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.
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 processing, HVAC, and any high-purity 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.
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.
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.
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.
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.
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.
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.
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.
Ultrasonic flow meters measure flow velocity in pipes. Compared with electromagnetic flow meters, mass flow meters, turbine flow meters and others, the greatest advantage of ultrasonic fluid flow measurement is that it is totally non-intrusive.
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 close to the consumer equipment, fix the device around the pipe and start measuring without stopping or modifying the pipe. 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 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.
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.
Are you having trouble measuring the flow of industrial process fluids over small pipe diameters?
The S-Flow ultrasonic flow meter 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.
