Flow meter is a measuring instrument used to measure the volume & mass flow rate of a liquid or a gas. A common application of such Flow meters is for measuring Volume Flow Rate of Water in pipes. Flow can be defined as the volume or mass of fluid flowing through the pipe per unit of time.  Measurement of flow either in a liquid or gas (including water/waste-water/effluent), an important parameter in many industrial & water infra processes.

To maintain the performance of industrial equipment and operations, it requires specific flow rates. Flow meter is also needed for studying water balance in networks, load management, custody transfer & revenue generation. Moreover in many process applications, maintaining the quality of the product requires accurate flow measurements.

Thus the Flow meter is a good investment that helps in industrial & infra processes management, and to provide a safer environment and security for personnel and processes. Flow meter have a wide range of applications ; they can measure the flow of liquids, pastes, and slurries in water/waste-water, dairy, agricultural, pharmaceutical, beverage, chemical, industries, fertilizer, medical, petrochemical, iron, steel, paper, mining, food, etc.

What are the factors to be considered while choosing the type of Flow meter? 

• Fluid/Gas Properties (i.e.conductivity)
• Process Specs & Condition (Line Size, Line above ground/below ground, Flow Range,  Line Pressure, Temperature, etc).
• Ruggedity of Construction
• Field Provenness
• Advanced Features
• User Friendliness & Supplier Support(Spares availability & Responsive Field Services, High MTBF)

Above factors will decide which type of flow meter to be considered, amongst Electromagnetic / Ultrasonic or Vortex or Coriolis or Thermal Mass Flow Meter or even Open Channel Flow meter (using Ultrasonic Level Transmitter & Convertor for conversion from level to flow).

RL Technologies Pvt Ltd, with its 25 years of technical expertise & over a decade of manufacturing and supply of flow meters and other instruments all over India, supported by the Pan-India Sales & Service Organization, is able to measure up to all the user’s strategic driving purchase factors as stated above.

Flow meter in Water Distribution Networks

The transportation of potable water involves the use of pipelines.  As it runs through densely populated areas, across rivers and other obstructions. The flow rate will be affected during the travel from its source to its destination.

While choosing a flowmeter for a water distribution network, accuracy is an important criterion, because the flow rate of potable water is already affected by different geographical conditions.

Another challenge associated with some remote water distribution networks is unavailability of Electricity; thus a Lithium battery-powered flow meter is the solution.

RL Technologies offers electromagnetic & ultrasonic flow meter with high accuracy and powered by lithium batteries(where required). It offers opportunities for water utilities to improve revenues even with reduced flow rates. RLT flow meter can measure down to 0.1 m/sec velocity & are specially calibrated to maintain flat accuracy over the entire flow range .

RLT Instrumentation’s world-class production facility has a ‘ Flow Validation & Calibration Centre ‘which can calibrate/validate any Flow meter from 10 mm to 3000 mm. This makes RLT unique in Asia.

Monitoring Water Leakage

Large size water pipe Applications for Revenue Water face a unique problem of revenue loss due to leakages from valves & fittings. Generally, water from ESR (Elevated Water Reservoir)flows to distribution/consumption points based on gravity flow. So, even when the flow valve is closed, due to leakage around worn-out valves, water continues to trickle into the collection area. If these flows are below 0.3 m/sec it’s generally not measurable with most Mags available in the market, which results in revenue loss.

RLT’s Magmeter has this UUB (Unique User Benefit ) that it can measure very low water flows down to o.1 m/sec. For Pipes as large as 500 mm & above, over a period of time, this is a huge saving in revenue for the Water Authority & ROI of 3 months, maybe!

Wastewater Treatment Process

Depending on the extraction point, the quality of raw water can vary. Pressure filter tanks are used in the process of water treatment which consists of layers of filters to remove one or several contaminants. These tanks are filled with quartz chips, filter the contaminated water and provide clean water.

The Electromagnetic Flow meter is used along with the pressure filter during the water treatment. It can be installed at multiple locations, such as, the inlet and outlet of the pressure filter for water flow measurement during water treatment. Thus flow meter add tremendous value to efficient monitoring & controlling of the Water Treatment Process.

Flow meter in Disinfection Dosing

In wastewater treatment, the untreated water from all the vertical wells is collected in deep containers during waterworks. To decrease the pH value of untreated water, soda ash neutralizing compound is used in the chemical treatment of water. Flow meters are used here too.

In every household, chemical compound monophosphates are used to protect the installed pipeline network from corrosion.

In drinking water, to eliminate the microbiological effects chlorine bleaching systems are dosed.

