How to measure the flow rate through pipes of small diameters ?
How to measure the flow rate through pipes of small diameters ?
The need for accurate measurement and control of fluids is ubiquitous in manufacturing processes, in research laboratories, during the transformation of raw materials into finished products and during packaging.
Continuous measurement, control, and analysis of fluid flow using appropriate measurement technologies improve the reliability, performance, and uptime of industrial processes, as well as environmental sustainability and compliance with standards and regulations.
This article discusses the growing challenges and modern solutions for fluid flow control on small pipe diameters.
Why is fluid flow management becoming increasingly important in the manufacturing industry?
Industrial fluid flow measurement and control technologies are well established for applications involving large pipes, but accelerating market trends present a distinct and pressing challenge: measuring flow in small pipes.
The move towards faster, smaller, more compact and less expensive machines has increased the need to measure fluid flow in small-diameter, densely-spaced pipes. Examples include semiconductors, pharmaceuticals, biopharmaceuticals and life sciences, food & beverage, HVAC, and any ultrapure water application.
Applications in small pipes and confined spaces require a new method of measuring and metering, and not just in terms of size.
Manufacturers are looking for accurate, efficient and cost-effective technology that offers ease of use, low or no installation costs, reliable data and low energy consumption.
What applications for small pipes are driving the trend in microfluidic measurements?
Semiconductor manufacturing
The semiconductor industry has revolutionised the way it miniaturises manufacturing technology. Micro-flow fluids are used for cleaning, rinsing, cooling, coating and other vital processes. For example, the equipment cooling process is carried out inside the machine itself, using very small, densely-spaced pipes up to 10 mm in diameter.
Laboratory tests and dosed mixtures
In the pharmaceutical sector, the process of creating and mass-producing medicines involves very precise dosing of the various components in the recipe. From laboratory testing through to dosing and mixing, several tubes are measured for the various active and inactive substances making up the final product.
These measurements must always be ultra-precise to guarantee maximum quality, safety and efficiency.
Heating, ventilation and air-conditioning efficiency
Controlling flow rates in HVAC pipework helps to save energy and water, as well as complying with environmental regulations. The recovery and recycling of condensate from HVAC systems are other cost-cutting and waste prevention measures involving compact condensate pumps and return systems.
Leak detection
Loss prevention is a fundamental need, whatever the size of the industry or application. Early detection of pipe leaks in upstream and downstream manufacturing processes is necessary to quickly stop otherwise costly spills. Accurate measurement of fluid flow can detect fluid loss and empty pipes.
Custody Transfer
Highly accurate fluid measurement is needed to ensure that fluid products handed over by sellers to buyers are packaged with the expected volume. Whether filling vaccine vials or dispensing drinks from fountains, the flow meter used must be designed to meet the specified accuracy requirements.
Local mandates
New local directives to control water consumption in drought-prone areas are driving the need for flow measurement devices for consumers. Monitoring domestic water consumption will enable consumers to take steps to avoid penalties for over-consumption.
Why is the type of fluid to be measured important?
Ultra-pure water, i.e. water purified to the highest standards, is an essential element in sectors such as semiconductor and pharmaceutical manufacturing.
Because all contaminants are removed, ultrapure water has no conductivity that can be measured or detected by an electromagnetic-type flow measurement device. In contrast, the transit time-based ultrasonic flow measurement method is ideal due to the properties of ultrapure water.
What are the main advantages of ultrasonic flow meters over traditional technologies?
All the other technologies have a much higher cost, as you not only have to buy the flow meter, but also pay welders to come and cut the pipes, weld flanges, etc.
With ultrasonic solutions such as Fuji Electric's S-Flow, you can measure directly near the consumer equipment, fix the device around the pipe and start measuring. Without stopping anything and without modifying the pipe. It's a very low-cost solution.
Discover ultrasonic and electromagnetic flowmeters
How do integral ultrasonic flowmeters such as S-Flow meet the challenges posed by small pipes?
This new approach uses small, compact measuring devices to integrate measurements inside manufacturing equipment, rather than outside.
In addition to the key benefits of a non-intrusive design, these clamp-on meters are specifically designed for small pipes and confined spaces, and come as standard with an accuracy of ±2.0%. They are significantly smaller than conventional technologies, as the flow sensor and transmitter are integrated to save space.
Lightweight and compact, they are easy to install on existing pipes inside production machines, while they are still running, and without grease, pipe modulation or adjustment of the distance between sensors.
Ultrasonic fluid flow meters of this type are suitable for a wide variety of applications with pipe diameters as small as 6 mm and for a wide range of pipe materials and fluids. Highly accurate flow rates are quickly displayed thanks to digital signal processing using the transit time method, with a response time of 0.5 seconds.
With an optional integrated temperature sensor, flow and temperature can be measured simultaneously. Plants reap a number of benefits, including savings in equipment, energy and leakage, as well as improvements in the production process and compliance.
Reaching the PINNACLE of flow measurement performance and reliability
Innovate and optimise with the clamp-on S-Flow ultrasonic flowmeter for measuring liquid flow in small pipes.
The S-Flow ultrasonic flowmeter makes it possible to measure fluid flow accurately, even on small pipe diameters. Using our advanced ultrasonic technology and innovative design, the S-Flow flow meter guarantees optimum performance for your industrial processes.
Easy to install by simply tightening 4 screws and no grease is required.
Integrated ultrasonic flow detector and flow transmitter for space savings.
A temperature sensor is available as an option for simultaneous measurement of flow and temperature.
Are you having trouble measuring the flow of industrial process fluids over small pipe diameters?
The S-Flow ultrasonic flowmeter offers an efficient solution.
Its accurate measurements and robust functionality can handle the most complex fluid measurements, ensuring that your industrial processes run smoothly and efficiently.
Don't let the challenges of flow measurement get in the way of your business !
Our experts can advise you on how to integrate the S-Flow ultrasonic flowmeter into your industrial processes.
