Flowmeters are essential for accurate measurement in industrial processes, but like all equipment, their performance can degrade over time. Recognising common issues—and applying practical solutions—ensures measurement reliability and process efficiency.
1. Flowmeter Inaccuracy
Problem: Wear, calibration drift, or changing fluid properties reduce accuracy.
Solution: Conduct calibration and maintenance regularly to manufacturer and industry standards. Always account for temperature, pressure, and fluid characteristics.
2. Blockages and Clogs
Problem: Debris or contaminants obstruct meter components, producing faulty readings.
Solution: Install upstream filters or strainers, and clean components routinely.
3. Pipe Vibrations and Pulsations
Problem: Vibrations or pressure fluctuations distort signals.
Solution: Fit pipe supports and dampeners. Use flow conditioners or straightening vanes to achieve stable flow profiles.
4. Air Bubbles and Entrained Gas
Problem: Gas pockets disrupt measurement, particularly in liquids.
Solution: Install degassing units or air eliminators and ensure correct meter positioning to limit air entry.
5. Calibration Drift
Problem: Measurement accuracy drifts gradually over time.
Solution: Recalibrate periodically, especially after process changes. Keep full calibration records.
6. Electromagnetic or Radiofrequency Interference (EMI/RFI)
Problem: External electrical signals interfere with flowmeter operation.
Solution: Shield cabling, ground correctly, and use meters with EMC compliance.
7. Sensor or Component Failures
Problem: Sensor or component breakdown causes erratic readings or failure.
Solution: Inspect on schedule and keep spare parts ready for rapid replacement.
8. Environmental Conditions
Problem: Extreme heat, humidity, or corrosive atmospheres degrade performance.
Solution: Use meters designed for the environment, with protective housings or coatings where necessary.
9. Improper Installation
Problem: Incorrect orientation or inadequate straight pipe lengths compromise readings.
Solution: Follow manufacturer guidelines closely to ensure accurate installation.
10. Power Supply Issues
Problem: Inadequate or unstable supply leads to unstable behaviour.
Solution: Provide reliable, stabilised power with surge protection as required.
A structured, proactive approach—covering installation, calibration, maintenance, and environmental protection—ensures consistent accuracy, reduces downtime, and extends equipment life.