Thus to control the dosing level highly accurate flow meters are used.

RL Technologies’s electromagnetic flow meter is used widely in all applications as described above with selectable liners & electrodes to prevent corrosion & erosion .

Wastewater Treatment

In the wastewater treatment process, the untreated water flows through a series of treatment stages.  First, it enters into automatic screening equipment which removes objects such as wood pieces, rags, grease, and plastics.

Next, it enters the grit removal stage where the heavy but fine material such as gravel, other mineral solids, and sand is removed.

Then the water enters the pre-purification stage consisting of four rectangular settling basins. This is followed by a series of water purification processes.

An electromagnetic flow meter is installed in the untreated water inlet of the pre-purification system along with either PTFE liners, a thin layer bonded to other polymers through a thermal lamination which guarantees a high degree of resistance to abrasive media and solids.

Whereas, on the Outlet of the STP/Waste-water Treatment/Effluent Water Treatment, an Electromagnetic Flow meter is used with the HR liner ( as for potable water applications).

Open Water Channel Flow meter Installation     

Usually, the water purification plant involves two-stage biological purification system that eliminates phosphate and nitrogen settled downstream of the wastewater filters. A water purification plant is also installed with a sludge treatment system and sludge digestion.

The untreated water flows into various collectors and then flows into the inlet of the plant. Thus flow measurement must be done with both a level measuring and flow measuring instrument. RL Technologies’s ultrasonic flow meter combined with a level transmitter with convertor is best suited for open channel liquid sludge measurement.

Flow meter in Water Distribution Channels

Throughout the water utility networks, partially filled water channels are used to distribute water. During storms to avoid any breakage, these large pipes and water channels are also partially filled to allow the unused volume, to avoid any flooding in its surroundings.

Thus to monitor the increase and decrease of water level throughout the year in open channels both velocity and level measuring instruments to be installed. RLT ultrasonic flow meter combined with a converter is also best suited for such channel volume flow measurement.

Flow meter in Sludge Monitoring

The sludge treatment process involves biological stabilization of the sewage sludge. In order to keep the sludge smell at a minimum, effective sludge digestions are required. The thickening of the main sludge undergoes in the main sludge thickener and before digestion, it is temporarily stored in sludge storage containers. In both main sludge thickener and pre-thickener, RLT magnetic flow meter can be used for accurate measurements of sludge.

Flow meter in Methanol Measurement

The reduced nitrogen compounds remain in the form of ammonia in the wastewater during light-duty aeration. The poisonous substance ammonia is converted into nitrate through the nitrification process and then further converted into nitrogen.

During the purification process, the methanol is injected to accelerate the process. In calculating the efficiency of ammonia purification the mass flow of liquid methanol is critical to plant managers.

RL Technologies’s Coriolis mass flow meter in homogeneous mixtures are practically made for this application to determine density, temperature, volume, volume concentration, and  percentage of solids accurately.

Flow meter in Aeration process

Heavy-duty aeration systems are used to supply oxygen to biological tanks in order to speed up the process of decomposition of sludge waste.

For the optimal growth of bacteria, compressed air is mandatory in aeration basins, and dissolved oxygen mass is also measured. To provide a constant 24/7 oxygen supply to the microorganisms in the water large compressors are used.

RL Technologies’s thermal mass flow meter are not affected by changes such as temperature so they can be used to obtain accurate measurements of compressed air.

Flow meter in Bio gas Measurement

Bacteria break down the sludge particles in the condition of both aerobic digestion (i.e presence of oxygen) and anaerobic digestion (i.e absence of oxygen) which releases bio gas. About 50% of bio gas contains methane and the rest will be carbon dioxide. Both methane and carbon dioxide are expensive and require accurate measurement.

RL Technologies’s thermal mass flow meters can measure extremely low velocities directly without the need to monitor temperature and pressure to infer mass flow. Treating water for water purification or RO Water (for Hospitals, Commercial Institutions, Pharma, Power (for thermal boilers) also involves flow meters.

Old Water Pipelines Flow Monitoring

Sometimes, Water Authorities need to measure Water in Pipelines, where there are operational limitations to cut the pipe, so in such situations, RLT provides External Insertion Type Ultrasonic Flow meter mounted on small tank nozzles welded on small pin-holes on the pipe.

The Pipes can be any size, even as high as 6000mm!

Sometimes, Operational limitations do not allow any puncture in the PipeLine (High-Pressure Water Networks).

In such cases, RL Technologies provides a solution with Clamp-on Type Ultrasonic Flow meter, where the sensors are permanently clamped to the outside of the Pipe & with Flow Reading on Transmitters connected to the sensors.

