Blog posts tagged with 'industrial'

Air-operated double diaphragm (AODD) pumps are highly versatile, reliable devices widely used across various industries for handling viscous, abrasive, and shear-sensitive fluids. Powered by compressed air, these pumps use two diaphragms in a reciprocating motion to transfer liquid. With no need for electricity, these pumps offer a versatile option for hazardous and demanding environments.

AODDs: Basic Parts and Operation

1. Diaphragms: Located on either side of the pump, the diaphragms are flexible membranes typically made of materials like PTFE or rubber. 
2. Air Chamber: The air chamber (also known as the air valve chamber) is where compressed air is introduced to alternate between the two diaphragms. 
3. Inlet and Outlet Manifolds: The inlet manifold allows the fluid to enter the pump chamber, while the outlet manifold directs the fluid out of the pump after it has been moved by the diaphragms. 
4. Check Valves: Each diaphragm chamber has two check valves, one at the inlet and one at the outlet. These valves are responsible for directing fluid flow in a single direction. Typically a ball and seat style check valve.  
5. Valve Assembly (Air Valve): The air valve assembly, typically located in the center section of the pump, controls the distribution of compressed air to the diaphragms. 
6. Fluid Chambers: Fluid chambers are located on either side of the diaphragms. 
7. Exhaust Port: As compressed air pushes one diaphragm, the air on the opposite side is expelled through the exhaust port. This port vents the air used to move the diaphragms, and in some applications, exhaust air is collected or muffled to reduce noise.
8. Center Section: This is the core of the pump, housing the air valve and the air distribution system. 

 

 

How These Parts Work Together

When the pump starts, compressed air is directed into the air chamber behind one of the diaphragms, causing it to push outward and transfer fluid out through the outlet manifold. Simultaneously, the opposite diaphragm is pulled inward, creating suction in its fluid chamber, drawing in new fluid through the inlet manifold. The air valve then alternates the air supply to the other diaphragm, repeating the process. This alternating motion allows AODD pumps to handle viscous, abrasive, and shear-sensitive materials efficiently and reliably.

 

 

This design makes AODD pumps ideal for industries where the safe handling of various fluid types—especially in explosive or corrosive environments—is essential. 

 

Advantages of an AODD Pump

1. Corrosion Resistance

Advantage: Built with materials like PTFE, Viton, and Santoprene, AODD pumps can handle a wide variety of fluids, including those that are abrasive, viscous, corrosive, or contain solids.

Benefit: This versatility allows them to be used in many different industries and applications, from chemical processing to food and beverage production.

2. Self-Priming Capability

Advantage: AODD pumps are self-priming, meaning they can start pumping without needing to be filled with fluid first.

Benefit: This makes them ideal for applications where the fluid source is below the pump or where frequent starts and stops are required.

3. Ability to Run Dry

Advantage: AODD pumps can run dry without damage, unlike many other pump types. This means operating the pump without fluid moving through it.

Benefit: This is valuable in situations where the fluid supply may be inconsistent or may be interrupted. For example, you could use an AODD to pump out the contents of a barrel without needing to monitor the liquid level and shut off the pump immediately when the barrel is emptied to avoid damage to the pump. 

It should be noted that although an AODD pump can run dry, prolonged operation with no fluid can be hard on the diaphragms and other components. 

4. Safety 

Advantage: While not all AODD pumps are inherently explosion-proof, they are powered by compressed air and don’t require electricity, eliminating the risk of sparks.

Benefit: This generally makes them safe for use in hazardous environments where flammable or explosive materials are present, such as in the oil and gas industry. Always be sure to check that your pump and pump materials are compatible and designed for your application and environment.

5. Gentle Pumping Action

Advantage: The reciprocating diaphragm movement in AODD pumps produces a gentle, low-shear pumping action compared to other pump types. 

Benefit: This makes AODD pumps preferable for handling shear-sensitive fluids, such as emulsions, suspensions, and biological materials, without damaging them.

6. Easy Maintenance

Advantage: AODD pumps have relatively simple designs with few moving parts, making them easy to maintain and repair.

Benefit: Maintenance can typically be performed on-site without the need for specialized tools, reducing downtime.

7. Pumping of Solids and Slurries

Advantage: AODD pumps can easily handle fluids containing solids or slurries without clogging.

Benefit: This capability is crucial in industries like wastewater treatment, mining, and construction, where the fluid being pumped often contains particles or debris.

8. Simple Control

Advantage: The flow rate of AODD pumps can be easily adjusted by regulating the inlet air pressure without the need for complex controls.

Benefit: Common air regulators are all that is required to adjust the pump. A simple ball valve can be used to turn the pump on and off.

