Maintenance Guides 1 min read

Flowmeter Troubleshooting Guide: Installation, Process Changes, De-Calibration, and Coverage

Technical analysis: Troubleshooting flow meter measurement errors: installation effects, process condition changes, cali

Гід по виправленню помилок вимірювального потокоміра: встановлення, зміни процесу, відхід від калібрування та покриття - UNITEC-D Industrial MRO
Цей гід присвячений виправленню помилок вимірювального потокоміра, виникаючих через неправильне встановлення, зміни у процесі, відхід від калібрування та покриття або забруднення. Використовується сис

1. Problem description and scope

This material is dedicated to correcting flow meter errors caused by improper installation, process changes, deviation from calibration, and coating or contamination. Measurement errors can affect data accuracy, production efficiency, and cost-effectiveness of operations. These problems can occur in various types of equipment, including pumps, piping, and cooling systems. Impact classification: critical (stop production), major (reduced productivity) or minor (minor deviation).

2. Organizational activities

Use of personal protective equipment (PPE): when working with flowmeters installed in high-pressure or high-temperature systems, it is necessary to use special protective clothing, gloves and glasses.
Ensure locking and tagging of energy: before performing any actions with the flow meter, it is necessary to ensure that it is locked and tagged.
Requirements for working with chemical liquids: if the flowmeter is installed in a system that tests highly aggressive liquids, it is necessary to perform an analysis for compliance with standards and use special protective equipment.

3. Necessary tools for diagnosis

The name of the tool Model Measuring range Purpose
Multimeter Fluke 87V 200 MΩ, 2000 V Measurement of electrical resistance, voltage, current
Thermal camera Fluke TiS10 -50°С to 550°С Detection of uneven temperature distributions
Vibration analyzer Keysight 2000X 0–20,000 Hz Detection of vibrational deviations
Manometer Testo 510 0–100 bar Pressure measurement

4. Check before diagnosis

Check Description
Current conditions Record temperature, pressure, flow rate, and environmental conditions
New changes Check if changes have been made to the system (eg fluid change, pressure change, temperature change)
A history of anxiety Record alarms caused by the flowmeter in the past tense

5. Systematic diagram of diagnostics

  1. Symptom: The flow meter displays incorrect values.
    1. Diagnosis: Check whether there are deviations in the measurements.
      1. If there is no deviation: Check if the flow meter is installed in the correct position.
      2. If the deviation is present: Check if there are changes in the process (temperature, pressure, liquid).</n
    2. Diagnosis: Check the electrical connection.
      1. If there is no connection: Establish a connection and check the stability of the signal.</n
      2. If the connection is present: Check the calibration of the flowmeter.

6. Matrix of causes of deviations

Symptom Reasons (by probability) Diagnostic testing Expected result
Invalid values
  1. Incorrect installation (90%)
  2. Changes in the process (75%)
  3. Departure from calibration (60%)
  4. Coating or contamination (40%)
  1. Check installation
  2. Check process parameters
  3. Check calibration
  4. Check the condition of the sensor
  1. The installation must be correct
  2. The process parameters must not change
  3. Calibration must be appropriate
  4. The sensor must be clean

7. Analysis of the reasons for each deviation

7.1 Incorrect installation

Incorrect installation of the flowmeter can lead to deviation of measurements. This is caused by incorrect installation angle, incorrect position or lack of flow opening. To confirm this reason, you need to check the position of the flow meter, the opening of the flow and the distance to the means of measurement.

7.2 Changes in process

Changes in temperature, pressure, or fluid can affect the accuracy of measurements. This may be due to the use of liquids that have high humidity, aggressiveness or high temperature. To confirm this reason, you need to check the process parameters and compare them with the established norms.

7.3 Departure from calibration

Deviation from calibration occurs due to sensor wear, environmental exposure, or improper storage. To confirm this cause, you need to check sensor calibration, storage and exposure to the environment.

7.4 Coating or Contamination

Covering or contamination of the sensor can lead to measurement deviations. This is caused by the accumulation of liquids, humidity or chemicals. To confirm this reason, you need to check the condition of the sensor and measure compliance with the established criteria.

8. Step by step repair procedure

8.1 Correcting incorrect installation

  1. Check the installation angle of the flow meter.
  2. Check if the thread is open.
  3. Set the flow meter in the correct position.
  4. Check the distance to the measuring devices.
  5. Check measurements after installation.

8.2 Correction of Process Changes

  1. Check temperature, pressure and fluid.
  2. Compare with established standards.
  3. Make changes to process parameters.
  4. Check measurements after changes.

8.3 Correction of deviation from calibration

  1. Check sensor calibration.
  2. Make changes to the calibration.
  3. Check storage and environmental exposure.
  4. Check measurements after changes.

8.4 Correcting Coating or Contamination

  1. Check the condition of the sensor.
  2. Clean the sensor from liquids, moisture or chemicals.
  3. Check measurements after cleaning.

9. Prevention methods

The reason Preventive strategy Control method Recommended interval
Incorrect installation Regular inspection of the installation Use of calibration tools monthly
Changes in process Regular checking of process parameters Use of monitoring systems Sunday
Departure from calibration Regular sensor calibration Use of calibration tools monthly
Coating or contamination Regular cleaning of the sensor Use of cleaning agents monthly

10. Spare parts and components

Component description Specification When to replace UNITEC-D category
Flow meter sensor Material: stainless steel, range: 0–1000 l/min After 1000 hours of operation or when deviations are detected 3450
connection Material: stainless steel, range: 0–100 bar After 1000 hours of operation or when deviations are detected 3450
Electrical contacts Material: copper, range: 0-1000 mA After 1000 hours of operation or when deviations are detected 3450
Protective plate Material: stainless steel, range: 0–100 bar After 1000 hours of operation or when deviations are detected 3450

Please refer to our e-catalog for detailed component information: https://www.unitecd.com/e-catalog/

11. List of sources

  • DSTU 2318:1999 – Requirements for measuring equipment
  • EN 1434-1:2003 – Standards for measuring flow meter
  • ISO 5167:2003 – Measurement of liquid flow
  • CE and UkrSEPRO certification
  • Original manufacturer's instructions
  • UNITEC-D profile guides

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