bearings prematurely. These vibrations are caused by small bubbles returning to liquid as the pressure increases.
To prevent dangerous cavitation, net positive suction head is a measurement of the pressure at the pump inlet above the vapor pressure of the pumped fluid. NPSH is usually 3 to 5 feet, more if possible, meaning that at least 3 feet of head pressure more than the is required by the system.
Flow meters are used in many industries to measure and control the movement of gases or liquids. Accuracy is crucial in order to ensure that the manufacturing process is going smoothly. Precise measurements are key to many kinds of manufacturing, processing and transfer processes. For this reason, manufacturers look for the highest quality flow meters available on the market.
Why Regular Calibration Is a Must
However, even the most durable and sensitive meter can become imprecise and lose accuracy after prolonged use. Some common causes are regular wear and tear, exposure to moisture or corrosion due to chemicals. Flow meter function can also become disrupted due to accumulation of dirt, impact or faults in the installation process. Regular inspection and calibration of your flow meter is necessary in order to ensure consistently precise readings. To ensure that your calibration of your flow meter achieves the results you want, it is smart to follow the following best practices.
Use Accurate Testing Equipment
First of all, make sure that your testing equipment is up to standard. This means that before you can start using your standard to test your flow meter’s measurements, you must take care to test your standard against another recognized standard and document the results. This will help you maintain a high degree of accuracy when checking the precision of your flow meter’s measurements.
Test Your Testing Equipment
In addition to comparing your standard’s accuracy to that of an already known standard, make sure that its measurements are sufficiently accurate. When you are using a standard to calibrate your flow meter, your standard typically needs to be four times as accurate as the meter you are testing. In some cases, the accuracy requirement can be different based on the specific type of calibration.
Ensure Typical Environment
Now that you have checked your testing equipment, you need to make sure that the testing environment is conducive to precise results. If you want to know how your flow meter is operating on a daily basis, you should test it under conditions that are as similar as possible to its typical environment. The type of substance whose movement is measured by the meter can affect operation, so be sure to test using the same substance. Factors such as heat, density and rate of movement can also affect operation; thus, for optimal testing accuracy, these should also be similar to the regular operating environment.
Consistent Flow
When testing, it is important to keep the flow rate steady. In a typical testing scenario, you will be making a real-time comparison between the flow rate of your meter and your testing standard. Thus, variations in system flow can lead to imprecise results and suboptimal calibration.
Eliminate Variations in Heat and Volume
For best calibrating results, your testing unit will need to measure everything your flow meter regularly measures, simultaneously. This means that it is important that there not be any variations in temperature or volume during the testing process. Before beginning the calibration, check the system for leaks or other irregularities that could compromise test results.
If you find that you are unable to calibrate your flow meter successfully, it may be time for a repair or an upgrade. Flow meters can lose function when they are being used in applications where a particular type or model is not optimal. Improper installation can also lead to damage that may not be easily fixed by recalibrating. Consult your manufacturer as to the best type of flow meter for your purposes.
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Bolts that are too long: If engineers are wasting money on excessively large bolts, they must be cutting corners somewhere.
Non-isolated control valves: Maintenance is always required, if there is no way to easily remove a valve then maintenance is not being done on the valve.
Lack of pressure gauges and connections: At some point it will be necessary to monitor the pressure at the valve. Build with future needs in mind.
No air vent caps: Valves that reduce pressure will buildup air pockets during operation, if this air is not vented you can bet a costly repair will be needed soon.
Click here for the full list of signs by Mark Gimson.
Hydraulic systems are dependent on every part within the system, any small leak or failure from one piece will bring the system to a grinding halt. The fluids used in particular systems can even harm personnel nearby or the environment in the occurrence of failure. Valves are critical to hydraulic systems as they control the flow of hydraulic fluid through the system to perform work. A preventative maintenance program should focus on valves more thoroughly than any other component.
Reactive maintenance expects to run components to failure, often valves fail first, and then enact repairs while productivity is zero and then make up for lost production time later. This process is costly and usually fraught with high tensions. A preventative maintenance schedule uses time or specific conditions to “schedule” repairs and replacements. This scheduling process can be in terms of time; i.e. replacing seals and gaskets every 2 years, or it may be based on operations; i.e. after every 5,000 cycles, or both depending on which “schedule” comes first.
Industry data shows that performing maintenance on a scheduled basis is three to five times less expensive than the same repair being made on a reactive basis.
Click here for the full article by Mickey Heestand.
A good design to a control room will facilitate efficiency and minimize liability. The design will enhance an operator’s efforts to produce the desired results in production. Since 2000 the International Organization for Standardization has produced a set of standards, ISO 11064, for control room design. Most of these standards deal with ergonomics and layout for the room, and adherence to these standards can greatly protect a company from injury lawsuits.
