Ultrasonic Flowmeters Prove Prevention is Better Than Cure

Clamp-on ultrasonic flowmeter proves that ideal tool for pump condition monitoring.

“A stitch, in time, saves nine” and “prevention is better than cure” are possibly expressions that most people would pay little attention to, or at best implement on an occasional basis. Antiquated as these sayings may be, in our more modern times, they form the basis of a very modern engineering term; condition monitoring.

In the past the idea of repairing a pump before it needed fixing was standard practice. More recently however, the demands made upon an engineer’s time have meant that in many cases equipment breaks down before anyone has the chance to do anything about a problem. The direct consequences of such behaviour are varied and can include expensive repairs, long periods of shut down and lost product quality. There is also a more indirect aspect to consider: - lost energy efficiency.

A pump which is suffering from wear or damage will continue to push fluid down a pipeline, but it will be doing this in a far less efficient manner than it should. This increases the risk of serious or irreparable damage to the appliance and also causes an increase in the energy usage. As companies strive to reduce their carbon footprint and energy prices continue to rise dramatically, running a damaged pump can result in more than just a longer-term repair.

Traditionally the only way to ensure that a pump was working correctly was to manually dismantle and visually check it. The drawbacks of this are that if the pump was fine then the engineer has spent time and money on unnecessary work. Furthermore, there is a good chance that components such as seals will have been damaged during the dismantling process, and will need replacing as a result.

A number of technologies now exist to provide more information to engineers on pump performance externally of the pump, however the most useful of these are clamp-on flowmeters. When looking at pump efficiency accurate flow data is a key factor. Testing of the pumps immediately after installation sets a benchmark for future monitoring work and can be used to verify the standard pump curves supplied by the manufacturer. As the ultrasonic flowmeters do not interfere with the pipeline, single or multiple pump discharge measurements can be taken without disruption of the process.

Whilst other instruments such as clamp-on ammeters can show the actual energy the pumps are using, and can generate an efficiency curve, it is the flow output that will help determine whether performance is dropping off with time. Once a possible issue is identified, vibration testing equipment can allow the customer to pick up on unusual noises and signs of damage. Alternatively, thermal imaging cameras can show when a pump is getting too hot, possibly indicating poor performance and excess energy consumption.

By looking at the actual flow output, the energy used and the head pressure the exact pump performance can be monitored. By combining this information with the vibration analysis it is possible to identify problems and recommend a solution. The allows the provision of a cost benefit analysis on the work that needs to be done, without incurring the problems associated with having to stop the pump.

Katronic Technologies have been involved in the area of pump performance metering for a number if years. Our accurate clamp-on meters are the key to checking pump performance, providing a logged accurate measurement of flow. Furthermore, the experience of Katronic engineers in this area is invaluable, and ranges from water and effluent pumps, to fire pumps and large cooling water pumps.

It is in the buildings services sector that ultrasonic meter evaluation is particularity useful, as the issues of energy loss are multiplied when the liquid being pumped has been heated or cooled. Failing to generate the correct flows through the pumps not only places greater loading on the boilers or chiller units but can also cause them to malfunction. In the case of industrial boilers, low flow rates can be a directly contributing factor to overheating or hot spots, which can damage the system.

For applications where the requirement to measure the pump output is only temporary, the Katronic portable flowmeter provides a truly flexible solution. One of the greatest advantages is that the meter will display and log flow rates, total flow and flow velocity information - essential for properly evaluating pump performance.

The large datalogging capacity of the Katronic instrumentation means that the flowmeter can simultaneously log flow and velocity information without the requirement of a costly external datalogger. All the measured information can then be neatly presented through the Katronic KATdata+ dedicated software, or by using a standard Windows-based spreadsheet.