Krohne vs Thermo Fisher Anti-Cavitation Equipment: Comparison & Best Fit

Introduction

Cavitation is the silent killer of hydraulic efficiency and mechanical integrity in water and wastewater systems. For municipal and industrial engineers, the challenge is rarely just about selecting a pump; it is about selecting the instrumentation loop that can survive, detect, and mitigate the conditions that lead to cavitation. When incipient cavitation creates two-phase flow (bubbles and liquid) or when process upset conditions introduce entrained gas, standard flow measurement and protection equipment often fail, leading to blind control loops and catastrophic pump damage.

A surprising industry statistic suggests that over 30% of unplanned pump failures in wastewater treatment plants are directly linked to undetected cavitation or dry-run scenarios that standard instrumentation failed to catch in time. Engineers typically rely on discharge pressure or motor amperage to detect these issues, but these are lagging indicators. By the time the amperage drops, the damage to the impeller or seal may already be occurring. The more effective approach is utilizing advanced flow instrumentation capable of maintaining measurement integrity during entrained gas events, thereby allowing the control system (SCADA/PLC) to react before hydraulic failure occurs.

This article provides a technical deep-dive into the specific instrument capabilities of two major market players, focusing on the Krohne vs Thermo Fisher Anti-Cavitation Equipment: Comparison & Best Fit. While neither company manufactures “anti-cavitation valves” in the traditional sense, both provide critical sensing technologies—specifically Coriolis, Electromagnetic, and Ultrasonic flow meters—that engineers utilize to monitor cavitation-prone regimes.

In municipal lift stations, thickened sludge lines, and industrial chemical dosing skids, the ability of a meter to distinguish between signal noise and actual flow during gas entrainment is the difference between a nuisance alarm and a saved asset. Poor specification here results in “chattering” control valves, VFD hunting, and eventual equipment failure. This guide will assist engineers in specifying the correct technology for these harsh hydraulic environments.

How to Select / Specify

Selecting the right instrumentation to manage and monitor cavitation risks requires a departure from standard datasheet specification. Standard accuracy statements (e.g., “±0.5%”) usually apply only to single-phase liquids. In a Krohne vs Thermo Fisher Anti-Cavitation Equipment: Comparison & Best Fit analysis, the primary selection criteria must shift toward signal stability, damping capabilities, and multi-phase performance.

Duty Conditions & Operating Envelope

The operating envelope must be defined not just by flow rate, but by the hydraulic state of the fluid. Engineers must calculate the Net Positive Suction Head Available (NPSHa) versus Required (NPSHr) and identify where the intersection occurs relative to the measurement point.

• Void Fraction (Gas Content): Standard magnetic flowmeters often experience signal jumping when gas bubbles pass the electrodes. Coriolis meters can stall completely. You must specify the expected percentage of entrained gas (by volume). Technologies like Krohne’s EGM (Entrained Gas Management) are designed to maintain oscillation up to 100% gas entrainment, whereas standard ultrasonic meters from Thermo Fisher may rely on Doppler shifts which actually require bubbles, or Transit Time which fails with bubbles.
• Vapor Pressure & Temperature: In industrial wastewater or hot water applications, the margin to flashing is slim. The equipment selected must withstand rapid temperature fluctuations associated with collapsing vapor bubbles.
• Turndown Ratio: Cavitation often occurs during low-flow/high-head conditions (recirculation) or high-flow/run-out conditions. The selected device must maintain accuracy across the entire pump curve, not just the Best Efficiency Point (BEP).

Materials & Compatibility

Cavitation creates shock waves that can erode liner materials and damage sensor internals. When comparing equipment, material hardness and bond strength are paramount.

• Liner Adhesion: In magnetic flowmeters, vacuum conditions caused by cavitation or siphon effects can collapse liners. PFA liners with mechanical reinforcement (wire mesh) or ceramic liners are superior to standard PTFE liners in these applications.
• Sensor Tube Material: For Coriolis meters, Titanium tubes offer superior resistance to the fatigue caused by the high-frequency vibrations of cavitation compared to 316L Stainless Steel, though at a higher capital cost.
• Electrode Material: In wastewater with high solids and potential cavitation, signal noise is high. Utilizing low-noise electrodes (e.g., Tantalum or specialized stainless designs) can improve the signal-to-noise ratio.