ISO 11064 helps establish good design standards with measurable results to avoid control rooms like many of us have experienced. Designed control rooms, control buildings and operation camps that feature a user-driven approach, work with ISO 11064 requirements, and integrate architectural, interior design and human-factors elements optimize performance.
First and foremost in the design process focuses on safety; locating the control room outside of blast zones, pathways of heavy equipment, and insecure environments. Further efforts deal with employee access and localities.
Turbine flow meters are a popular way of measuring liquid and natural gas flow. Also known as an axial turbine, this type of meter consists of a turbine wheel that is placed in the stream of the flow. The flow pushes the meter’s angled blades, causing the turbine to rotate. Flow rate can be determined based on the turbine’s rotation rate once it becomes steady. The rate of rotation is typically picked up by electronic coils that are connected to the meter’s housing, and then turned into readings that can be accessed by the user.
Minimal Flow Disruption
One advantage of a turbine flow meter is that it offers minimal disruption to the flow. Because the flow can continue right through the turbine, there is little pressure loss and speed can remain fairly high. For this reason, they are often preferred for purposes water distribution, fire protection and for large commercial projects, where a high rate of flow and high pressure is desirable. On the other hand, applications where flow rates are low will typically use meters that are considered more accurate but tend to impede flow rates, such as displacement meters.
Ensuring Maximal Accuracy
Turbine meter measurements can be affected severely by factors such as flow profile, temperature and flow rate and content. Strainers installed near the meter can help protect the turbine from debris that could damage it. Depending on specific conditions, users may choose to put additional protective measures in place to ensure maximally accurate and consistent flow measurements.
New Developments
With today’s advancements in technology, turbine flow meter accuracy has also improved. Increased sensitivity allows for the precise measurement of even extremely low flow rates in some models. Manufacturers also continue to develop blade and rotor materials that are highly sensitive, durable and less vulnerable to drag and other factors that have traditionally decreased accuracy. Some types of turbine meters are also able to measure and record variations in flow with a high degree of precision. Another way in which flow meter makers have reduced inaccuracy is by reducing the rotor’s inertia. A high inertia would keep the rotor spinning fast even after flow had decreased, leading to inaccurate results. A low inertia lets the turbine reduce speed together with the flow.
Maintenance and Calibration
Regular inspection and calibration is essential to keeping a turbine flow meter accurate. For best results in calibration, test your meter under conditions that are as close to normal operating settings as possible, keeping the flow composition, rate and temperature substantially similar. In addition to regularly scheduled inspections, check your meter in the event that you are receiving inconsistent or unusual readings that cannot be explained by actual variations in the flow.
Malfunction may occur as a result of regular wear and tear, impact by debris, corrosion, or buildup of dirt or viscosity. Problems may also happen if your meter is calibrated incorrectly or was not properly installed. While some problems can be fixed by recalibrating or performing minor repairs, others may necessitate partial or total replacement. If you are using an older turbine flow meter, be aware that recent developments have substantially improved measurement accuracy; thus, it may be wise to invest in an updated model.
Intrigued by the fascinating world of turbine flow meters and their precision in fluid measurement? Explore our diverse range of high-quality turbine flow meters, where cutting-edge technology meets reliability. Visit our products page today to discover the perfect solution for your flow measurement needs.
Turbine flowmeters are a common component for machines used in the aviation,chemical and energy industries. Crucial for measuring the flow rate of fluids or gases, quality turbine flowmeters are necessary for determining accurate metrics, and by extension creating a quality product or carrying out an important service. Engineering innovation and design has made it possible for many well-built turbine flowmeters to enter the marketplace. While shopping around for a flowmeter, keep in mind these important features:
Reliable digital reading – Current day products allow for easy measurement reading by possessing a digital output sensor that keeps track of the rate and amount of gas or fluid traveling through the flowmeter.
Versatility – Ideally, your flow meter should measure both pulsating and fluctuating flow with a quick response time.
Low rotor inertia – Lower inertia ensures better efficiency and accuracy during operation.
Plan Your Project With a Professional
Whether you need one flowmeter or several dozen, consulting with someone who is an expert in the industry can be beneficial both in terms of financial savings and product knowledge. A knowledgeable company representative can assist in determining which flowmeter product is the most economically viable and expertly designed for your needs. Simply looking at brochures with specific product specifications might not truly tell you what you need to know.
Take care to speak with someone who is open to collaboration. A representative willing to listen to the details of your project can offer input pulled from previous clients and an in-depth understanding of the flowmeter industry. In fact, major flowmeter companies often offer engineering services if there is no flowmeter on the market perfect for your project. Offering state-of-the-art design techniques and meticulous testing, these companies are able to create a product that can take your project to the next level.
