66 Water / Wastewater
Titan Enterprises Explains Possible Reasons for Flowmeter Failure During Installation “Why Has My Pulse Flow Meter Sensor Failed?”
The majority of fl ow meters with a pulse output use a rotating element with internal magnets. These magnets trigger a solid-state sensor giving a pulse output proportional to the liquid fl ow rate.
Titan Enterprises Ltd, who has been designing and manufacturing fl owmeters for over 40 years, explains some of the reasons why these sensors might fail and what can be done to prevent damage that can lead to costly repairs and process downtime.
High quality Hall effect sensors are typically used within Titan’s pulse precision fl ow measurement devices. The sensors operate between 4.0Vdc and 30Vdc, however, there are a number of scenarios that will cause the Turbine and Oval Gear fl ow meters to fail, even though the installer believes the fl ow device has been installed correctly.
If a fl ow sensor fails, it may be for one of the following reasons:
• Incorrect Wiring: Care must be taken when wiring the sensor power supply and pulse output of the fl owmeter. The sensor is unable to cope with incorrect wiring - reverse polarity or short circuiting can cause the sensor to fail suddenly, completely and permanently.
• Unregulated Power Supply: Exceeding the maximum 30Vdc to the Hall Effect sensor will damage the unit. A good quality regulated DC power supply is recommended for powering a pulse fl ow meter.
• Electrical Interference / Voltage Spikes: Other connected equipment containing inductors (coils), or electromagnetic components (such as solenoid valves or pumps) can produce high voltage spikes when switching. These spikes can be a hundred to thousands of volts and if on the same circuit, will damage the fl owmeter sensor beyond repair.
Electrical interference can also occur even without a direct connection if cabling is routed close to high-power equipment.
A failure mode that is commonly seen, is where a simple solenoid valve is operated on the same power supply as the fl owmeter. When the solenoid de-energises in 1ms it produces a spike of 100s of Volts. Some of this voltage spike feeds through to the sensor, momentarily exceeding the 30Vdc maximum of the sensor causing it to fail.
What can be done to prevent catastrophic failures in fl ow measuring systems?
Neil Hannay, Senior R&D Engineer with Titan Enterprises observes: “The majority of damage tends to be caused during the installation of the fl owmeter. Minor errors can result in a non-operational meter before the customer has even started, leading to costly repairs or replacements, as well as process downtime, that can be avoided.”
Titan Enterprises manufacture over 70,000 fl owmeters each year that are used in a wide variety of industries, processes and applications, so troubleshooting for customers is not uncommon, particularly for those who are unfamiliar with Titan’s fl ow metering products.
Neil says: “Titan provides written data and instruction sheets with all our fl ow meters, and we have also published some installation tutorial videos to help our customers and prevent any mis-wiring that can damage the units.”
Next-generation electrochemical
“We’re thrilled to be launching this exciting new product upgrade which provides our customers with a smart and reliable sensor” commented Kenny Petrie, Sentek’s founder and Technical Director. “At our core, we constantly strive to provide our customers with exceptional quality at a reasonable price, and the features of this new design achieves just that.”
Whether used for testing biological samples in a lab, monitoring pH in a brewery, or the measurement of soil conductivity, the electrodes, and their striking cap design, brought the dependable experience, that Sentek customers have become accustomed, to an incredible price point. This has always been the purpose of Sentek’s electrodes, and now the product is getting even better.
Along with free technical support for the life of the probe, the upgrade delivers zero solution leakage on re-fi llable electrodes, by applying years of hands-on experience. The new electrodes offer durability and easier maintenance using robust, easy-to-clean ABS material and electrode information and specifi cation are conveniently displayed on the electrode stem of key sensors.
These new electrodes will go into production later this year but are available already for pre- ordering. The new design will be applied to the Sentek branded range of electrodes and will improve the usability of this essential testing equipment signifi cantly.
More information online:
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sensors to be launched later this year Sentek has developed an innovative new design for their highly acclaimed range of electrodes that features zero leakage, fi ll stopper technology and sensor information displayed clearly on the stem, in an all-new, streamlined cap design, whilst maintaining the same, affordable price..
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The following installation checklist will go a long way to preventing common causes of pulse fl ow meter sensor failure:
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MACHEREY-NAGEL GmbH & Co. KG Valencienner Str. 11 52355 Düren, Germany Office phone +49 24 21 969-0
Office Fax +49 24 21 969-199 E-Mail:
sales@mn-net.com
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