Hydraulics & Process Performance

The interaction between the fluid mechanics and the sensor physics is the critical differentiator.

• Signal Damping: The device must offer adjustable damping (time constants). However, excessive damping hides the spikes that indicate the onset of cavitation. The best fit is equipment that offers “smart” filtering—rejecting hydraulic noise while reporting the fundamental flow variable.
• Diagnosis of Sound Speed: Advanced flowmeters can measure the speed of sound through the medium. A drop in the speed of sound is a primary indicator of micro-bubbles (incipient cavitation). Equipment that outputs this diagnostic variable allows the SCADA system to trim pump speed automatically.

Installation Environment & Constructability

Cavitation is frequently caused by poor piping geometry (elbows too close to pump suction). The monitoring equipment is often forced into these compromised locations.

• Straight Run Requirements: Thermo Fisher’s clamp-on ultrasonic meters generally require significant straight runs (10D-20D) to resolve the flow profile. If placed near a cavitating pump, the distorted profile will yield significant errors. Krohne’s electromagnetic and Coriolis meters generally require less straight run (0D-5D depending on the model), making them more suitable for tight pump rooms.
• Vibration Immunity: Cavitating pumps generate structural vibration. Coriolis meters, which rely on vibration for measurement, must have effective decoupling (massive splitters or adaptive filtering) to operate in this environment.

Reliability, Redundancy & Failure Modes

How does the device fail when the fluid turns into a foam or slug flow? This is the central question in the Krohne vs Thermo Fisher Anti-Cavitation Equipment: Comparison & Best Fit discussion.

• Measurement Stall: Many legacy Coriolis meters “freeze” the last known good value when density drops rapidly (gas entrainment). This is dangerous for control loops. The specification should require continuous measurement updates even during multi-phase events.
• Redundancy: For critical lift stations, engineers should consider using the flowmeter’s density output as a check against the pressure transmitter. If pressure drops and density drops simultaneously, cavitation is confirmed.

Controls & Automation Interfaces

The “equipment” is only as good as its integration into the control strategy.

• Diagnostic Outputs: Modern specifications should require the output of “Process Noise” or “Drive Gain” (for Coriolis) via Modbus, EtherNet/IP, or PROFIBUS. This value correlates directly to the energy required to drive the sensor tubes and is a proxy for aeration/cavitation levels.
• Response Time: The total loop time (sensor sensing + processing + output + PLC scan) must be faster than the time it takes for cavitation to damage a seal.

Lifecycle Cost Drivers

While instrumentation is a fraction of the pump cost, its failure leads to expensive pump repairs.

• CAPEX: Thermo Fisher clamp-on ultrasonics are generally lower CAPEX and non-intrusive, requiring no shutdown to install. Krohne Coriolis mass flow meters represent a high CAPEX.
• OPEX: The hidden OPEX is the cost of false alarms. If a meter falsely reports low flow due to bubbles, and the PLC shuts down the plant, the operational cost spikes. Equipment with advanced Entrained Gas Management (EGM) reduces these nuisance trips.

Comparison Tables

The following tables break down the technical differences between the primary technologies offered by these manufacturers in the context of difficult, cavitation-prone hydraulic regimes. Table 1 compares the technological approaches, while Table 2 focuses on application suitability.