9. Suction Lift Capability

Advantage: AODD pumps can achieve significant suction lift (30 feet or more!), making them capable of drawing fluid from deep or difficult-to-access locations.

Benefit: This makes them useful in situations where the fluid source is located below the pump, such as in sump pits or underground storage tanks.

 

Specific AODD Pump Applications Across Industries

The unique design of AODD pumps allows them to fit into several different applications. Let’s examine some specific scenarios where an AODD pump can excel while other transfer pumps fall short.

Safe Transfer of Corrosive and Hazardous Fluids

In the chemical industry, AODD pumps are essential for safely transferring corrosive and hazardous substances. Their seal-less design significantly reduces the risk of leaks, enabling secure handling of acids, solvents, and aggressive chemicals.

Specific applications: AODD pumps with poly body and Teflon diaphragms can be used to pump high concentrations of phosphoric acid and Kynar body pumps with Teflon diaphragms can handle sulfuric acid. 

AODD Pumps in Food and Beverage Production

AODD pumps are widely utilized in the food and beverage sector to handle products like sauces, syrups, and beverages. Their mild pumping action preserves the quality and consistency of materials that can change in viscosity when agitated or stirred (creams, sauces, condiments, etc.).

Specific applications: There are also AODD pumps designed for handling large solids and slurries associated with the meat and poultry processing industries. These pumps are sanitary pumps designed for quick and easy cleaning. Typically featuring high-grade stainless-steel bodies.

Mining and Construction: Heavy-Duty AODD Pumps for Slurry and Dewatering

Mining and construction industries present unique and rugged applications. The need for dewatering dirty water and sludge where the contents and solids sizes are often varied and unpredictable. The right AODD pump can withstand tough environments. They are also portable and can run dry without damage, making them a reliable choice in these demanding fields.

Specific Application: Warren Rupp offers durable pumps with metal bodies (aluminum, cast iron, stainless). The Sandpiper Beast is a tough, clog-resistant pump designed to move fluids with debris up to 2 inches in diameter.

Petroleum Industry

In the oil and gas industry, AODD pumps move crude oil, gasoline, diesel, and other petroleum fluids. The pumps’ lack of electrical components provides explosion-proof safety, making them ideal for hazardous environments. 

AODDs are ideal for handling oils and hydraulic fluids of various weights making them a versatile option for fleet maintenance. 

Specific Applications: The Zeeline NS1040UL is a UL-rated AODD that will safely pump gasoline and diesel fuels up to 37 gallons per minute. 

AODD pumps also work excellent for handling waste oil. 

Car and Fleet Wash

Transferring different soaps, detergents, wax, and sealers requires a pump that can move the fluid without resulting in foaming. It also must handle a wide range of different chemical combinations and viscosities.  

Specific applications: This Yamada poly pump is versatile and has wide chemical compatibility for soaps, detergents, and other cleaning products. 

 

 

What Materials are AODD Pumps Made From?

AODD pumps are constructed from a variety of different materials. Different materials are used for the main components: the housing, check valve balls, seats, and diaphragms. 

The housing (or body) of an AODD pump consists of the fluid chambers and inlet/outlet manifolds. Common materials include:

• Aluminum: Lightweight and suitable for oils, coolants, and certain solvents but may corrode with acidic or abrasive fluids.
• Stainless Steel: Durable and resistant to corrosion, making it ideal for food, beverage, pharmaceutical, and certain chemical applications.
• Polypropylene: A cost-effective, lightweight plastic that resists a wide range of chemicals. 
• Kynar (PVDF): A chemically resistant plastic with excellent durability, often chosen for aggressive chemicals like acids and solvents.
• Cast Iron: Highly durable but susceptible to corrosion with certain chemicals. They are commonly used for demanding applications in construction and mining. 

The check valve balls are in direct contact with the fluid and must be resistant to the medium you are pumping. Common materials include:

• Santoprene: A thermoplastic elastomer with good chemical resistance, typically used for water-based fluids and certain chemicals.
• PTFE (Teflon): Highly resistant to chemicals, suitable for aggressive solvents, acids, and high-temperature applications.
• Nitrile (Buna-N): Good for petroleum and certain chemicals but less resistant to extreme temperatures.
• Viton: Excellent for high-temperature and a variety of chemical applications.

Seats create the sealing surface for the balls, and their material affects the pump’s fluid compatibility. Common seat materials:

• Polypropylene
• Stainless Steel
• Santoprene and Buna-N

Diaphragms are crucial in AODD pumps, as they directly handle fluid and pressure. The choice of diaphragm material influences chemical resistance, flexibility, and temperature tolerance.