Flow meter in RO Plant         

In such plants, normal potable water is further purified using an RO process for other safer uses including medicinal, pharmaceutical, etc.

Depending upon the level of purity, the conductivity of water could be below 5 micro-mho/cm.  Electromagnetic Meter is unsuitable here.

Hence, in such applications, Ultrasonic In-line Flow Meter or even Vortex may be used.

RLT has vast experience in such applications with our Ultrasonic & Vortex flow meter.

 On-Site Validation of Flow in Water Distribution & Plant Fluid Networks

Instrument Plant Technicians are often faced with Operational issues,  like :

A Plant Operator reports that a Flowmeter is reading inaccurately due to their knowledge of plant conditions & experience or even theoretical calculations like Pump Speed etc(sometimes not considering actual pump efficiency). 

RLT Provides 2 unique solutions :

• RLT Electromagnetic Flow (EMF) meter provides a proactive in-line, in-built diagnostic tool in software & available on a transmitter display called the ‘Coil Strength ‘ in mV to the User. This measurement when compared with the threshold value (also available) confirms, in the unlikely event, whether the instrument is old ( or any other process reason) is in its active life mode or the sensor needs replacement.
• If the EMF is still in its active life cycle, then whether the Flow meter is out-of-calibration. Here, one can use RLT’s Portable Ultrasonic Clamp-on Flow meter to temporarily mount the clamp-on sensor near the EMF & check for the actual flow & validate whether the EMF is showing correctly & is still in good calibration mode

This validation by Portable Clamp-on Flow meter is also applicable as per ISO guidelines.

The above-stated real-life process measurement issue is universal & RLT is proud of the fact that we are one of the few Instrumentation Co’s which has a time-tested solution for the same.

Process Plants (Non-Hazardous Type )

All RLT Flow meter can also be used for in-plant process applications like Power ( Thermal & Hydro ), Sugar, Distillery, Brewery, Milk & Food Production, Pharma, Chemical Factories, Cement & Metal Industries, etc. Here, the process fluids could be water, chemicals & gases.

Conclusion

Thus flow meter have a wide range of industrial applications in many industrial areas. RL Technologies Pvt Ltd, with its 25 years of technical expertise & over a decade of manufacturing and supply of flow meter and other instruments all over India; supported by the Pan-India Sales & Service Organization is ever ready to support the Flow Metering Needs of all Customers in India & Overseas !

Hope you find this blog useful and informative. Let me know what you think in the comment section below

“Get in touch with us today to learn more about our products and services”. Let’s help you prevent pollution & add value to global sustainability!.

FAQ

How to choose the type of flowmeter?

• Fluid/Gas Properties (i.e.conductivity)
• Process Specs & Condition (Line Size, Line above ground/below ground, Flow Range, Line Pressure, Temperature, etc)
• Ruggedity of Construction
• Field Provenness 
• Advanced Features
• User Friendliness & Supplier Support(Spares availability & Responsive Field Services, High MTBF

What is flowmeter?

Flow meter is a water flow measuring instrument used to measure the volume & mass flow rate of a liquid or a gas.

What is the importance of flow measurement in industries?

To maintain the ideal performance of industrial equipment and operations require specific flow rates. Estimation of cost for many gases and liquids are based on the flow measurement, making it necessary to accurately measure and control the flow rate. 

What are industrial areas used ?

 Flowmeter has a wide range of application, it can measure the flow of liquids, pastes, and slurries in water, dairy, agricultural, pharmaceutical, wastewater, beverage, chemical, industries, fertilizer, medical, petrochemical, iron, steel, paper, mining, food, etc.

What is the use of flowmeters in open channels?

Thus to monitor the increase and decrease of water level throughout the year in open channels both velocity and level measuring instruments to be installed. RLT Solution’s ultrasonic flow meter combined with a controller is best suited for channel volume flow measurement.

What is the use of flowmeters in wastewater treatment?

The Electromagnetic Flowmeter is used along with the pressure filter during the water treatment. It can be installed at multiple locations such as the inlet and outlet of the pressure filter for water flow measurement during water treatment.

What is use of flow meter in  water distribution channel?

The transportation of potable water involves the use of pipelines.  As it runs through densely populated areas, across rivers and other obstructions. The flow rate will be affected during the travel from its source to its destination.

While choosing a flowmeter for a water distribution network, accuracy is an important criterion, because the flow rate of potable water is already affected by different geographical conditions, thus it strictly needs an accurate measurement device.