Table 1: Technology Comparison – Performance in Multi-Phase/Cavitating Flow

Feature / Characteristic	Krohne (Focus: OPTIMASS / OPTIFLUX)	Thermo Fisher (Focus: Polysonic / Sx30)
Primary Technology	Coriolis Mass Flow (with EGM) & Electromagnetic	Ultrasonic (Doppler & Transit Time)
Response to Gas Bubbles (0-5%)	OPTIMASS: Continuous measurement; EGM algorithm maintains tube oscillation. OPTIFLUX: Generally stable, some noise on electrodes.	Doppler: Requires bubbles/solids to function (Good). Transit Time: Signal usually fails or degrades significantly.
Response to Slug Flow (>10% Gas)	Maintains operation; accuracy degrades but flow indication persists. Does not stall.	Signal loss is likely for Transit Time. Doppler may saturate or become erratic if signal attenuation is too high.
Process Noise Filtering	Advanced digital signal processing (DSP) specific to rejecting hydraulic noise.	Variable depending on model; often relies on signal strength averaging.
Cavitation Detection Capability	High. Can output “Drive Gain” or “Density” drops to SCADA to trigger pump protection.	Moderate. Can use “Signal Strength” or “Sound Speed” changes as a diagnostic.
Structural Vibration Immunity	Modern twin-tube designs are well-balanced, but extreme pump vibration requires careful mounting.	Clamp-on sensors are susceptible to pipe wall noise caused by cavitation; wetted transducers are better.
Maintenance Profile	Low. No moving parts. Clean-in-place (CIP) compatible.	Low for clamp-on (no process contact). Coupling gel may need refreshing on clamp-ons.

Table 2: Application Fit Matrix – Where to Specify Which Brand/Tech

Application Scenario	Best Fit Strategy	Krohne Strengths	Thermo Fisher Strengths
Return Activated Sludge (RAS) Risk: Air entrainment from aeration basins.	Electromagnetic or Doppler Ultrasonic	OPTIFLUX: Industry standard, robust liners, handles solids well.	Polysonic (Doppler): Excellent non-intrusive option for aerated liquids. Good retrofit solution.
Polymer Dosing Risk: Off-gassing, pulsating flow.	Coriolis Mass Flow	OPTIMASS: Unmatched ability to handle viscosity changes and gas bubbles without stalling.	Less applicable; ultrasonic signals struggle with viscous, attenuating polymers.
Raw Sewage Lift Stations Risk: Cavitation, ragging, vibration.	Electromagnetic	OPTIFLUX: Full bore design prevents clogging. Diagnostic functions detect electrode noise.	Doppler: Can work, but pipe liners (cement/epoxy) in old pipes block ultrasonic signals.
Effluent / Clean Water Pumping Risk: High head cavitation.	Transit Time Ultrasonic or Mag	OPTIFLUX: High accuracy, minimal pressure drop.	Transit Time: Very accurate for clean water; clamp-on allows easy verification of pump performance.

Engineer & Operator Field Notes

Specifying the hardware is only step one. The operational success of the Krohne vs Thermo Fisher Anti-Cavitation Equipment: Comparison & Best Fit largely depends on commissioning and maintenance strategies.

Commissioning & Acceptance Testing

When commissioning flow instrumentation in systems prone to cavitation, standard “zero and span” procedures are insufficient.

• Zero Calibration: Never perform a zero calibration while the pump is running, especially if the pump is vibrating. Ensure the pipe is full and the fluid is static. For Thermo Fisher clamp-on meters, ensure the acoustic coupling is verified with the diagnostic signal strength (“Signal Quality” > 50-60%).
• Drive Gain Baserunning (Coriolis): For Krohne OPTIMASS units, record the “Drive Gain” or “Tube Amplitude” when the system is running normally. Set a PLC alarm at 10-15% above this baseline. This differential will be your early warning system for cavitation (which requires more energy to drive the tubes).
• Sound Speed Validation (Ultrasonic): For Thermo Fisher units, validate the measured sound speed against the theoretical sound speed of the fluid at the current temperature. A significant deviation often indicates entrained air or poor sensor spacing.

Pro Tip: In wastewater applications, disable “Flow Cutoff” or “Low Flow Cutoff” during troubleshooting. These features often mask the erratic, low-amplitude signals that occur during the onset of cavitation, hiding the problem until it becomes severe.

Common Specification Mistakes

Engineers often copy-paste specifications from previous projects without analyzing the hydraulic profile.

• Over-Smoothing: Specifying a high damping value (e.g., 30 seconds) to get a “steady number” on the SCADA screen. This hides the hydraulic instability. Operators think the flow is stable while the pump is destroying itself. Keep damping low (< 3-5 seconds) and use the PLC to average for reporting, while using raw data for control logic.
• Ignoring Pipe Liners: Specifying clamp-on ultrasonic meters (Thermo Fisher) for cement-lined ductile iron pipe. The liner often delaminates or contains air gaps, blocking the acoustic signal. In these cases, a wetted electromagnetic meter (Krohne) is mandatory.