• Santoprene: A flexible, durable option for a range of chemicals, commonly used in general applications.
• PTFE (Teflon): Excellent chemical resistance, suitable for aggressive fluids, and has a longer lifespan in abrasive applications. 
• Buna-N (Nitrile): Good for petroleum-based fluids and general applications but limited by lower chemical and temperature resistance.
• Hytrel: A thermoplastic polyester with good chemical resistance, flexibility, and durability for various industrial fluids.

 

AODD Pump Limitations

The AODD family is very versatile and offers unique benefits but there are some limitations:

Requires Continuous Air Supply

AODD pumps need a reliable, continuous supply of compressed air to function. In remote locations or applications where compressed air is not readily available, additional equipment (like air compressors) may be needed, adding to setup costs.

Efficiency and Air Consumption

AODD pumps rely on compressed air to operate, which can lead to high air consumption, especially when running at high flow rates or under heavy loads. This can increase operating costs.

Compared to other types of pumps (like centrifugal pumps), AODD pumps typically have lower energy efficiency. This can be a drawback in applications where energy efficiency is a primary concern.

If energy efficiency is a priority, Graco offers electric motor-driven double diaphragm pumps. This provides you with the benefits of an AODD with significantly lower (up to 80%) operating costs. 

Pulsing

The “back and forth” nature of the pumping operation can result in a pulsating flow. This can be mitigated with pulsation dampeners, but it may still not be ideal for applications requiring a steady, continuous flow.

Pressure

An Air-Operated Double Diaphragm (AODD) pump typically operates at a maximum pressure of around 100 psi, although certain specialty models can handle higher pressures. These pumps are generally not suitable for high-pressure applications that exceed their design limits. Most AODD pumps have a 1:1 pressure ratio, meaning the liquid discharge pressure matches the air inlet pressure. For example, if the air supply is set to 50 psi, the pump will produce a liquid discharge pressure of approximately 50 psi.

 

Ready to Choose the Right AODD Pump?

Explore our selection of Air-Operated Double Diaphragm (AODD) Pumps, tailored for a wide range of applications. Our team is ready to assist you in finding the perfect pump for your industry’s needs.

MP Pumps has been manufacturing quality centrifugal pumps for more than 80 years. Over this time, they have developed and improved upon their designs to offer reliable and affordable fluid-handling options for a variety of industries and applications.

There is almost certainly an MP pump that will work for you, but sorting through the various types can be tough. As a master MP Pumps distributor, Dultmeier Sales can help you pinpoint the right one. Here's a detailed look at the different MP Pumps available, their common uses, and the advantages and disadvantages of each type.

 

MP Pumps Company Overview

MP Pumps has been around since 1942, proudly crafting high-quality centrifugal pumps from their home base in Fraser, Michigan. They've got a pump for just about everything from making sure your fertilizer and ag chemical system runs without a hitch to keeping industrial processes flowing smoothly, to moving petroleum products efficiently.

 

MP Pumps Company Info:

• Founding: 1942
• Location: Fraser, Michigan.
• Phone Number: (800) 563-8006
• Parent Company: Ingersoll Rand
• Website: MP Pumps

 

Industries Covered:

• Agriculture
• Fuel
• Transportation
• Irrigation
• Marine
• Industrial

 

MP Pump Types

MP Pumps has an extensive product line. They manufacture self-priming pumps, straight centrifugal pumps, chemical pumps, circulator pumps, petroleum pumps, and more.

Dultmeier Sales can supply just about any MP pump but we focus primarily on the ag, industrial, and petroleum pumps. These industries rely on the MP Flomax, Chemflo, and Petrolmaxx lines. One of the most common is the Flomax self-priming pump series, so let's start there.

 

MP Flomax

Description: These are self-priming centrifugal pumps. Available in materials like cast iron and stainless steel. Versatile, and capable of handling a wide variety of fluids. Many parts are interchangeable with other Flomax models.

 

Common Uses: The MP Flomax pump can be implemented in countless situations. Dultmeier Sales has been selling the Flomax series pump for use in agriculture for several years. Specifically, nurse trailer and sprayer tender truck transfer pumps, as well as fertilizer and agrochemical bulk plant pumps. They are excellent at handling water, agrochemicals, and fertilizer but they can be used with other liquids as well.

 

Key Features:

• Capable of flows up to 750 GPM.
• Handles pressures up to 230 head feet.
• Stainless steel shaft sleeve for durability and corrosion resistance.
• Self-Priming
• Viton seals standard
• Removable bolt-on FNPT flanges means your piping remains in place when servicing the pump
• Wear plate can be replaced to extend the life of the pump
• Suction check-valve holds liquid, protecting the pump seal when it re-primes

Find Flomax Pumps Ready to Ship Today!

 

Flomax Pump Options

When it comes to connecting the pump to an engine or motor, MP offers the Flomax pump in two basic configurations. The pedestal version and the PumpPak version.

