The need for precise measurement and control of fluids is omnipresent 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.
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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: flow measurement on 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 processing, heating, ventilation and air conditioning, and any ultrapure water application.
Applications in small pipes and confined spaces call for a new method of measuring and counting, and not just in terms of size.
Manufacturers are looking for accurate, efficient and cost-effective technology characterized by ease of use, low or no installation costs, reliable data and low energy consumption.
The semiconductor industry has revolutionized the way it miniaturizes 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.
In the pharmaceutical sector, the processes involved in the creation and mass production of drugs involve very precise dosing of the various recipe components. From laboratory testing through to dosing and mixing, several pipes 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.
Flow control in HVAC piping contributes to energy and water savings, as well as compliance with environmental regulations. The recovery and recycling of condensate water from HVAC systems are other cost-cutting and waste prevention measures involving compact condensate pumps and return systems.
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. Precise measurement of fluid flow enables the detection of fluid losses and empty pipes.
Highly accurate fluid measurement is needed to ensure that fluid products handed over by vendors to buyers are packaged with the expected volume. Whether filling vaccine vials or dispensing beverages from fountains, the flowmeter used must be designed to meet specified accuracy requirements.
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.
Ultra-pure water, i.e. water purified to the highest standards, is an essential element in sectors such as semiconductor and pharmaceutical manufacturing.
As 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 for the properties of ultrapure water.
Ultrasonic flowmeters measure flow velocity in pipes. Compared with electromagnetic flowmeters, mass flowmeters, turbine flowmeters and others, the greatest advantage of ultrasonic fluid flow measurement technology is that it is totally non-intrusive.
All other technologies are much more expensive, as you not only have to buy the flowmeter, but also pay welders to come and cut the pipes, weld the flanges, and so on.
With ultrasonic solutions such as Fuji Electric's S-Flow, you can measure directly close to the consumer equipment, fix the device around the pipe and start measuring. Without stopping anything or modifying the pipe, this approach is governed byISO 24062:2023, which formalizes the installation and performance of this type of flowmeter. It's a very low-cost solution.
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 specially 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 can be easily installed on existing pipes inside production machines, while they are still running, without the need for grease, pipe modulation or adjustment of the distance between sensors.
Ultrasonic fluid flowmeters of this kind 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 visualized 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 benefit from several advantages, including savings in equipment, energy and leakage, as well as improvements in production process and compliance.
The S-Flow ultrasonic flowmeter makes accurate fluid flow measurement possible, even on small pipe diameters. Based on our advanced ultrasonic technology and innovative design, the S-Flow flowmeter guarantees optimum performance for your industrial processes.
Are you having trouble measuring the flow rates of industrial process fluids on small pipe diameters?
The S-Flow ultrasonic flow meter offers an efficient solution.
Its precise measurements and robust functionality can handle the most complex fluid measurements, ensuring that your industrial processes run smoothly and efficiently.