O&M Burden & Strategy

• Coupling Compound (Ultrasonic): Thermo Fisher clamp-on meters utilize a coupling gel. In hot pump rooms or outdoor applications, this gel can dry out over 1-2 years, causing signal loss. Maintenance schedules must include re-coupling.
• Electrode Coating (Mag Meters): Grease buildup in wastewater acts as an insulator. While Krohne meters often feature “virtual reference” or advanced diagnostics to detect coating, they eventually require cleaning. Specify meters with electrode cleaning circuits or removable measuring tubes if coating is rapid.

Troubleshooting Guide

Symptom: Flow reading spikes erratically.

• Diagnosis: Check the raw signal noise. If using a Krohne Mag meter, look at the electrode noise value. If high, it could be solids impingement or cavitation bubbles collapsing near the electrode.
• Test: Throttle the discharge valve slightly (increasing backpressure). If the noise disappears and the flow signal stabilizes, the issue was cavitation, not electrical noise.

Design Details / Calculations

To properly apply Krohne vs Thermo Fisher Anti-Cavitation Equipment: Comparison & Best Fit principles, engineers must understand the sizing logic that governs multi-phase flow capability.

Sizing Logic & Methodology

The goal is to size the meter such that the fluid velocity is high enough to carry entrained gas bubbles through the sensor (preventing accumulation/slugging) but not so high that it creates additional pressure drop leading to flashing.

1. Determine Minimum Velocity: In vertical lines, fluid velocity must exceed the “bubble rise velocity.” A rule of thumb for wastewater is to maintain > 3-5 ft/s (1-1.5 m/s) through the meter.
2. Calculate Pressure Drop: Use the manufacturer’s sizing software. Ensure that the pressure at the meter outlet remains above the fluid’s vapor pressure plus a safety margin (typically 5 psi).
   Check: $P_{outlet} > P_{vapor} + P_{margin}$
3. Evaluate Sigma (Cavitation Index): For control valves or restrictions near the meter:
   $sigma = (P_{upstream} – P_{vapor}) / (P_{upstream} – P_{downstream})$
   If $sigma$ is approaching 1.0, measurement instability is guaranteed. Move the flowmeter upstream of the restriction (valve) if possible to keep it in the high-pressure zone.

Common Mistake: Installing flowmeters on the suction side of a pump to “monitor suction conditions.” This creates a pressure drop exactly where you cannot afford it (lowering NPSHa). Always install flowmeters on the discharge side, unless strictly necessary and sized with negligible pressure drop (e.g., full-bore mag meter).

Specification Checklist

When writing the Division 40 specification, include:

• For Gas-Prone Applications: “Flowmeter shall utilize digital signal processing capable of maintaining measurement during two-phase flow events up to 20% gas by volume (Void Fraction).”
• Diagnostic Output: “Transmitter shall provide a secondary analog or digital output proportional to signal strength, drive gain, or sound speed to facilitate predictive maintenance.”
• Empty Pipe Detection: “Sensor must include active empty pipe detection to prevent false totalization during dry-run conditions.”

Standards & Compliance

• AWWA M6: Manual of Water Supply Practices for Water Meters.
• ISO 4064: Water meters for cold potable water and hot water.
• NAMUR NE 107: Self-monitoring and diagnosis of field devices. Specifying NE 107 compliance ensures the meter communicates errors (like “Entrained Gas”) in a standardized format.

FAQ Section

What is Entrained Gas Management (EGM) in Krohne flowmeters?

Entrained Gas Management (EGM) is a proprietary technology developed by Krohne for their OPTIMASS Coriolis flowmeters. Historically, Coriolis meters would stall (stop measuring) when gas bubbles dampened the tube vibration. EGM allows the meter to maintain tube oscillation and continue measuring mass flow and density even with entrained gas levels ranging from 0% to 100% (slug flow). This is critical for applications like polymer dosing or unloading tankers where air ingestion is common.

Can Thermo Fisher ultrasonic meters measure cavitating flow?

It depends on the technology used. Thermo Fisher’s Doppler ultrasonic meters (like the Polysonic series) actually require discontinuities like bubbles or solids to reflect the signal, so they may function well in aerated wastewater. However, their Transit Time meters (designed for clean liquids) will often fail or lose signal if significant cavitation bubbles interrupt the acoustic beam. Selection must be based on the specific type of ultrasonic technology.