 

Pedestal: A pedestal pump is designed to be long-coupled to motors, or other drives. It features a bearing pedestal and solid shaft.

 

 

PumpPAK: This version of the Flomax pump is designed to be mounted directly to an engine or motor. There are versions to mount on gas-enines, hydraulic motors, and C-face electric motors.

 

 

Flomax Pump Sizes

Flow rate is always key for any pump type. There are Flomax pumps made to deliver up to 750 GPM:

• Flomax 5 - 1-1/2 inch ports, Up to 145 GPM
• Flomax 8 - 2 inch ports, Up to 170 GPM
• Flomax 10 - 2 inch ports, Up to 225 GPM
• Flomax 15 - 3 inch ports, Up to 320 GPM
• Flomax 30 - 3 inch ports, Up to 500 GPM
• Flomax 40 - 4 inch ports, Up to 750 GPM

Find Flomax Pumps Ready to Ship Today!

 

Materials

The Flomax line is available in several materials. Pumps constructed with cast iron housings and impellers, stainless shafts, and Viton seals are most common. All stainless pumps are available for more corrosive applications.

 

Pump Drives

An MP Flomax pump can be driven a number of ways. Whether you require an electric motor, engine, or hydraulic motor. The pedestal pump version can be assembled on a baseplate with motor and long-coupled together. The PumpPak version can be mated directly or close-coupled to C-face electric motors or gas engines.

Various shaft sleeve sizes and bolt patterns are available so you can easily connect an MP pump to almost any C-face motor or gas engine.

If you would like a more detailed explanation of close-coupled and long-coupled pump units, be sure to read this guide to the best fertilizer pump options.

 

Chemflo Series

Description: Some liquids are more harsh on pumps than others. The MP Chemflo stainless steel pump family is built to withstand more severe applications and corrosive liquids. There are several different variations within this family to be compatible with different types of liquids.

Common Uses: Agricultural chemical mixing, fertilizer transfer, water treatment, de-icing liquids, and other industrial fluid transfer.

Key Features:

• Corrosion-resistant 316 stainless wetted components
• Suitable for a wide range of chemicals
• Available in a variety of sizes

 

MP Chemflo Pump Options

The Chemflo pump family is made up of more than 30 unique models. These different models are designed to be used in many different applications. They vary in flowrate, drive type, port size (flanged & NPT), etc.

 

Sizes

Chemflo pumps come in very low to high-flow options. Their CFX pumps have 1/2 to 1-inch ports with flow rates ranging from 10-40 GPM. The larger versions are available with 1-1/2 up to 3-inch ports and these pumps will provide maximum flow rates of 150-395 GPM.

 

Materials

One of the primary features of this pump series is the cast 316 stainless steel components used to construct the pump. While stainless is not an answer for 100% of liquids, it does offer resistance to the effects of a much wider range of liquids when compared to cast iron.

While the housing, impeller, and other components are made from stainless steel, the mechanical seal is available with a variety of options including Viton, EPDM, and Teflon. You can always refer to our chemical compatibility charts to evaluate which materials and elastomers will be compatible with the liquid you need to pump.

 

Drive Options

Like other MP pumps, the Chemflo series comes in a variety of setups included long-coupled pump and motor units, close-coupled pump and motor units, and hydraulic-driven units.

For more details and an explanation of close-coupled and long-coupled pump units, be sure to read this guide to the best fertilizer pump options.

 

PetrolMaxx Series

Description: Pumping fuels in high-volume applications requires the right type of pump for efficiency, compatibility, and safety. MP's PetrolMaxx series is a self-priming pump similar in design to the Flomax family but constructed with materials compatible with fuels. There are variations to ensure compatibility with diesel, biodiesel, gasoline, E85, and more.

Common Uses: High-volume fuel transfer. Loading and unloading bulk fuel trailers and trucks. Filling large equipment for construction and agriculture.

Key Features:

• Self-priming
• Available to mate directly to engines/motors or with a bearing pedestal for long coupling
• Flow rates of 150-700 GPM
• Options for Ethanol, Biodiesel, Gasoline, Diesel, and More

 

MP PetrolMaxx Options

For safety and compatibility, it's crucial to use the right pump for each type of fuel. That's why MP has created a variety of pump models designed specifically for different fuels. Each model is built with materials that match the unique properties of the fuel it's meant to handle, ensuring safe and reliable operation.

One of the most popular versions is made to handle diesel. Dultmeier sells hundreds of two-inch PetrolMaxx pumps driven by gas-engines for high-volume diesel fuel transfer. These pump units help fill equipment much faster than the common 12-volt fuel pumps. You can get flow rates well over 100 GPM with the right size hose and fuel filters.

