Titan Enterprises shares key insights to help engineers and operators navigate the challenges of precision flow metering to ensure accurate measurements and safe process operations.

Metering liquids under pressure may seem straightforward at first glance – install a flowmeter in the product line, connect it to an instrument, control the measurement with on-board software, wire in a valve and pump, and switch the flow system on. However, real-world applications reveal a host of complexities that must be addressed to achieve precise and repeatable results.

Where hydraulic systems are concerned, flowmeters play a critical role in maintaining system integrity and effectiveness. Sustaining consistent process conditions, however, can be challenging. Hydraulic systems rely on the precise movement of fluid to transmit power; any deviation from the required flow rate can lead to performance issues, excessive wear, or system failure.

Ideally, hydraulic system designs should aim to minimise as many variables as possible within a reasonable cost. Once this foundation is established, equipment such as flow meters, pumps and valves can be selected to effectively compensate for any parameter variations.

Flowmeters are designed to measure the rate and/or volume of fluid flowing through a hydraulic system via a variety of outputs, from a simple mechanical display to full data logging, providing real-time data on the rate of fluid movement, monitoring system health, detecting leaks or blockages, and optimising performance. Accurate flow measurement is also crucial for maintaining consistent pressure and ensuring that actuators and other components receive the correct volume of fluid.

Hydraulic fluids are typically viscous oils, petroleum or synthetic-based, utilised for their stability at operating temperature and lubricating properties.

Critical considerations for hydraulic fluid systems

1. System repeatability:

Hydraulic stability is essential. Air pockets in the line can lead to dynamic flow situations, causing volumetric errors in delivery. Ensuring a hydraulically locked system eliminates such variability and enhances repeatability.

2. Stable process conditions:

Changes in pressure, temperature, or flow rate can push flowmeters into unpredictable operational zones, affecting calibration and accuracy. Maintaining consistent conditions is vital for reliable performance.

3. Pulsating flow management:

Pulsation from certain pumps can disrupt flow rates, especially in aggressive chemical applications. Pressure regulators and pulsation dampers should be incorporated into flow systems to achieve a smooth and constant flow.

4. Strategic placement of flowmeters:

Positioning the flowmeter just before the dispense valve minimises fluid inertia and improves measurement accuracy.

5. Understanding the impact of viscosity on flowmeter accuracy:

Selection of any flow measurement device should always consider the fluid viscosity as turbine meters typically loose accuracy and performance as the fluid viscosity increases; whereas the performance, accuracy and range of positive displacement flowmeters increases with viscosity.

6. Valve selection and calibration:

Fast-acting solenoids are ideal for smaller pipelines, while larger setups benefit from solutions like multi-stage shut-off systems or “automatic overrun compensation” programming to fine-tune results.

7. Optimising electronic flowmeters:

High-performance meters (such as Titan’s ultrasonic Atrato® flowmeter) can predict stop signals in advance, ensuring consistent delivery even at high speeds.

Enhancing process efficiency

Hydraulic systems, particularly in the aerospace industry, are operating at increasingly higher pressures, making the selection of an appropriate flowmeter becomes even more critical. These flowmeters must not only provide accurate measurements but also be capable of withstanding pressures beyond the system’s maximum operating levels, incorporating a suitable safety factor to ensure long-term reliability and safety.

By accounting for these factors during system design and commissioning and investing in the appropriate flow measurement technology that suits the application requirements, engineers can eliminate common pitfalls in liquid metering and ensure the liquid flow system performs with precision and consistency. For more information, visit Titan’s website.

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