Most modern processing plants utilize a central high-pressure cleaning system that allows multiple operators to clean faster than with a low-pressure system. For washdown applications, this approach improves efficiency as the job can be completed with less water and fewer chemicals, which ultimately reduces operational costs.
High pressure pumps are a crucial component of plant washdown systems. The pumps must be consistently operated within manufacturer specifications to provide the utmost performance and reliability and reduce the need for costly maintenance.
Plant Operating Demands
Food processing plants are finding ways to conserve water and energy by making adjustments to their current systems or implementing new technology. Some plants have added pumps or switched to larger capacity pumps in their washdown systems, and this equipment runs at full flow and pressure when in operation.
A large poultry processing facility in the Southeastern U.S. uses washdown pumps within its plants. Shortly after the pumps were installed, one of the units was damaged internally by incorrect operation. The pump had too little flow for an extended period of time while the motor was running at full speed. Although the installation includes a small bypass line, operating the pump in low flow conditions resulted in complete failure.
The poultry processor incurred an $8,500 repair bill for the damaged pump, which would have cost approximately $23,000 to replace.
Value of Flow Management
As a result of this incident, the poultry processor tried several methods to protect its pumps from low flow conditions. One way was to install pressure sensors and use the readings from these devices as an input for pump controls. This method proved to be problematic and thus another method had to be found.
Since the outlet pressure of the washdown pumps was fairly high with hot temperatures, an ultrasonic clamp-on flow meter was considered as an alternative to a traditional inline meter, which would have required a full system shutdown and incurred high installation costs. By utilizing ultrasonic clamp-on technology, the flow meter could be installed while the pump was in operation.
Transit time ultrasonic flow meters measure flow rate by propagating ultrasonic waves into liquid-filled pipes and measuring the time of flight. With clamp-on technology, the meter is non-intrusive and provides many advantages including:
- Reduced installation costs
- Uninterrupted production
- Installation flexibility across a wide range of pipe sizes
- No pressure head loss
- No contact with internal liquid
- No moving parts to maintain
- Allows for routine maintenance activities throughout the life of the meter without having to cut into pipes
Choosing the Correct Meter
Working with a trusted Badger Meter representative, the poultry processing plant chose to install the Dynasonics® TFX-5000 Ultrasonic flow meter. These advanced meters proved to be the answer to the low flow problem with washdown pumps, reducing the poultry processors maintenance costs and improving asset reliability.
Custom solutions for every application with BlueEdge from Badger Meter
The Dynasonics TFX-5000 Ultrasonic flow meter is the latest solution for measuring volumetric flow rates and is available in a variety of configurations to meet individual application requirements in the most challenging and demanding environments. The meter features a large easy to read graphical display and provides connectivity with a variety of communications protocols such as Modbus RTU and Modbus TCP/IP and is also compatible with BACnet. In addition, the flow meter supports encoded output or use with Badger Meter ORION® Cellular Endpoints for connecting to the AquaCUE® or BEACON® Software as a Service (SaaS) cloud-based software suite. Alternatively, it can link directly to building management systems.
Forming part of the BlueEdge suite of scalable water technology, software and services from Badger Meter, the solution provides actionable data for proactive decision-making and offers a comprehensive approach to water management that drives innovation and sustainability. This unique approach is designed to improve the visibility and optimization of assets, delivering instant access to data and performance analytics. Expertly
crafted and tailored to individual needs, BlueEdge solutions are deployable at every point along a smart water journey.
The TFX-5000 installed within the poultry plant provides flow rate information to a Variable Frequency Drive (VFD). This control solution prevents washdown pumps from running in low flow conditions for an extended period of time as well as staging a second pump during high demand situations. It controls pump operation to closely match system demand — resulting in significant savings in energy costs.
Benefits to System Performance
The use of ultrasonic flow meters enabled improved diagnostics to accurately measure flow, help to identify potential pump operating issues and initiate appropriate preventative maintenance programs, hence extending life of the plant assets. Learn more about the benefits of the Dynasonics TFX-5000 here.
Experience has shown that employing a flow control solution with a VFD to control washdown flow rates helps to save energy and extend equipment life. Using controls to regulate the volume and pressure in the washdown system allows plants to save water while cleaning is being done as well as accurately maintain the pressures required at each operator hose, resulting in higher efficiency and reduced operational costs.
Conclusion
The flow measurement system installed at this busy poultry processing facility has provided a quick return on investment. The custom BlueEdge solution allows the washdown system to achieve minimum flow rates or completely shut off when demand is low without the potential for severe equipment damage, allowing plant personnel to spend more time meeting production demands and less time worrying about equipment.
Designed to meet the changing needs of water utilities and industrial customers worldwide, BlueEdge addresses common challenges in water management and has solutions available for every unique application.
The future of water management is here.
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