 

MP Petroleum Pump Sizes

• 1-1/2 Inch
• 2 x 2 Inch
• 3 x 3 Inch
• 4 x 3 Inch
• 4 x 4 Inch

See More MP PetrolMaxx Pump Options Here

 

Materials

As mentioned earlier, the PetrolMaxx family of pumps consists of several pumps fitted for specific fuels. The materials used include: steel, aluminum, cast iron, ductile iron, nitrile, 316 SS, Viton, Ni-resist, and more.

 

Drive Options

You can fit a PetrolMaxx pump to a gas-engine, electric motor, or hydraulic motor. It is important to note that some fuel types may require the use of an explosion-proof motor or gas-engine.

Dultmeier sales builds pump units on baseplates for easy installation. The units are available close coupled to electric motors or engines, and long coupled to electric motors. There is also a complete fuel unit with a hose reel, pump, fuel filters, fuel nozzle, and base plate.

 

View All Pump & Engine Units

View Pump & Electric Motor Units

 

Final Thoughts

MP Pumps has been a reliable supplier for years offering a wide range of pump solutions. Dultmeier sales has relied on MP as a competitively priced and durable pump for the rigors of the primary industries we have served. Including the fertilizer and ag chemical world as well as for de-icing, industrial, and fuel transfer.

 

Tech Ag & Industrial Sales

Shane Blomendahl is a tech sales veteran at Dultmeier Sales with over 10+ years of experience in liquid handling products covering several industries and applications.

Learn More About Author

 

Flow meters are some of the most versatile and integral components in any fluid handling system. From agriculture chemical production to water treatment facilities, meters offer a reliable means to monitor how efficient your operation is and provide a tangible reading to identify potential issues within the plumbing system. This makes choosing the right flow meter for your application even more important. Selecting the wrong meter causes inaccuracies within your flow monitoring processes and creates inefficiencies throughout the rest of the system, not to mention significant unintended costs.

Dultmeier Sales is here to ensure that doesn't happen.

In this guide to flow meter selection, we'll take a look at several common meter types and the various applications in which they are used. We will also highlight some key considerations to keep in mind so that you always choose the best flow meter for your application needs. So, without further ado, let's get started.

 

Understanding What a Flow Meter Does

Simply put, a flow meter is a device that measures the flow of material-typically either liquids or gases-through a pipe. It determines how much material passes through the pipe (or hose) in a given period. It typically provides this measurement in units like gallons per minute (GPM), liters per second (L/s), or cubic feet per minute (CFM).

While this concept is straightforward, selecting the right flow meter for your specific task, however, can be more complicated.

 

Fill-Rite mechanical flow meters & digital flow meters

 

How to Choose the Right Flow Meter

First off, It is important to note that no two meters are exactly alike. Depending on application and metering needs, you may have several meter options or a single very specific one from which to choose. Complicating things further are the many external considerations your meter must satisfy in order to accomplish its intended purpose. As they say, the "devil is in the details," and the same goes for choosing the best flow meter for your application.

Below are some key characteristics to keep in mind when selecting the proper flow meter:

• Accuracy & Repeatability
• Type of Fluid (liquid, gas, slurry, steam)
• Density
• Viscosity
• Conductivity
• Temperature
• Pressure
• Flammable/Oxidizer
• Corrosiveness/Toxicity
• Flow Range/Turndown
• Materials of Construction
• Environment/Location & System Configuration
• Hygiene Requirements (pharmaceutical, food processing, etc.)
• Costs
  • Initial Investment
  • Installation
  • Long-term Maintenance

While the meter you ultimately select should ideally meet every factor above, ensuring it meets the most important ones for your operation will help guarantee you receive the best results. Let's dive into a few of the main ones on which you should focus.

Accuracy & Repeatability

Near the top of the list when evaluating flow meter specs is flow meter accuracy. Accuracy is how close a measurement is to the actual true value passing through a system. Expressed as a percentage (i.e. +/- 1%) accuracy represents how close the meter's output is to its calibrated parameters. Generally, the lower the percentage, the more accurate a meter is.

However, accuracy is not the only side of the coin. Repeatability, or the production of like outcomes under the same conditions, is perhaps even more important when evaluating which flow meter to choose. This is because accuracy is only reliable so far as its consistency. As you can see below, repeatability is possible without high accuracy, but high accuracy is not achievable without repeatability.

Flow meter accuracy & repeatability

If your flow readouts are unreliable-meaning you receive inconsistent results despite the same conditions-then you aren't gaining any value. Likewise, if your flow volume falls short of or exceeds your meter's rated flow range (also known as turndown), you won't receive accurate readings either.

