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Specific Operation Methods
One method involves conducting a comprehensive annual inspection of the electromagnetic flowmeter. This includes visual checks, converter characteristic tests, measurement value calibration, voltage measurements, insulation resistance testing, and circuit verification. Zero point adjustment is crucial due to potential drift, but "online zero adjustment" requires stopping the flow, which is not always practical. Therefore, online inspections often skip sensor-related checks and focus on converter calibration instead, comparing results with historical data to determine if the instrument should continue operating, be repaired, or replaced.
Another approach uses online inspection to identify issues when the flow cannot be stopped. A general-purpose instrument like an analog annunciator can be used to test the converter’s accuracy. For the sensor, checks include measuring the electrode inductive resistance, excitation coil insulation resistance, and copper resistance, as well as indirectly checking the excitation current and magnetic field strength. When flow can be stopped, the sensor can be accessed for cleaning and inspection of the lining and electrode condition.
Key Inspection Points
Zero point checks are essential but often skipped in practice due to site limitations. Instead, separate checks on the converter are performed. Technically, this should only be done after confirming the sensor’s insulation resistance is normal. If the zero point deviation exceeds 5% of the full scale, it may indicate a problem. Typically, the zero difference between the converter and the meter is less than 1%.
Checking the connection cables involves verifying the conduction and insulation resistance of signal and excitation lines, as well as ensuring proper grounding.
Converter checks involve using calibrated instruments to simulate sensor signals for zero adjustment and calibration. Comparing current results with previous data helps assess performance.
Flow sensor checks include evaluating the excitation coil resistance, insulation, and electrode contact resistance. Measuring polarization voltage can also help detect electrode contamination.
Insulation resistance checks between the signal and excitation circuits are important to prevent interference. Cleaning and inspecting the lining ensures long-term reliability.
Author's Recommendations for Effective Daily Maintenance
First, companies should develop standardized inspection procedures based on ISO9001 requirements. Larger organizations may create detailed guidelines such as “Online Verification Method†or “Online Calibration Specifications.â€
Second, promoting the use of specialized inspection tools is recommended. These tools are already in use in industries like water treatment and metallurgy. Portable PCs and dedicated instruments can streamline the process, allowing technicians to perform inspections efficiently in the field or lab.
Detailed analysis of two methods for daily maintenance of electromagnetic flowmeter
Introduction
The primary goal of routine maintenance for electromagnetic flowmeters is to ensure or confirm that the device operates under controlled and reliable conditions. Routine maintenance typically falls into two categories: online inspection and offline inspection. The main objective is to verify that the flow measurement values remain accurate and consistent with the expected performance standards. In industrial applications, electromagnetic flowmeters are commonly used for flow control, and the fluids they measure are often corrosive or abrasive. As a result, failures in these devices are frequently caused by corrosion, insulation degradation, electrode contamination, or foreign material buildup.
Traditionally, periodic maintenance involves removing the flow sensor from the pipeline for inspection and calibration. However, to minimize the risk of damaging the lining during removal, it's common to first measure the insulation resistance on the pipeline to detect any abnormalities before deciding whether to proceed with further checks. Companies that follow ISO9001 standards typically divide their maintenance efforts into three parts: one-third for online inspections, one-third for cleaning wetted parts while the pipeline is removed, and one-third for offline flow calibration.