One of the primary issues that can occur during the operation of an electromagnetic flowmeter is a fault within the meter itself, typically caused by damage to internal components or structural parts. Another common issue arises from external factors, such as improper installation leading to flow distortion, sediment buildup, or scaling. This chapter focuses on the second type of failure—those caused by external conditions. These faults can be further categorized based on the time of occurrence: 1) commissioning period failures and 2) operational period failures. Commissioning period failures happen during the initial setup after installation, often due to incorrect selection or installation of the device. Operational period failures occur after some time in use, usually due to deposits on the electrode lining or new environmental interferences.
From the perspective of the fault source, these problems can originate from three areas: 1) piping and installation, 2) environmental factors, and 3) fluid characteristics. The first category is most commonly seen during the commissioning phase, while the latter two can affect the system both during commissioning and throughout normal operation.
During the commissioning phase, common issues include improper installation, environmental interference, and fluid-related problems. For example, incorrect placement of the sensor, such as at a high point in the pipeline where gas can accumulate, or lack of back pressure causing an air pocket in the tube, can lead to measurement errors. Environmental factors like stray currents, electromagnetic waves, or nearby motor fields can also interfere with the signal. Additionally, if the fluid contains bubbles or solid particles, it may cause fluctuations in the output signal or even lead to signal loss if the bubbles cover the electrodes.
Once the flowmeter has been in operation for some time, other types of faults may appear, such as buildup on the inner walls of the sensor, lightning strikes, or changes in the environment. Accumulation on the sensor’s inner surface can alter the measurement area or even cause a short circuit or insulation problem, leading to inaccurate readings or complete failure. Lightning can induce high voltage surges into the system, damaging sensitive electronics, especially through power lines or signal cables. Changes in environmental conditions, such as new sources of interference, can also disrupt the flowmeter's performance over time.
To ensure reliable operation, proper installation, regular maintenance, and effective shielding and grounding are essential. Understanding these potential causes helps in diagnosing and preventing failures effectively.
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