Precision readings go hand in hand with any well-tuned operation. Choosing the best flow meter accuracy and repeatability percentages that meet your application requirements ensures your system maintains the precision readings you desire.

Liquid, Gas, or Semi-Liquid?

The type of fluid you work with is another big factor when choosing which flow meter best fits your application. Fluid type breaks into four categories: gas, liquid, slurry, and vapor-each with its own unique characteristics.

Properties such as fluid density, temperature, viscosity, and corrosiveness/acidity all must be determined before a final selection. This ensures you avoid choosing a flow meter incompatible with the fluid type you are attempting to measure. Electromagnetic flow meters, for example, won't work with non-conductive fluids like hydrocarbons. Likewise, few meter types are capable of measuring slurries because of their unique semi-liquid characteristics.

Illustration of how slurry particles behave between homogenous & heterogeneous mixtures

Here is a short list of flow meter types commonly used for the four fluid categories:

• Gas: Coriolis, Thermal Mass, Positive Displacement, Turbine, Variable Differential Pressure, Ultrasonic
• Liquid: Coriolis. Thermal Mass, Positive Displacement, Variable Flow, Paddlewheel, Turbine, Variable Differential Pressure, Ultrasonic, Electromagnetic
• Slurry: Coriolis, Electromagnetic, some subsets of Differential Pressure
• Vapor: Vortex, Ultrasonic, Floating Element

While not comprehensive, this list should offer a good starting point. That said, not every meter listed may work for your specific setup or needs. For instance, if your operation handles multiple fluids, you'll want to ensure that the meter you go with is compatible with all fluids-not just one. Otherwise, you likely spend valuable time calibrating your flow meter each time you handle a different product or troubleshooting why your inventories are off from your readouts.

Location & System Configuration

Meter location, as in real estate, is another major consideration. Will the flow meter be installed inside a controlled environment or outdoors in the elements? Is space a non-factor, or must size be considered? Certain flow meters even require stretches of straight pipe before and after the meter to generate accurate flow readings.

As a rule of thumb, pipe lengths of 10X (where X = pipe diameter) are needed before and after a meter for straight runs of pipe. So, if your plumbing's diameter is 2" you would need 20" or approximately 2 feet of pipe before and after the flow meter. This goes for just about any meter type, but it is always best to check the manufacturer's specs.

Also, keep in mind horizontal or vertical mounting. Some meters can be mounted in either orientation while others must be in one orientation or the other. Variable flow meters, for example, rely primarily on gravity in order to measure flow rate. Thus, they must be installed vertically to work. Determining how and where a meter will be installed while choosing a meter saves installation time and avoids costs related to unintended system reconfiguring.

Differentiating Between Volumetric vs. Mass Flow

Before we break down various flow meters, it is important to say a word on flow measurement. While there are many types of flow meters, most used today fall under two primary categories according to how they calculate flow: volumetric and mass.

As their name suggests, volumetric flow meters measure flow by calculating the volume of a fluid. Flow is often directed through an intrusion metering device such as a turbine or orifice plate, which then measures fluid velocity proportionally to the volume of matter passing by. Volumetric flowmeters make up the majority of meter types today and include turbine, magnetic, positive displacement, ultrasonic, and vortex meters to name a few.

Volume flow vs. mass flow within a cylinder

Mass flow meters, meanwhile, calculate flow rate by measuring the mass of a fluid. Mass meters have become increasingly popular due to their precision performance and truer reading of product flow compared to older metering technologies. In the diagram above, for instance, the product volume significantly changes depending on the position of the piston-even as mass remains the same. Today, mass meters have more or less become synonymous with Coriolis mass meters, but other types do exist. We'll discuss how mass meters work later in the article.

Whether you choose volumetric meters and mass meters depends on your application and metering needs, as well as your operational preferences and cost differences. In the end, you can still calculate volume to mass or mass to volume so long as the fluid density, surrounding temperature effects, and other conversion factors are all understood.

Comparing Flow Meter Types

There is, unfortunately, no such thing as a universal flow meter. Each flow meter type has fluids and applications for which it is well suited, and similarly, ones for which they are not. The following is a breakdown of some of the most common types of flow meters and the pros and cons of using each one.

Positive Displacement Flow Meters

Pros

• Accurate across wide flow ranges
• *Can handle very viscous fluids
• Versatile applications-simple, reliable design
• Require no power supply
• Cost-effective

*Thicker viscosity fluids create larger pressure losses & reductions in flow rates

Cons

• Requires medium to high-flow applications
• Experience greater pressure drops
• Larger/heavier than other meters
• Not recommended for dirty fluids or gases
• Some subsets require constant lubrication
• Many moving components need regular maintenance and replacement

Positive displacement (PD) meters consist of chambers featuring mechanical components that rotate in relation to volume flow. As fluid passes through, the reciprocating components-generally a type of gear, vane, or diaphragm-divides the fluid into fixed, metered volumetric units. The number of units rotated through within a specified time frame directly correlates to flow rate. Subtypes include screw meters, rotary vane meters, diaphragm meters, reciprocating or oscillating piston meters, and helical or oval gear meters.