How does a flowmeter help prevent pump cavitation?

The flowmeter itself does not prevent cavitation, but it acts as the “eyes” of the control system. By monitoring diagnostic variables—such as a drop in the speed of sound (Ultrasonic) or an increase in drive gain (Coriolis)—the PLC can detect the onset of micro-bubbles before audible cavitation occurs. The control logic can then automatically reduce pump speed (VFD) or throttle a valve to restore NPSH margin, saving the pump from damage.

What is the difference between Krohne and Thermo Fisher for wastewater applications?

Krohne is generally more focused on inline, wetted instrumentation like Electromagnetic (Mag) meters and Coriolis meters, which are standard for permanent, high-accuracy wastewater process control. Thermo Fisher is often favored for portable or non-intrusive applications using clamp-on ultrasonic technology, or for analytical measurements (pH, DO). For a permanent sludge line flowmeter, a Krohne Mag meter is the typical engineering choice; for a temporary check of a raw water line, a Thermo Fisher clamp-on is ideal.

Why is magnetic flowmeter signal noise a problem during cavitation?

Cavitation bubbles collapsing near the electrodes of a magnetic flowmeter create electrical spikes that look like flow. This results in a “noisy” signal where the flow rate jumps erratically on the SCADA screen. If the noise is severe, it can mask the true flow rate or cause false totalization. High-end meters (like Krohne’s OPTIFLUX) use specific filtering algorithms and high-frequency excitation to distinguish this hydraulic noise from the actual flow signal.

What is the typical cost difference between these technologies?

Cost varies by pipe size. For small diameters (< 2 inch), a Krohne Coriolis meter is significantly more expensive ($3,000-$6,000+) than a simple mag meter ($1,000-$2,000). Thermo Fisher clamp-on ultrasonic meters have a fixed cost regardless of pipe size (typically $4,000-$8,000 depending on features), making them very expensive for small pipes but highly cost-effective for large pipes (> 24 inch) where inline mag meters become extremely costly.

Conclusion

Key Takeaways

• Define “Anti-Cavitation”: In this context, it refers to instrumentation that can survive and detect cavitation to protect pumps, not valves that prevent it physically.
• Technology Fit: Use Krohne Coriolis (with EGM) for high-value chemical dosing with gas risk. Use Thermo Fisher Doppler Ultrasonic for non-intrusive monitoring of aerated sludge/wastewater.
• Avoid Transit Time: Do not specify Transit Time ultrasonic meters for pump suction/discharge where cavitation is expected; the signal will likely fail.
• Use Diagnostics: Specification must require the output of diagnostic variables (Drive Gain, Signal Strength, Speed of Sound) to the SCADA system for predictive pump protection.
• Installation Matters: Avoid placing clamp-on meters on lined pipes or near elbows in cavitation-prone lines. Inline Mag meters offer the best reliability for permanent installations in tight pump rooms.

The decision between Krohne vs Thermo Fisher Anti-Cavitation Equipment: Comparison & Best Fit ultimately comes down to the criticality of the measurement and the physical access to the pipe. For permanent, mission-critical control loops in wastewater lift stations or sludge processing—where the fluid may contain entrained gas or solids—Krohne’s electromagnetic and EGM-equipped Coriolis meters offer superior resilience and integration capabilities. They provide the robustness required to survive the hydraulic shocks of cavitation while maintaining measurement authority.

However, for retrofit applications, temporary troubleshooting of suspected cavitation issues, or monitoring large-diameter raw water lines where cutting the pipe is impossible, Thermo Fisher’s ultrasonic solutions provide an invaluable toolset. The “Best Fit” is achieved not by brand loyalty, but by matching the sensor physics (Conductivity vs. Acoustics vs. Coriolis Force) to the specific void fraction and turbulence of the application. Engineers who specify based on these hydraulic realities will reduce lifecycle costs and extend the operational life of their pumping assets.

source https://www.waterandwastewater.com/krohne-vs-thermo-fisher-anti-cavitation-equipment-comparison-best-fit/