From different types of valves to filter strainers in Singapore, there are numerous components involved in handling, transferring, and storing fluids in the most efficient and safest way possible across a diverse range of applications. A key part of this whole equation is flow metres, which process managers, engineers, and technicians alike rely on to deliver the real-time data they need for various fluid handling and transfer processes.
While modern flow sensors now feature high levels of reliability, accuracy, and durability, that does not mean they are infallible. They can still fail or produce inconsistent or inaccurate readings over time and, in some cases, right out of the box. Therefore, it is important to familiarise yourself with the common problems that may affect flow metres to ensure you always get a good handle on your system’s productivity and product quality levels. Issues such as faulty steam traps can contribute to flow metre malfunctions, impacting the overall efficiency of your operation.
1. Sensor fouling
Flow metres are not immune to various types of fouling, which can occur over time depending on the process in which they are used. A few common examples include rust and corrosion, which eventually erodes metal parts scaling caused by sodium, magnesium, and calcium deposits, sludge-like grime, oil, and other impurities, and slime from microorganisms.
Fouling thickens and impedes the flow of liquid and gas. Not only that, it also covers sensor surfaces and fluid intakes over time, with more intrusive instruments and those that rely on many moving parts being at higher risk. Flow metres with reactive metal components are especially susceptible to scaling and corrosion when used in chemical processes.
2. Obstruction or blockages
Systems often experience obstructions and blockages that slip under the radar. These can happen anywhere from upstream to between flow metre sensors, causing inconsistent or inaccurate readings and potentially affecting all the metres in a pipeline.
3. Wear and tear
All sensors experience gradual wear and tear caused by various factors like friction on the moving parts of certain instruments and damage from the thermal expansion and contraction of parts like resistance-temperature detectors. This phenomenon particularly occurs at an accelerated rate in applications with high temperatures or pressures involving corrosive media or significant changes in temperature.
4. Improper installation
While uncommon, faulty and incorrect flow metre installation can still happen from time to time and affect the consistency and accuracy of readings. For instance, there is the simple mistake of installing the metre backwards and causing the sensor order or intake direction to be reversed. In rare cases, flow metres could be used to measure fluids they were not designed for, resulting in bad readings. Lastly, local flow issues like bubbles, undiagnosed turbulence, and pressure drops may affect a metre’s sensors.
5. Incorrect calibration
Flow metres must be calibrated to the medium they are measuring, particularly their pressure, temperature, viscosity, and density. No matter how mechanically sound a quality flow metre may be, calibrating it incorrectly will naturally lead to poor readings. There are several ways that can cause a metre’s calibration to be inaccurate, including manufacturer error, use with incompatible gas or liquid mix, and gradual calibration drift over time. Moreover, exposure to unexpected fluid types can also make existing calibration settings inaccurate.
6. Unexpected changes in the fluid
Whether it’s the pressure, viscosity, temperature, or something else, any sudden changes in a fluid’s property could lead to the measurements exceeding the flow metre’s calibrated sensor range. In rare cases, these changes could also prevent the instrument from working properly. This issue typically occurs in certain oil and gas production processes and saturated steam applications.
Conclusion
While there are quite a few problems to look out for when using flow metres, most of them can fortunately be prevented or mitigated. A few ways to do so include making sure they are properly installed and calibrated, maintaining them regularly, and buying exclusively from reputable suppliers.
Techmatic Controls is one such provider of industrial solutions that cater to the petrochemical, oil, and general process chemical industries. Whether you’re in the market for essential components like flow metres, strainers, safety relief valves, or anything else, we are the one-stop destination for all your industrial product needs.