 

TCS 700 Series Rotary Fuel Meter with Register

Since PD meters only measure flow while fluid passes through, they're ideal for applications where metering is crucial to calculate fluid usage. The TCS 700 series rotary vane meters, for example, are widely used in oil and gas custody transfer industries, while diaphragm meters are commonly installed on residential or municipal water and gas lines. Their fluid-driven design additionally makes positive displacement flow meters one of the more cost-effective options since they require no outside power supply to operate. However, these meters are ill-suited for impure fluids such as wastewater or slurries, as the suspended soils can clog or slow the reciprocating elements and create inaccurate readings.

Electromagnetic Flow Meters

Pros

• Obstruction-less/No moving components
• Highly accurate-unaffected by density, viscosity, turbulence, or pipe configuration
• Can handle wide flow ranges & multiple fluid types
• Zero pressure drop
• Bi-directional
• Cost-effective

Cons

• Cannot measure gases, vapors, or non-conductive liquids
• Limited fluid temperature range
• Interference possible with certain suspended fluids
• Specialized subsets can be expensive

 

Electromagnetic flow meters, also known as magnetic flow meters or magmeters, are rather unique in the technology they use to measure flow. Magmeters feature two parts, a transmitter and an inline sensor, the latter of which features coils that generate a magnetic field. When a conductive fluid passes through the field, a voltage is produced proportional to flow. This flow principle is known as Faraday's Law.

 

 

Unlike other meters, magnetic flow meters can measure fluids regardless of fluid density, viscosity, or flow turbulence. This makes mag meters highly accurate and reliable across a wide range of solutions. Additionally, their design features no obstructions in the pipe, making these meters ideal for a wide spectrum of applications, from highly sanitary liquids to slurries and highly corrosive fluids. Electromagnetic meters can be found in industries such as pulp and paper, metals and mining, food and beverage, water and wastewater, chemical transfer, and many more.

 

Magnetic meters, however, only work with conductive fluids. This means hydrocarbons such as oils, gasoline, or deionized liquids are not recommended with mag meters. Suspended solids, such as those found in various ag chemicals and fertilizers, can also sometimes pose a problem. The suspended soils, which may not be conductive, can interrupt the magnetic field and throw off the reading's accuracy. Newer, specialized magmeters such as slurry magmeters are engineered to counteract this magnetic interference. However, these units generally feature heftier price tags compared to standard models.

Turbine Flow Meters

Pros

• Highly accurate
• Cost-effective
• Capable of measuring low flow rates
• Versatile applications-simple, reliable design

Cons

• Not recommended for dirty or suspended liquids
• Require straight pipe runs for best results
• Limited to certain pipe sizes
• High flow rates can cause damage or inaccuracies
• Moving components need regular maintenance and replacement

Like paddlewheel or propeller flow meters, turbine meters feature a multi-bladed rotor mounted inline to fluid flow. Sensors attached to one or more of the turbine blades transmit the number of revolutions the turbine makes. The speed at which these revolutions happen is proportional to volumetric flow rate. Similar to positive displacement meters, turbine and paddlewheel meters only measure flow when fluid mechanically acts upon their metering components.

 

 

Because turbine meters provide accurate readouts in relation to linear flow-even at low flow rates-they are widely used in the oil and natural gas, custody transfer, and petrochemical industries. In fact, turbine meters are often used to help verify the accuracy of other meter types.

Turbine meters aren't without their limitations, though. For starters, turbine meters are not well suited to handle dirty or highly viscous fluids, as the turbines can be easily fouled by the soils. These meters also require straight runs of pipe before and after the meter to stabilize flow for the most accurate results. Additionally, larger pipe diameters are incompatible from an engineering standpoint. This limits where and for what applications turbine meters can be installed. Finally, as with any technology with moving components, regular maintenance is necessary to keep these meters in peak-performing condition.

Coriolis Flow Meters

Pros

• Extremely accurate
• Low maintenance
• Can handle a wide spectrum of flow ranges
• Compatible with many dirty, corrosive & difficult to handle fluid types
• Versatile installation-no straight pipe runs required
• Serviceable without removing from the pipeline
• Easy in-field calibration
• Capable of measuring gases

Cons

• Expensive initial investment
• Not suited for low-pressure gases
• Limited to certain pipe sizes

Coriolis meters, more commonly known as mass meters, differ from other meter types in that they measure mass flow instead of volume flow. These meters also feature a unique means of calculating flow rate based upon the Coriolis Principle. Check out the video below for a quick look at Coriolis meter technology.

