Ultrasonic flow meters provide a number of advantages, from ease of installation and limited downtime to lack of intrusion into your pipes. These meters provide reliable measurement data without the need to interrupt your process or risk leaks in your facility. You may however be overwhelmed by the choices of ultrasonic flow meters on the market.
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The team at Cross Process Solutions are experts when it comes to ultrasonic flow meters. We are experienced in start up, commissioning, troubleshooting, and flow verification. If you are looking for a new ultrasonic flow meter, working with an expert is key in making sure you pick the right meter for your application. While there are certainly very sophisticated ultrasonic meters available, they may not be necessary for every project. Below are some key considerations when selecting the right meter.
Medium
One of the key considerations when selecting an ultrasonic meter is the medium that will be measured. Water is the easiest and least expensive to measure. This includes chilled water, medium temperature hot water, and domestic water flow. If you are measuring anything with solids mixed in such as wastewater or a slurry, it becomes more difficult to measure flow. Some process chemicals and gasses are also quite complicated to measure. If you are measuring any of these more difficult mediums then it will likely require a more sophisticated ultrasonic flow meter.
Temperature
Temperature plays a huge role in selecting an ultrasonic flow meter. In general, anything in a “normal” temperature range is easier. Once the temperature goes above 250 degrees fahrenheit the application requires something more advanced. The same is true for extremely cold mediums such as liquid nitrogen.
Pipe Type
When it comes to pipe type, stainless steel, copper, and carbon steel pipes are pretty easy for ultrasonic flow meters. On the other hand, pipes made of ductile iron or anything with a liner such as asbestos cement are considerably more difficult. Likewise pipes with thicker walls can pose more of a challenge for lower end ultrasonic meters.
Pipe Size
In general, ultrasonic flow meters can handle anything from .5 inch to 256 inches in diameter. However, something to keep in mind is that they will not work if the pipe is not full of the medium.
Pipe Run
Pipe run refers to the length of pipe you have available to install the ultrasonic flow meter. Longer runs are easier, so if you have a shorter pipe run it can be done, but will require a higher end flow meter.
Needed Accuracy
Another consideration is the needed accuracy for the application. If you are just verifying flow or making sure you have flow, use of a less advanced meter may be the best choice. However, if you are using the flow data for billing purposes or to control a batching process, you will want to make sure that the data is very accurate and should invest in a better quality meter.
Signal Output
Do you need a simple 4/20 ma output or do you need a digital output that will feed data into your facility’s control system? If you are doing more with your data, you will need to plan to spend more for a meter that can communicate with your controls.
Configuration
Are you collecting measurement from a single point or are you looking for a dual channel output with multiple sets of transducers? As you might imagine, a single point measurement system is considerably less expensive than one with multiple sets of transducers.
Overall, at Cross we want to help you find the perfect meter for your application. If, by chance, an ultrasonic flow meter isn’t the right your particular application, Cross has expertise in a wide array of flow measurement types. We’ll work with you to determine exactly the right type of meter to suit your application, your budget and your reporting requirements. Contact us today to talk with a flow expert about your unique flow measurement needs.
If you are looking for a non-intrusive and accurate method to measure fluid flow in your process, ultrasonic flow meters could be the perfect solution.
In this article, we will discuss tips for selecting and installing ultrasonic flow meters in your process.
Before we dive into the tips, let’s first understand what ultrasonic flow meters are. Ultrasonic flow meters measure the velocity of a fluid by sending ultrasonic waves through a pipe or conduit and calculating the time it takes for the waves to travel. This is called Transit TIme ultrasonic measurement, which is about 95% of ultrasonic applications. Any easy analogy is when traveling by an airplane to a particular destination. The time travelled depends on wind speed either with or against the airplane. If one can replace an ultrasonic signal with an airplane and substitute wind speed with flow velocity, measuring the time it takes to arrive in destination, one can measure wind speed.
The speed or velocity of the fluid can then be used to calculate the flow rate. Ultrasonic flow meters can be used for various fluids, including liquids and gasses.
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There are two types of ultrasonic flow meters: transit-time and doppler. Transit-time meters are used for liquids and measure the time it takes for an ultrasonic wave to travel upstream and downstream in the fluid explained above.
Doppler meters, on the other hand, are used for liquids and gasses and measure the frequency shift of the ultrasonic waves caused by the movement of particles in the fluid. Where Transit time techniques are best in clean liquids, Doppler techniques are best with dirty liquids and must have particles or bubbles in the flow stream for accurate measurement. An analogy with this type of measurement is when getting caught speeding by a policeman. The policeman sends an ultrasonic signal to your car, the return frequency measured by the policeman’s speed gun is proportional to how fast you are driving.
The accuracy of the ultrasonic flow meter is an important consideration when selecting one for your process. The accuracy can be affected by factors such as temperature, pressure, and fluid composition. Make sure to evaluate the accuracy requirements of your process before selecting an ultrasonic flow meter. Transit time ultrasonic technology is far more accurate than Doppler techniques. Doppler should only be used with the fluid is so dirty or have high content of particles and bubbles no more than 40% in a flow stream.
Ultrasonic flow meters work best in large pipes and has limitations in small pipes because ultrasonic signals returned to the transmitter is too fast to measure in small pipes, usually less than 0.5 inches . Moreover because ultrasonic meters are installed outside the pipe, pipe material is very important in considering using ultrasonic technology. Pipes covered with insulation material, or has inside liners or material that are non-uniform like fiberglass or made out of several compound materials should be avoided. Consider the pipe material and size when selecting an ultrasonic flow meter.
The location of the ultrasonic flow meter in your process can affect its accuracy. Select an installation location that meets the manufacturer’s recommendations and is free from obstructions that could affect the fluid flow. Therefore pipe straight run requirements, such as before or after valves, other instruments, elbow, bends, curves etc. must be determined.
Proper installation and calibration are critical for the accuracy and reliability of ultrasonic flow meters. Make sure to follow the manufacturer’s instructions for installation and calibration, and consider hiring a professional to install if you are not experienced in the process.
Like any other equipment, ultrasonic flow meters require regular maintenance to ensure accurate and reliable performance. Make sure to consider the maintenance requirements of the flow meter when selecting one for your process.
The cost of ultrasonic flow meters can vary widely depending on the type, accuracy, and features. Therefore, evaluate the flow meter’s cost in relation to the benefits it will provide to your process. Normally lower scan rates are cheaper but can only work in clean fluids while higher scan rates which are more expensive can accommodate a certain amount of particles or bubbles in fluid.
Ultrasonic flow meters may need to be integrated with other equipment in your process, such as data acquisition systems or control systems. Make sure to consider the compatibility of the flow meter with other equipment when selecting one for your process.
Select an ultrasonic flow meter from a manufacturer that provides adequate support, such as technical support, training, and documentation. This will ensure that you can get the most out of your flow meter and troubleshoot any issues.
Finally, consider the future expansion needs of your process when selecting an ultrasonic flow meter. If you anticipate changes to your process in the future, make sure to select a flow meter that can accommodate those changes.
In conclusion, selecting and installing the right ultrasonic flow meter for your process is crucial to ensure accurate and reliable flow measurements. It’s important to consider factors such as the type of fluid being measured, the pipe size and material, and the required level of precision.
By following the tips outlined in this guide, including conducting a thorough site survey and working closely with a reputable vendor, you can ensure a successful installation and optimal performance of your ultrasonic flow meter.
As a result, you can improve process efficiency, reduce waste, and ultimately increase profitability with accurate flow measurements.
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