Rely on a Product Warranty
Whether pre-made turbine flowmeter or custom designed flowmeters come with a product guarantee ensuring that your part will be replaced free of charge if it breaks because of a design error. Usually valid for up to one year after your purchase, this warranty is an excellent way to ensure that your purchase is protected in case of a breakdown. Without a warranty, your company is at risk for profit loss for an event that could have been easily remedied with no loss of collateral.
Install Your Product Properly to Ensure Maximum Functionality
The best way to protect your machine from malfunctioning is ensuring that everything is installed correctly. While many have in-house employees able to complete this job, others chose to rely on professionals from the company delivering their product. In some cases an outside professional is able to install your product more precisely, especially if it is custom designed. Proper installation ensures that your flowmeter is taking accurate measurements and working correctly in conjunction with other parts of the machine.
Whether you need a turbine flowmeter for an airplane or a manufacturing plant, taking the time to choose a quality product from a company just as passionate about engineering as you is the key to a successful project. At Flowmetrics, we share your passion for engineering excellence. Explore our range of top-notch turbine flow meters to find the perfect solution for your needs.
Flow meters today are designed to function with flow computers. An efficient and sophisticated piece of equipment, the flow computer is able to receive and interpret signals from digital and analog instruments such as flow meters, temperature and pressure gauges, flow control valves, samples and liquid provers. The computer makes a complete record of all data received, along with any changes to parameters.
Diverse Uses
In order to fulfill its intended function, a flow computer must be highly precise and able to monitor and record measurements in extremely small increments. Another universally necessary characteristic is durability. These devices are in use across a variety of industries, where they are frequently employed in an environment with varying temperatures and may come into contact with damaging gases or liquids. In order to ensure that measurements and records remain reliable and accurate, it is important to ascertain that your flow computer’s casing and components are designed to perform in the environment you need.
Flow computer are used in many diverse industries today in order to obtain precise measurements and analyses of products. These devices are sometimes referred to as cash registers, due to being widely used to monitor custody and transfer of substances such as natural gas and oil. Computers are also used to monitor and record steam, liquids and gases by food and drink manufacturers, water companies, plants that mine and process metals and minerals, chemical factories, pulp and paper companies and power stations.
Precise Function
Flow computers are used to monitor the flow of gases and liquids in many types of industries, from petrochemicals to food manufacture. In order to obtain optimal results, it is best to choose a computer that is most suited for your purposes. Today, there are many types of computers available with a wide range of attributes and options. It is important to select the one that performs the full range of measurements you need without being cluttered with unnecessary functions. For example, some flow computers also perform chemical analyses and gas density calculations. Other functions may include:
Environmental compliance monitoring;
Remote metering capacity;
Heat flow equations.
Most flow computers need some additional configuration and calibration in order to perform most accurately. Look for models that are easy and intuitive to set up; an overly complicated system is more likely to cause setup errors and ultimately cause inaccurate reporting from your computer.
Maintenance and Inspection
To remain at the peak of their function, computers should be inspected regularly. Scheduled inspection and maintenance is a good way to assure that you are getting the precise measurements you need, along with a comprehensive record. If your flow computer was installed many years ago, some of its components may be obsolete and no longer available on the market; support from the manufacturer may be very limited or entirely non-existent. With new advances in digital technology being made continually, computer manufacturers are able to offer ever-increasing precision in measurement. Updated proprietary metal alloys are also available for durable and secure casing.
The flow computer is an essential part of many types of industries. Manufacturers rely on it for accurate measurement and analysis of work product. Keep your in good order with regular inspections and updates when necessary.
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From the installation near Monaca, Pa liquefied natural gas will be exported to consumers, and industry leaders expect growth in liquefied natural gas demand to remain. Ethane crackers utilize high heat, catalysts, and solvents to break the molecules of larger ethane into ethylene.
As supply of crude oil deposits dwindle, more energy producers are focusing on liquid natural gas for itsportability. Once cooled below its vapor point, natural gas compresses 600 times which makes it easier to transport and ship to other regions including international destinations.
Recently, the U.S. Energy Information Administration projected domestic ethane production to grow from 1.1 million barrels per day in 2015 to 1.4 million barrels each day in 2017, an increase of 300,000 barrels daily.
Hydraulic-power units in Colorado’s Carter Lake are being fit with smart systems to optimize the flow rate of water through the dam. Through the use of PID controllers, position feedback devices, and backup manual valves installed in parallel Carter Lake Hydroelectric maintains the flow of water through its wicket gates in turn regulating the generation of electricity from the flowing water.
The entire hydaulic system is designed for long term use with little maintenance. Redundant oil filters maintain internal hydraulic components, fluid check valves prevent counter-flow from harming sensitive pressure sensors and flow meters.
