Enhancing Pump Operation at Large Poultry Processing Facility

At a large poultry processing facility in the Southeastern U.S., high-pressure pumps were used to support wash-down operations throughout the plant. Shortly after installation, however, one of the pumps experienced a costly failure that highlighted the need for better visibility into actual system flow.

Protecting Pumps from Low-Flow Conditions

The damaged pump had operated at full motor speed with too little flow for an extended period. Although the system included a small bypass line, the low-flow condition caused internal recirculation and heat buildup, eventually resulting in complete pump failure.

The poultry processor incurred approximately $8,500 in repair costs. Replacing the pump entirely would have cost approximately $23,000.

To prevent similar failures, the facility initially installed pressure sensors and used their readings as an input for pump controls. The approach proved problematic because pressure alone did not provide the direct flow information needed to identify potentially damaging operating conditions.

Plant personnel needed a more reliable way to measure flow and use that information to adjust pump operation as wash-down demand changed.

Adding Flow Measurement Without Interrupting Operations

The poultry processor worked with Voigt-Abernathy Co., a distributor of industrial rotating and process equipment, to identify an alternative approach.

With high outlet pressures and elevated temperatures in the wash-down system, installing a traditional inline flow meter would have required modifying the piping and shutting down the system. A clamp-on ultrasonic meter offered a non-intrusive alternative that could be installed while the pump remained in operation.

The facility selected the Dynasonics^® TFX-5000 Ultrasonic Clamp-on Flow Meter. Using transit time ultrasonic technology, the meter measures flow from outside the pipe without contacting the process liquid or creating additional pressure loss.

The external installation eliminated the need to cut into existing piping while providing the direct flow measurement required for pump control.

Integrating Flow with Pump Control

The TFX-5000 was incorporated into a pump control package consisting of a duplex variable frequency drive (VFD) panel and ultrasonic flow measurement.

Flow data from the meter provides an input for controlling pump speed and run time based on actual system demand. In automatic mode, the primary pump operates to maintain the required system pressure while the flow meter monitors changing conditions.

If flow remains too low for a specified period, the system can reduce the pump to a minimum speed or stop it entirely, helping prevent the internal recirculation and heat buildup that caused the previous failure.

During periods of higher demand, the flow meter can signal the control system to start a second pump. As demand decreases, the second pump shuts down while the primary pump continues operating.

By combining direct flow measurement with variable-speed control, the facility can more closely match pump operation to actual wash-down requirements rather than continuously operating equipment at full capacity.

Improving Pump Reliability and System Efficiency

Following installation of the flow-based control package, the original wash-down pump continued operating without premature failure. The approach provided the facility with a way to identify low-flow conditions and respond before they could cause significant equipment damage.

Matching pump operation more closely to system demand also reduces unnecessary pump operation and energy use while maintaining the flow and pressure required for wash-down activities.

Based on the results of the initial application, additional control packages combining Dynasonics ultrasonic transit time flow meters and VFDs were deployed for the customer.

With direct flow measurement incorporated into pump control, the poultry processing facility gained greater visibility into wash-down system operation while helping reduce maintenance costs, extend equipment life and improve overall system efficiency.