Metering pumps are a common solution for consistent flow rates across various industries. However, they are not a panacea. Organisations must take additional measures to maintain high metering pump accuracy. By Emily Newton, www.revolutionized.com
Why metering pump accuracy matters
It’s all too easy to assume metering pumps are a complete solution in and of themselves. While they do deliver consistent flow rates by design, no pump mechanism alone is enough to stay exact over time. Too many variables can affect their accuracy, from temperature fluctuations to wear and tear.
Metering pumps’ variability may be subtle, but even small changes can lead to significant concerns in sensitive industries. In the pharmaceutical sector, flow rate inconsistencies could produce varying concentrations of liquid medicines. Failing to catch such defects could qualify as an inspection deficiency, leading regulators to revoke or suspend licenses in some cases.
In other scenarios, variable flow rates may affect product quality, disrupt automated workflows or require scrap and rework. All of these outcomes can be expensive and time-consuming. Catching potential flow issues earlier in the process is far more cost effective. Consequently, businesses must go beyond simply installing a metering pump.
How to improve metering pump accuracy
Because many variables can affect metering pump accuracy, there are also multiple ways to address this problem. Here are some key steps and solutions to prevent such inconsistencies.
Choose the right kind of pump
Optimal accuracy begins with pump selection. The term “metering pump” covers a wide range of mechanisms and technologies. Organisations must find the ideal type for their specific workflow to ensure relevant consistency standards.
Diaphragm pumps are often preferable to plunger alternatives as they are less likely to break down and more leak-resistant. However, their output can briefly change from uneven pulsation. Using two or more diaphragms alleviates the issue and improves efficiency, but additional monitoring is still essential.
Operations with higher throughput needs or extreme pressures should consider gear pumps. These designs are less prone to inconsistency from pulsation, so they deliver more repeatability. At the same time, they have several moving parts, making maintenance a larger concern. Businesses must determine which factors matter most to them and review their budgets and experience levels to find the optimal solution.
Use IoT flowmeters
After choosing the right pump type, businesses must install a flow meter. Like the pumping mechanism itself, these can vary, with the ideal fit depending on process specifics. Across all options, though, organisations should consider Internet of Things (IoT) connectivity.
Flowmeters are often simple, passive devices, which is beneficial for energy consumption and maintenance. At the same time, having to inspect and interpret a gauge manually is time-consuming and introduces considerable room for error. An IoT-connected sensor may be more complex, but it can provide remote readings to reduce travel time and automatically alert technicians when conditions fall outside acceptable limits.
Many facilities already use such devices, as evidenced by the more than 26 million industrial IoT connections in the U.K. Those that have yet to embrace this technology must provide sufficient IT infrastructure first. Most importantly, they must have the power and network capacity to host multiple connected devices.
Calibrate flowmeters
Once organisations implement flowmeters, they must calibrate them according to their needs. Every business has unique levels of acceptable variability, so teams must determine their specific ranges to know what constitutes inaccuracy in their workflows.
Similarly, facilities can improve metering pump accuracy by selecting the right metrics to track. Most flow meters measure a liquid’s velocity to determine its flow rate, but temperature, viscosity and pressure can also play a part. Highly sensitive operations may need to track more of these factors, requiring calibration and benchmarking for each one.
Businesses should also consider their needs in terms of the actual meter readings. Displaying flow measurements as an expression of volume is preferable if changes in density are a prominent concern. In most cases, though, mass is a more helpful metric, as it’s less sensitive to errors from viscosity changes.
Implement predictive maintenance
Pumping systems can only sustain consistent accuracy if the pump and any measuring tools remain in good condition. Consequently, a preventive maintenance plan is crucial. Going a step beyond and implementing predictive maintenance (PdM) is even more beneficial.
PdM uses IoT sensors to detect system health issues before they’re evident to the human eye. The devices then alert technicians to repair the pump or meter while the problem is relatively small. As a result, companies both prevent breakdowns and minimise planned downtime by only maintaining equipment when necessary.
Some organisations have increased machine availability by 99% and reduced costs by 30% by implementing PdM. Savings aside, such improvements extend the life span of a metering pump and its monitoring tools. Businesses have greater assurance in their machinery’s accuracy over time as a result.
Address complementary systems
Metering pump accuracy is also a matter of the surrounding components. An optimisation strategy that focuses only on the pumping mechanism itself is incomplete. It must also calibrate and monitor the condition of any motors, pipes and valves within the system.
Leaks are among the most common issues, as a drop in air pressure or loss of fluid can stem from multiple areas. Flow meters may also be unable to detect these issues if they happen further down the pipe, away from the pump. Additional meters and IoT-connected leak detectors are the most effective solution.
Organisations should also right-size their motors to the task at hand. Fixed speed options are affordable and easy to maintain, but they may fail to account for other fluctuations, making them unreliable for high-sensitivity applications. By contrast, variable speed drives are more efficient and will prevent more irregularities but may require additional maintenance.
High metering pump accuracy drives overall improvements
Companies in industries from pharmaceuticals to water to manufacturing require consistent liquid flows. Consequently, they all need to ensure metering pump accuracy. While that may seem challenging initially, taking the time to meet higher standards will produce a ripple effect of benefits.
More consistent metering pump performance will minimise downstream issues and streamline quality assurance. Overall efficiency and regulatory compliance become easier to manage as a result.