 

Advantages of Mass Meters

Mass meters generally hold an NTEP certification and are widely used in legal-for-trade (resale) applications. In the Dultmeier Sales world, this generally means fertilizers or chemicals with respect to the agricultural industry. Back in the 1990s, Dultmeier Sales partnered with Kahler Automation to offer some of the first automated solutions for fertilizer/chemical plant automation.

The mass meter was at the heart of the system because it was new technology that allowed end-users to sell using the real-time density of the product - a truer way to meter liquids. For example, water is known to be 8.34 lbs. per gallon at 70°F. However, as temperature drops, the weight of water increases. Thus, the solution of water becomes denser as the ambient temperature drops. This would mean static volumetric calculations would be off if one pumped 1000 gallons of water and converted to 834 lbs. (using 8.34lbs/gal as the constant conversion factor) if the water were only 50°F.

This same principle happens with fertilizer and chemicals - as they are generally water-based solutions. Volumetric meters of the time; however, were unable to account for this change in density in relation to volume flow. Take this scenario for example, which was quite common in the 1990s and early 2000s:

Let's say that it's 40° F. and we're loading a 10,000 gallon tender trailer, running 32% Nitrogen into the vessel. We're using a paddlewheel meter as our measuring device and pumping the product into the vessel. Once we reach our hit point of 10,000 gallons - the automated equipment shuts down and we send our trucker to the scale. The scale breaks in 20 lb. increments.

Our potential for error:

• Paddlewheel meter runs at approx. +/- 2% accuracy (mass meter is +/- .3% accuracy)
• Paddlewheel cannot determine density reading, so we have a static calibration factor that was calibrated at 70° F. (or another temperature) and we are using that static factor to now calibrate pounds to gallons at 40° F.
• Scale breaks in 20 lb. increments vs. mass meter measuring in increments of 1/10th of a pound
• Scale cannot account for "slosh" or movement of liquid as truck stops abruptly on the scale

Considering these many variables and the potential for error, it's no wonder why inventories could, and often would, be way off come year-end. We know that a solution's density changes constantly if in an ambient environment. For this reason alone, mass meter technology is the preferred method of measurement in many instances. By using a mass meter that can continually read this fluctuation in density on the fly, we offer our customers a better method to dispense and record inventory.

Today, Dultmeier works with Easy Automation Inc. to provide automated plant solutions using mass meters in addition to other state-of-the-art meters, controls, and equipment.

Flow Meter Price, Performance & Popularity

Unfortunately, there is no universal flow meter that works for every application. Depending on how diversified your operation is, that could mean multiple types of flow meters are needed. While it is fair to research the most popular meters for your industry, don't buy the first meter you think will work.

Price, quality, and other key factors do play a significant role in a flow meter's overall performance. Simply because everyone else uses a certain meter does not mean you should be. Low purchase cost, for instance, shouldn't be the deciding factor in choosing the best flow meter for your application. When choosing a flow meter, you have to consider not only the initial purchase price, but the overall lifetime costs and long-term returns on investment, too.

 

For instance, while a Coriolis meter boasts a hefty price tag at initial investment, it provides a great ROI because less maintenance and greater product savings are realized over the long run. Mass meters' exceptional accuracy, versatile flow ranges, and fluid compatibilities, minimal wearable parts, and the ability to recalibrate without removing the meter from the pipeline all translate to fewer dollars spent overall. When it comes to the bottom line, spending more money upfront can outweigh years of hemorrhaging dollars spent repairing or replacing inefficient meters.

That said, not every operation needs an expensive, high-end flow meter. It's a good idea to run a cost assessment evaluating application needs against initial investment costs and long-term cost savings. This way you have the best picture of whether a certain meter is practical or worth the price tag over the long haul. If you need help assessing meter options and determining what is best for your application(s), we are always just a phone call away at 1-888-677-5054.

Final Words

We hope this article has provided some insight into the world of flow meter solutions. Although we covered some of the most common types, these are by no means the only flow meters out there. Choosing the best type of flow meter for your application all starts with knowing what you need and researching your best options. Compare all associated costs-both short and long-term-and avoid making a decision based on price tags alone. Ultimately; however, the manner in which you choose to meter is entirely up to you.

If you have any questions regarding flowmeter selection, give us a call at 888-667-5054 or dultmeier.com. Dultmeier Sales carries a diverse inventory of chemical and water flow meters, flow meter repair parts, and flow meter accessories. No matter what meter your operation requires, our experience and technical expertise will help make sure you select the right one.