How ultrasonic flowmeter technology can help improve energy efficiency

In recent decades, industrial energy efficiency has been significantly improved. Even so, a large part of global energy demand is still used in manufacturing operations. The large amount of energy consumed by factories has a major impact on the economy and the environment.

For today’s industrial organizations, maintaining sustainable operations has become a key requirement. As the green energy movement gains momentum, manufacturing facilities are seeking to improve energy efficiency. One of the very important priorities is effective energy management. The task of the plant manager is to manage all the flowing energy in his facility. They and their facility operators and MRO teams need proven technology to monitor energy consumption in various applications.

By deploying advanced flow measurement technology, many industrial sites can significantly improve their operational efficiency and apply industry-recognized energy management strategies. Very new ultrasonic flow meter solutions enable factories to obtain the information they need to achieve their sustainability goals, reduce energy costs, and improve overall performance.

Typical measurement requirements

The factory MRO department must find ways to better monitor key energy-related factors, such as combustion air and gas flow, to identify losses and improve profitability. By monitoring the fuel end-use locations of the entire plant and measuring the consumption rate of each application, plant personnel can gain insight into potential areas of efficiency optimization. This is also the case of power consumption. In both cases, it is only necessary to determine the location of the resource loss to achieve a reduction in energy use.

For example, in boiler operation, the combustion efficiency of the air and fuel mixture is a key issue. Excessive oxygen will reduce the operating efficiency of the boiler and cause undesirable pollutants. Likewise, too little oxygen will result in incomplete combustion of the fuel and will create soot deposits that clog the surface and reduce the efficiency of the boiler.

Comparing the flow of natural gas, propane and other fuel gases with the steam and hot water output of these assets can help drive operational efficiency plans. Evaluating equipment performance based on accurate flow data can also help factories optimize strategies. Reducing fuel usage is one of the very simple ways to reduce operating expenses (OPEX) and increase profits.

Deploy metering technology

Whether industrial organizations are trying to meet strict energy consumption requirements and comply with greenhouse gas (GHG) standards, or want to apply industry best practices to optimize processes, they can use advanced measurement technology to provide the information needed to achieve energy efficiency goals and save Capital and improve plant performance.

In applications that need to measure hot water and heating liquids, such as measuring boiler output to determine whether equipment is operating effectively, factory personnel can deploy flow meters with integrated temperature measurement functions to measure supply and return temperatures, and then calculate the heat energy in the BTU. Temperature measurement is usually achieved by using a precision resistance temperature detector (RTD), while liquid flow measurement can be done by electromagnetic flowmeters, turbine flowmeters, ultrasonic flowmeters, or various other flow measurement techniques.

In recent years, ultrasonic flowmeters have become a common choice for engineers, operators, and maintenance technicians who are concerned about equipment energy management. These devices use proven non-invasive measurement technology, do not involve moving or wetted parts, and will not cause pressure loss. The flow sensor is made of standard silica gel and can be connected to the pipeline for a long time. Ultrasonic instrument design provides a wide turndown ratio and provides maintenance-free operation-all of these are important advantages over traditional mechanical and digital instruments.

Transit time ultrasonic flow meters are particularly suitable for thermal measurement in thermal energy monitoring applications. With this clip-on meter, the ultrasonic signal is transmitted to the downstream flowing fluid, and then another signal is transmitted to the upstream flowing fluid. Compare the time the acoustic pulse travels downstream with the time the pulse travels upstream. This differential time is used to determine the velocity of the flowing fluid, and then calculate the volume flow in the pipe.

Using a pair of matched RTD temperature sensor probes, the transit time ultrasonic flowmeter can use the temperature of the supply and return lines of the heating or cooling circuit to measure thermal energy (BTU). These meters usually provide input and output interfaces, batch control and alarms, and flow/energy accumulation, and can be used by the host, burner management system (BMS), PLC, or flow controller for monitoring and control purposes.

The solution that combines clip-on transit time ultrasonic flowmeters with precision RTDs provides a cost-effective way to measure volumetric flow and obtain energy readings to evaluate the efficiency of boiler and cooler operation and other plant equipment. By measuring the flow rate and the temperature difference (ΔT), the user can calculate the energy consumed in BTU. The equipment efficiency can then be calculated as a baseline, and continuous performance can be continuously monitored.

With clamp-on ultrasonic flowmeter, there is no need to cut the pipe during installation, and no heat license is required for on-site welding. The device can provide high accuracy for most flow and BTU energy measurement applications. This type of instrument also offers an extremely wide turndown ratio and provides maintenance-free operation.

In conclusion

Monitoring energy consumption in industrial equipment applications is essential for improving the efficiency of plant operations, identifying waste of resources, and minimizing greenhouse gases entering the atmosphere. Modern flowmeter technologies, such as transit time ultrasonic flowmeters, can provide accurate flow energy measurement to meet corporate energy management goals while supporting today’s green energy plans.

When specifying flow measurement solutions, plant managers, operators, engineers, and maintenance and reliability professionals should consider all relevant application factors (for example, fluid type, flow rate, accuracy, and turndown requirements, etc.). It is recommended to consult an instrument supplier with very good technology for a specific installation, rather than taking a one-size-fits-all approach.